Process Industry Informer December 2019 by Process Industry Informer

December 2019

www.processindustryinformer.com

Volume 15 No. 5

The Ukâ&#x20AC;&#x2122;s leading publication serving the process industry

Secure

manufacturing Tips for effectively protecting Operational Technology

In this issue:

Solids Handling & Processing supplement New Columnist Gavin Smith 10+ Feature articles

Digital | Online | Mobile - The UKâ&#x20AC;&#x2122;s No. 1 Media for the manufacturing process industries

Corrosive environments. Costly blowdowns. Hidden costs. Don’t let your efficiency evaporate.

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Contents

FEATUREDARTICLES ARTICLES FEATURED SAFELY EXTENDING Secure manufacturingOPERATIONAL INTELLIGENCE Tips for effectively FROM THE CONTROLprotecting ROOM Operational TO THE PLANTTechnology FLOOR

PRODUCT PRODUCTSECTIONS SECTIONS NEWS & EVENTS

04-11 PAGE

Measurement NEWS & EVENTS Maintenance IIoT

04 12-22 – 06

08 &28-31 10-11

Compressors

FOOD INDUSTRY FOCUS

Water & Environmental

POWER SUPPLY

Heating

CELL DISRUPTION

Drives & Motors HEALTH & SAFETY Cooling

32 25 36 25 40 4626

PUMPING Fluids & Liquids Handling

28 – 32 47-51

SHAPA supplement FILTRATION

performance

55-5132

HEATING & COOLING

36 – 38

PROCESS MEASUREMENT

42 – 43

DRIVES EDITOR Phil Black: philblack@piimag.com SHAPA NEWS

CROSS CONTAMINATION FOOD INSPECTION RISKS The Manufacturing Divide RECEIVE HYGIENIC HAND

51 – 77

SALES & MARKETING MANAGER Guy Ullmann: guyullmann@piimag.com EDITOR

HIDDEN TRUTHS EIGHT BEST PRACTICES FOR about cooling system IMPROVED LABORATORY water filtration GRAB SAMPLING

CIRCULATION MANAGER

CIRCULATION MANAGER Jean info@piimag.com ARTCaunin: DIRECTION

Jayden Ken

OFFICE MANAGER Diane Ullmann: dianeullmann@piimag.com

Advertisement & Editorial Offices

ART DIRECTION Process Industry Informer, Passfield Business Centre, Louise Brooks & Jayden Ken Lynchborough Road, Passfield, Liphook, Hants GU30 7SB

IS GAS GENERATION THE SOLUTION TO RISING Powdercosts? Valve Options energy

Tel: 01428 751188 Fax: 01428 751199 Advertisement & Editorial Offices Email:Industry info@piimag.com Process Informer, Passfield Business Centre, Web: www.piimag.com Lynchborough Road, Passfield, Liphook, Hants GU30 7SB Tel: 01428 751188 Fax: 01428 751199 Subscriptions: UK £25 | EIRE £35www.piimag.com Email: info@piimag.com Web:

Overseas prices on application © Process Industry Informer

Subscriptions: UK £25 | EIRE £35 Overseas prices on application © Process Industry Informer

WHY WILL EFFECTIVE WASTE MANAGEMENT Considerations when sourcing be more important than Pneumatic Conveyors ever before in 2019?

39 62

44 74

BRITISH INDUSTRY TO BENEFIT FROM UK GOVERNMENTCONVEYORINVESTMENT BELTING Who sets the BACKED standards? into innovative energy efficiency technologies

Printed by Bishops Printers Ltd

RF & MICROWAVE How the food industry MATERIAL MEASUREMENTS: can save time, money and techniques and applications resources on cleaning

SALES & MARKETING OFFICE MANAGER MANAGER Guy Ullmann: guyullmann@piimag.com Diane Ullmann: dianeullmann@piimag.com

Phil Black: philblack@piimag.com

PUBLISHING / ADVERTISING MANAGER Jean Caunin:peterullmann@piimag.com info@piimag.com Peter Ullmann:

DIGITAL FARMS TO SUPERMARKET SMART Easy Radar SHELVES – A NEW ERA OF CONNECTIONS

PUBLISHING / ADVERTISING MANAGER Peter Ullmann: peterullmann@piimag.com

SERVING UP FINANCE: OEMS CAN HELP THEIR CUSTOMERS important to be looking inWhy theit’s food and beverage at plastic packaging sector embrace digitalisation alternatives with integrated finance

13 – 25

WHAT DOES THE FUTURE Top tips to perfect HOLD FOR SCADA? your co-generation

All All product product announcements announcements published published in in Process Process Industry Industry Informer Informer are are paid paid for. for.All Allcopy copysubmitted submittedfor forpublication publicationininProcess ProcessIndustry IndustryInformer Informermust mustbebelegal legaland andmust mustcomply complywith withthe theBritish BritishCode CodeofofAdvertising AdvertisingPractice Practice and for publication, publication, or or not, not, at at the the publishers’ publishers’ absolute absolutediscretion. discretion.When Whendeemed deemednecessary necessaryallallcopy copymay maybebeedited editedand andclassified classifiedatatthethepublishers’ publishers’discretion. discretion. material contained Process Industry Informer and is is accepted accepted for AllAll material contained in in Process Industry Informer is is published in good faith, but it is emphasised that the publishers do not in circumstances accept responsibility for the accuracy or otherwise of any advertisement or message published (nor is any kind of warranty published in good faith, but it is emphasised that the publishers do not in circumstances accept responsibility for the accuracy or otherwise of any advertisement or message published (nor is any kind of warranty expressed expressed or implied by such publication) and that the publishers specifically disclaim all and any liability to advertisers, readers and user of any kind for loss or damage of any nature whatsoever and however arising, or implied by such publication) and that the publishers specifically disclaim all and any liability to advertisers, readers and user of any kind for loss or damage of any nature whatsoever and however arising, whether due to whether due to inaccuracy, error, omission or any other cause, and whether on the part of the publishers of Process Industry Informer, or their servants or agents, or any other person. inaccuracy, error, omission or any other cause, and whether on the part of the publishers of Process Industry Informer, or their servants or agents, or any other person. is the the intention intention of of the the publishers publishers in in general general to to run run copy copy as assupplied suppliedby byadvertisers, advertisers,advertorial advertorialitems itemsheadings, headings,which whichare arenot notcharged chargedfor, for,will willbe beselected selectedby bythe theEditor, Editor,and andother otherminor minorchanges changesmay maybebemade, made, Although it is the Editor’s Editor’s discretion, discretion, for for the the sake sakeofofthe theclarity, clarity,totoavoid avoidoffence, offence,forforlegal legalreasons reasonsorortotoensure ensureconformity conformityto to house style. Copy supplied over length to the amount Units abbreviations at the house style. Copy supplied over length willwill be be cutcut to the amount paidpaid for. for. Units andand abbreviations will will be be standardised in accordance with house style. No part of this publication may be reproduced or transmitted by any means without the prior written consent of the publishers. No part of this publication may be reproduced or transmitted by any means without the prior written consent of the publishers.

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News & Events

Bite size news Planning application submitted for National Manufacturing Institute Scotland A planning application has been submitted for the development of the National Manufacturing Institute Scotland (NMIS) situated at the centre of the Advanced Manufacturing Innovation District Scotland (AMIDS) in Renfrewshire. NMIS is a £65 million, industry-led international centre of manufacturing expertise led by Scottish Government in partnership with its enterprise and skills agencies, University of Strathclyde and Renfrewshire Council. Operated by Strathclyde, as a national facility for Scotland, it is where research, industry and the public sector work together to transform skills, productivity and innovation to attract investment and make Scotland a global leader in advanced manufacturing.

Clean air research converts toxic air pollutant into industrial chemical A toxic pollutant produced by burning fossil fuels can be captured from the exhaust gas stream and converted into useful industrial chemicals using only water and air thanks to a new advanced material developed by an international team of scientists. Read more here

Read more here

Leading diagnostic engineer warns against recent claims that the future of predictive maintenance should be led by data science… and not engineers! THE opening keynote speaker at the 2019 Condition Monitoring and Diagnostic Engineering Conference (COMADEM) warned against recent claims that the future of predictive maintenance should be led by data science, and not engineers. Professor Andrew Ball, a renowned expert in the field of diagnostic engineering, delivered the first of the keynote presentations at the COMADEM Congress, which was attended by over 180 delegates and held at the University of Huddersfield in the UK. Read more here

BSI helps boost the manufacturing industry with guide to digital technology adoption Supporting the UK’s Industrial Strategy, the new guide sets out practical guide for UK manufacturing industry to adopt digital technology BSI, the business improvement company, has released PAS 1040:2019 Digital readiness – Adopting digital technologies in manufacturing – Guide to provide organizations with the guidance needed to assess and improve their readiness to adopt digital technologies such as artificial intelligence, robotics, and the internet of things. Read more here Process Industry Informer • November - December 2019

News & Events

Inspirational water documentary premieres in Los Angeles

One year ago, a documentary crew set off on an incredible journey to meet with pioneers who are finding solutions to one of the world’s biggest challenges – water. After filming across five continents, hearing from the innovators changing the global water landscape and gaining support from high profile activists Matt Damon and Jaden Smith, the result is Brave Blue World, a documentary that paints an optimistic future for our most valuable resource. The journey’s next step will be a Hollywood premiere on 16 December at the Paramount Theatre, Los Angeles, with many of the key protagonists, including Jaden Smith, in attendance. Executive producer and founder of BlueTech Research Paul O’Callaghan, who spearheaded the project, said: “This is a huge milestone for us. The Brave Blue World documentary is a collaboration and celebration of the scientific

and technology advancements that have been taking place, often behind the scenes, to deliver water services. “From a NASA research centre, where we learned how water is recycled in space and a textile plant in India that is meeting 90% of its water needs from recycled water, to the world’s largest algae-powered wastewater treatment plant in Spain and a children’s home in Kenya, where 50 litres of water a day is being provided from humidity in the air, we heard many inspiring stories. We’re tremendously excited to be able to share these with a wider audience and move water up the global agenda as an issue we can solve in our lifetime.” “What I’m most proud about is the plethora of global experts we’ve found to tell their stories. Collectively, we can now help raise awareness of these issues and help fasttrack the potential solutions.” The movement’s biggest surge of support so far came at Web Summit, Lisbon, one of the largest technology events in the world. Paul joined Jaden Smith and Gary White of Water.org, a company he co-founded with Matt Damon, for a

panel discussion that shone a light on Brave Blue World to an audience of 15,000 people from the tech world. Paul said: “As well as being Hollywood stars, Jaden Smith and Matt Damon are water activists and entrepreneurs whose work in this space is really changing lives. For them to be involved in our documentary has lifted it to stratospheric heights.” “It is often an apocalyptic picture painted about the millions of people lacking access to safe sanitation and water. But through Brave Blue World, we can spread the message that the situation is improving, the technology is there, and within our lifetime we can cure these global problems.” Anyone interested in hosting a local screening for your organisation or community can get in touch via aoife. kelleher@braveblue.world Details of local screenings will be announced soon. Brave Blue World has been made in association with Prospect Arts production company and: Partners – WEF, DuPont Water Solutions, SUEZ, L’Oreal and Xylem Impact partners - Water.org, Water Alliance, Aqualia and 501cTHREE

Fulton announces changes to senior roles Fulton continues to strengthen its team with a number of senior roles changes. Having joined in 2017, Leigh Bryan has assumed the role of national consultant specialist. Commenting on the role, managing director Carl Knight says: “Leigh was instrumental in successfully integrating the ultra-low NOx

VSRT into Fulton’s current portfolio and introducing it to the UK market. In his new role, Leigh will remain an integral member of the management team and, thanks to the success of the VSRT steam boiler, will provide specification support, documentation and CPD training to specifiers and consultants across numerous markets.”

Process Industry Informer • November - December 2019

Ruth Price, who joined Fulton in 2012 as North of England and North Wales area sales manager, has also been promoted and, in her new role as senior sales engineer, will work closely with new and existing customers across the UK to advise on optimum boiler and steam systems specifications for their project.

For further information contact Carl Knight Fulton Limited, Fernhurst Road, Bristol, BS5 7FG Tel: 0117 972 3322 Fax: 0117 972 3358 E-mail: sales@fulton.co.uk Web: www.fulton.co.uk 6

News & Events

Konecranes Demag UK Ltd signs the Armed Forces Covenant Lifting equipment manufacturer and service provider, Konecranes Demag UK Ltd, has signed the Armed Forces Covenant. The company has made a commitment to support the Armed Forces community and recognise the contribution to society and business made by serving, reservist and veteran military personnel. As an Armed Forces friendly organisation, it has pledged to promote a recruitment pathway for service personnel, their spouses and partners, ensuring that no member of the Armed Forces faces disadvantage in seeking employment. The company also recognises that in some circumstances special treatment may be appropriate and has promised support, including special leave and deployment, for reservists and leaders of military cadet organisations. The company already has military leavers within its ranks, including former RAF personnel who are working in training and branch management roles. The company is now focusing on a programme of further recruitment of

employees from service backgrounds. To this end, it has been working closely with the Career Transition Partnership (CTP), an agreement between the Ministry of Defence and Right Management Ltd, which provides resettlement services for those leaving the Royal Navy, Army, Royal Air Force and Marines. Regardless of time served, all members of the Armed Forces may benefit from CTP support when leaving service. The CTP also operates as an intermediary for employers wishing to hire service leavers. To date, it has assisted over 235,000 service leavers with the transition to civilian life and supported thousands of organisations looking to employ ex-service personnel. Karen Winfield, UK HR Director, Konecranes Demag UK Ltd, stated: “There is a strong synergy between the training and education programmes provided to engineers in the Armed Forces and the skill sets required by lifting equipment Service Technicians. As such, exmilitary personnel represent a large pool of talent from which we can recruit for our national network of aftersales’ support services.”

ULTRAFLO U1000MKII-FM THE NEW ALTERNATIVE TO CUTTING PIPES AND MECHANICAL METERS FROM MICRONICS, FOR SIMPLE, LOW COST FLOW MEASUREMENT FROM OUTSIDE THE PIPE!

NEW!

Pipe range has been extended to 6" pipes.

The U1000MKII-FM is an ultrasonic permanent/ fixed clamp-on flow metering solution for measuring flow rate and total flow with a volume pulse output and optional Modbus or 4-20mA flow proportional output, which can be used as a stand alone meter or as part of an integral management system. Simple to install – connect power and enter the pipe inside diameter, adjust the sensors and clamp-on the pipe – no specialist skills or tools required! A cost effective alternative to traditional in-line meter installation, plus dry servicing, providing minimum downtime and maximum availability!

Suitable for: Steel, Plastic and Copper pipe, 25mm – 180mm OD

Compact, rugged and reliable, the U1000MKIIFM has been designed to provide sustained performance in industrial environments.

MADE IN BRITAIN

For fur ther information call us on There is a strong synergy between the training and education programmes provided to engineers in the Armed Forces and the skill sets required by lifting equipment Service Technicians.

+ 44 ( 0 )1628 810456 or email sales@micronicsltd.co.uk w w w.micronicsflowmeters.com 1247-Micronics U1000 MkII HM Ad 130 x 380mm Sept 2016 v1.indd 3

13/09/2018 20:04

Process Industry Informer • November - December 2019

News & Events

JWF Process Solutions gains UK-wide operational clout with Stream Measurement acquisition - Combined group will have turnover in excess of £10m, partnering with UK and international corporates in the Oil and Gas, Food and Beverage, Chemical, Petrochemical, Pharma, Energy, Utilities and Automotive sectors - Client base includes Ineos, Repsol, Nestlé, Diageo, National Grid, Thames Water, Centrica, BMW, Astra Zeneca and Babcock International Glasgow-headquartered JWF Process Solutions Ltd, engineering specialists in measurement and instrumentation products and services, has gained a UK-wide operational footprint with the acquisition of Manchester-based flow measurement specialist Stream Measurement Ltd. Founded in 1962, JWF has UK and international customers across the Oil and Gas, Food and Beverage, Chemical and Petrochemical sectors and counts Repsol, Chrysaor, Apache, Nestle, Diageo, Macallan, Ineos, PetroIneos and Babcock International among its client base. Stream Measurement, established in 1999 following a management buy-out from Schlumberger, covers the Utilities, Energy, Automotive, Food and Beverage and Pharma sectors, with key customers including National Grid, Centrica, Phoenix Gas, Thames Water, Boots Manufacturing, Greencore, BMW and Astra Zeneca. The combined group will have turnover in excess of £10 million, headcount of 37, UK-wide coverage, an extended partner network, strong synergies and enables JWF to further develop its service-related activities. JWF, who moved to a new world-class facility in 2015 and also has operational bases in Aberdeen and Teesside, offers a full package of instrument and measurement solutions encompassing

instrumentation, metering, flow surveys, commissioning, calibration and tank calibration. Kenneth Fairbairn, Chief Executive of JWF Process Solutions, said: “JWF’s unique position in the market is underpinned by the partnerships we have in place with manufacturers across the globe, relationships that allow us to select the best solution to meet client expectations such as technical specifications, quality, materials, delivery timescales and cost - which are all crucial to our customer base. The acquisition of Stream Measurement gives us added strength in existing and new industry sectors, a high-quality team of people who share our customer-first focus, UK-wide reach and the opportunity to build an even stronger services division at the combined group.” Andy Maber, Commercial Director, Stream Measurement said: “This is a very exciting time for both Stream and our customers. We are adding new products, services and increasing our geographic support, whilst the team at JWF complement our existing flowmeter expertise with their years of instrumentation and measurement experience.” Robert Allan, Managing Director, JWF Process Solutions, said: “The markets we work in are going through a period of transformational change. Oil and Gas in the UK is seeing a number of mergers and acquisitions and the Energy and Utility markets are continuing to expand due to their requirements for increased levels of specialist metering support. The Stream acquisition further strengthens our ability to provide full turnkey measurement solutions across all markets.” JWF is on track for revenue in excess of £8 million in the current year (year to 31st December 2019).

Left to right in photo are Nigel Bradbury, Robert Allan, Kenneth Fairbairn, David Gemmell and Andy Maber (by Stewart Attwood)

Process Industry Informer • November - December 2019

News & Events

VEOLIA CROWNED AT PRINCES FACTORY

Veolia Water Technologies will supply a new anaerobic treatment plant and associated biogas treatment system to the largest food production site operated by international food and drink group Princes.

Water Technologies’ innovative Biothane Advanced Upflow Anaerobic Sludge Blanket (UASB) solution set it apart from other competitors. We have developed a strong relationship with the company’s team and look forward to working with them towards our target commissioning date.”

The landmark project was signed into action on 1st July 2019, with Veolia Water Technologies scheduled to finish the commissioning by 2020. The parties developed a strong working relationship, which is helping ensure the project stays on track. Further opportunities have been identified to continue improving aerobic plant operations on-site, after the initial installation is complete.

To meet the client’s needs, Veolia Water Technologies worked with its internal techno centre, Biothane. The company is one of the world’s leading companies in the field of biological treatment of industrial wastewater and biogas with more than 40 years of experience. Biothane’s technical expertise and its position within the Veolia Water Technologies organisation made it the ideal partner for planning a muchimproved anaerobic digestion system. Together, the team worked to craft a solution bespoke to Princes’ needs.

Speaking on the project, Rob James, Factory Manager at Princes commented: “We’re delighted to have started work with Veolia Water Technologies and look forward to seeing its new anaerobic digestion plant and associated biogas treatment commissioned at our Long Sutton site. The tender process during this project was highly competitive, but Veolia

The site, which is located in Long Sutton will be fitted with the third generation of UASB technology. The Biothane Advanced UASB process maximises the conversion of the organic contamination in the production effluent to biogas. The biogas produced will serve as a source of energy for the production site. The plant capacity is able to produce approx. 20,000 MWh per annum of

gross calorific value. This corresponds with an approximate annual average gas consumption of 1700 UK households. The effluent water produced is of high quality and will, after final treatment, be discharged to river. Speaking on the project, Simon Emms, Business Development Manager at Veolia Water Technologies commented: “It’s great to have been awarded this contract. Together with Biothane, we have devised an innovative concept that will deliver real benefits to Princes. Our expertise in the technologies and services, as well as our commitment to supporting the customer through their buying journey made us the obvious choice. We’re really excited to deliver the project and can’t wait to start looking at future opportunities.” For more information about Veolia Water Technologies, please visit: www.veoliawatertechnologies.com. For more information about BIOTHANE®, please visit: www.biothane.com.

APEX DYNAMICS ANNOUNCES NEW APPOINTMENT TO BOOST UK PRESENCE APEX Dynamics, a global leader in the design, manufacture and supply of precision servo gearboxes, has strengthened its position in the UK and Ireland markets with the appointment of a new National Sales Manager. First of a number of key appointments boosting the sales team at APEX Dynamics UK, this is part of an ongoing strategy by the business to establish itself as a major player in the UK by investing in people and resources to develop new products and further expand its global sales network.

Joining the APEX Dynamics bandwagon as National Sales Manager is Andrew Parsons, who has extensive experience spanning two decades in engineering and motion control technology, both internally and in providing external support for key customers and system integrators. Managing Director of APEX Dynamics UK, Mike Gulliford, said: “Andrew is just the guy we have been looking for to succeed in this position to help us communicate our outstanding servo gearbox product features and support to clients in the UK and Ireland. We are

delighted he is bringing his pedigree and experience in mechanical motion control systems to the position.” For enquiries please contact: Mike Gulliford Managing Director APEX Dynamics UK Telephone: 0121 737 1170 Email: mikeg@apexdynauk.com Website: www.apexdynauk.com

Process Industry Informer • November - December 2019

News & Events

WES Ltd launches new initiative to tackle skills gap with the WES Academy WES Ltd, the leading UK manufacturer of chemical dosing systems for a wide range of industrial process applications, is taking action to bridge the skills gap with the launch of the WES Academy. The skills gap crisis is an ongoing concern for many manufacturing and engineering businesses in the UK, as fewer apprentices come into the sector and an ageing workforce leave. The gap has been particularly recognised in the Utilities sector, which has set up the Energy and Utilities Skills Partnership, with a core aim being to attract, train and enhance the utility sector skills base. WES is addressing the situation by taking positive action with a series of proactive initiatives. These include working with Southampton Engineering Training Association (SETA), running a highly regarded apprenticeship scheme and, through its recently launched skills programme, to upskill its current workforce with the WES Academy training programme. The Academy includes technical and commercial training documents, modules and seminars held at WES’ inhouse training facility. New starters can get to know the basics such as understanding the use of chemicals, through to more specific technical training that includes such topics such as ‘ test procedures for a dosing rig’ and ‘ correct procedures for emptying chemical bunds’.

Process Industry Informer • November - December 2019

The Academy is designed to be a continuous learning program with increasing competency of individuals demonstrated & monitored via the WES SharePoint intranet system. The WES Academy is open to all employees and remote access allows offsite employees the option to log in to the training platform from their tablets. Kevin Wheeler, Managing Director of WES Ltd, explains, “It’s vital that we upskill our entire workforce so that our skills pipeline can deliver our overriding long-term goals. WES Academy helps secure our business and the future of all our

employees by addressing any competency gaps whilst helping to develop their career.” He adds, “Taking on apprentices also enables us to give something back to the local community by providing employment and opportunity for young engineers. This approach and our Academy mean that we are striving for a solution to secure our continued growth and a prosperous future. It also reaffirms the WES brand value of: “Your chemical. Our knowhow.” For further information, contact: WES Ltd Email: info@wes.ltd.uk Web: www.wes.ltd.uk

News & Events

Seeley International has won at the coveted Energy Awards 2019 With 23 categories rewarding different aspects of the industry, the awards recognise the leading people, products, projects and services in the sector from Innovation of the Year to Broker Initiative to Retail Energy Project of the Year. Breezair direct evaporative cooler (model TBSI 580) has been named Energy Efficient Product of the Year 2019, by a panel of esteemed judges. The results of the Energy Awards 2019 were revealed on the 21st November at the Hilton Park Lane, London where the energy industry elite came together for a night of recognition and celebration of the sector’s achievements, with awards presented by comedian Miles Jupp. Breezair TBSI 580 has won in the Energy Efficient Product of the Year and was praised by the expert judging panel, who are drawn from across the energy sector.

Judges agreed that evaporative cooling technology has a lot of potential, both in energy and environmental terms. The addition of inverter technology looks like improving efficiency further. ‘Could be a game- changer’ judges commented. The environmental effect of having no refrigerant in the system was also noted. Evaporative cooling can be the most energy-efficient solution when cooling large industrial and commercial areas, using water as a refrigerant and up to 80%

less energy than conventional air conditioning systems. Andrew Gaved, Editor of Emap’s H&V News magazine, who cohosts the Energy Awards said: “To get to the target of Net Zero carbon emissions by 2050 – which is now a legal requirement of course - will take a huge amount of innovation and a massive collaborative effort from the energy sector, but the good news is that that is exactly what has been on show at the Energy Awards. It should give us all hope for the future.” Seeley International

uksales@seeleyinternational.com eurosales@seeleyinternational.com www.seeleyinternational.com

Process Industry Informer • November - December 2019

Measurement

ABB optimises efficient water usage and treatment with launch of new analytical transmitter The AWT420 opens up new opportunities for water quality measurement in utility and industrial applications ABB has expanded its digital analytical measurement range of solutions with the launch of the AWT420 transmitter. The new fourwire, dual channel analytical transmitter measures multiple parameters in a single device, optimising process performance for efficient water usage and treatment. It is simple to integrate, is data secure and fast to upgrade in the field. Capable of measuring multiple parameters including pH/ORP, conductivity, dissolved oxygen and turbidity, the AWT420 is versatile and user friendly. Key to the transmitter’s versatility is its use of interchangeable communications and sensor modules enabling the transmitter to be upgraded as required without having

to purchase additional units. Modules for HART, Profibus or Foundation Fieldbus communications and ABB’s digital EZLink pH/ ORP, conductivity, dissolved oxygen or turbidity sensors are available. Each pluggable module is factory calibrated and can be removed and exchanged via the transmitter’s hinged door, allowing fast upgrading in the field. The transmitter’s intuitive interface, simple set-up menus and onebutton calibration routine also eliminate the need for specialist installation or commissioning expertise. Additional operational flexibility is provided by the transmitter’s dual channel design. Users can opt for analogue or digital sensors or a mixture of the two, providing the convenience and associated cost savings of using a single device for multiple measurements. The inclusion of integrated PID enables the transmitter to provide direct or reverse acting control. In pH

applications, this function can also be used to provide dual acid/base control. When it comes to installation, wall, pipe and panel-mounting options enable the AWT420 to be fitted virtually anywhere. With a choice of corrosionresistant polycarbonate or durable metal versions, plus a safe, non-incendive design and USFMc and ATEX / IECEx approvals, the AWT420 provides a single solution for both standard and hazardous applications in the utility, process, power and marine sectors. For maximum usability, the AWT420 incorporates a host of features enabling quick and easy access to measurement, diagnostic and audit data. The transmitter’s easy-tonavigate full-colour TFT display means sensor data can be quickly located and viewed in-situ via the device’s display or saved onto an internal SD card for analysis using ABB’s DataManager Pro tool.

The inclusion of Bluetooth technology also enables operators to obtain up-tothe-minute information and technical support via a smartphone using ABB’s EZLink connect app. To avoid data tampering, multi-level security access prevents unauthorised configuration or calibration changes. Password protection ensures that changes can only be made by authorised users, with the details of any alterations, including dates, times and the person responsible, stored in an audit trail. Multi-level security access also ensures that users can only perform tasks within their specific profiles, with a choice of readonly, calibrate and advanced security access levels. For more information about ABB’s digital transmitter range, visit www.abb.com/ measurement

Ultrasonic Flowmeters Help Reduce Drug Production Costs Titan Enterprises reports that its Atrato and MetraFlow ultrasonic inline flowmeters are used by drug manufacturers to streamline production and reduce costs. These devices measure a liquid’s rate of flow with extraordinary levels of accuracy, helping drug manufacturers control small details that make a big difference during production. Production of pharmaceutical drugs presents difficult challenges for process instrumentation used to monitor and optimise the process. Typically drug production processes require devices able to cope with low flow rates and constructed from ultra-pure materials so as to maintain hygienic, sterile and sanitary conditions. Process Industry Informer • November - December 2019

The Atrato range of inline low flow flowmeters use patented ultrasonic technology, which enables it to operate with excellent accuracy over a very wide flow range (0.002 to 20 litres/ minute). The rugged, clean bore construction makes the Atrato ideal for almost any low flow application. Different models of this non-invasive flow measurement device are available for metering fluid flow from -10°C to +110°C and pressures up to 30 bar (435 psi). The Metraflow ultrasonic flowmeter was designed for customers tasked with applications that pose fluid compatibility challenges. Using patented ultrasonic technology, with a single unbroken PFA measurement tube, the MetraFlow is able

to reliably operate with excellent accuracy across flow ranges from 20 to 5000 ml/ min, having excellent turndown of 50:1; repeatability (+/– 0.1%); linearity and a reading accuracy of better than +/– 0.5% full scale. For further information please visit here and here or contact Titan Enterprises on +44-1935-812790 / sales@flowmeters.co.uk. 12

Measurement

New ABB Ability™ Verification tool helps pump hire company improve confidence in its flow measurements Leading pump hire company overcomes issues with verification of flowmeters used in its packaged pumping systems ABB’s new digital flowmeter verification tool is helping a pump hire company ensure its customers can count on accurate measurement of pumped flows in their applications. Reducing verification testing to just minutes, the new tool enables Selwood Pumps to quickly and easily verify the accuracy of flowmeters used in its packaged pumping systems between hires. Selwood, the leading pump rental solutions company in the UK, uses ABB’s WaterMaster flowmeters as part of its packaged pumping solutions that are rented to customers across a wide range of industries. The company carries out a verification of each flow meter both before and after every customer rental to ensure that it is within its original calibrated specification such that the next customer can have confidence that their flows are being accurately measured. Selwood was originally using ABB’s VeriMaster verification system, which consists of a software package that tests key parameters such as resistance and voltage to check flowmeter sensor and transmitter calibration. The VeriMaster system uses an infra-red scanner which is attached to the flowmeter transmitter and connected to a PC via a USB cable.

“We had used the VeriMaster system for a while and found that it worked well while the transmitters were still new,” explains Carl Whitfield, Electrical Asset & Support Manager for Selwood. “However, wear and tear incurred as a result of our customer’s applications meant that we started having issues keeping the infrared scanner connected to the transmitter, which led to verification tests taking hours rather than minutes.” Searching for a solution to the scanner problem, Selwood contacted ABB through its supplier, WH Good Automation Ltd, one of ABB’s network of Instrumentation Alliance Partners. By coincidence, ABB had completed work on its new ABB Ability™ digital cloud-based verification tool and was looking for companies to help evaluate it. In contrast to the VeriMaster-based verification tool, the new ABB Ability™ digital platform offers both an infrared scanner and a HART connection, providing a fast and robust connection for the transfer of data between the flowmeter and the software. Providing an instant and reliable connection, the new tool has helped Selwood Pumps to reduce the verification testing time for its WaterMaster flowmeters to just a few minutes. “The new tool is much quicker and easier to connect,” says Whitfield. “Unlike other companies that verify their flowmeters only occasionally, we have a high turnover of testing of our meters and can test up to 50 a month. The new verification method connects instantly, drastically cutting the time we need to spend.” Selwood conducted beta testing of the new software for three months, making suggestions for enhanced features that would make testing even easier. “We suggested that a facility to search the system’s data for flow meters based on our own fleet numbers would be convenient,” says Whitfield. “ABB responded by updating the software to provide a database feature, which makes it very quick and easy to find details of tests on individual meters.

Process Industry Informer • November - December 2019

Measurement

“Now, I can simply input a particular flow meter ID and see its complete verification history, which our audit team finds very useful.” The input and recommendations of the pump solutions team at Selwood has influenced the design of the verification package and the database searching feature will form part of the finalized product. Whitfield is to train staff in Bristol to use the new software. Adds Whitfield: “ABB has said the new software will also be able to verify the MagMaster flow meter eventually, which is useful for us as we have several MagMasters in our hire fleet.” David Lincoln, ABB’s Measurement and Analytics Digital lead, found that

Selwood’s input was very useful in developing the software.

new possibilities that other customers might find useful.”

“The software was not far from commercial release, so getting Selwood to test it was very valuable. In using it to help solve Selwood’s verification issues, we gained valuable feedback and additional ideas that helped us to further refine the tool in ways that could help broaden its functionality for other users as well.”

Paving the way for a data-led future The new software forms part of the cloudbased ABB Ability™ digital platform. Ultimately, data from any of a user’s installed instruments and analysers will be available to view online via the myABB business portal, which provides a complete list of devices linked to the customer sites they are installed at and recommends services at defined intervals.

“Carl gave us some very positive feedback and explained that it was very easy to connect to the software. We already thought the tool was good, but this was the confirmation we needed.” The feedback about the HART connectivity was also useful in that it gave ABB a better appreciation of the additional communication features of the new tool. “We had developed the platform to connect over several different methods,” says Lincoln. “If Selwood had not had these issues, we might not have fully appreciated the potential in the software. It was very helpful that a customer had identified

“There is a shift in how people see and use information and also in what they expect from manufacturers such as ourselves in terms of support and future product developments,” says Lincoln. “By using the data gathered by our ABB Ability verification tools and optionally uploaded to myABB, we will be able to obtain a clear picture of what is installed and how it is performing. With this information, we can assist customers in a range of areas such as maximizing product lifecycles, better management of spare parts and providing easy access to installation manuals and data sheets.”

ABB launches highly accurate, non-invasive temperature sensor New non-invasive temperature sensor opens unprecedented opportunities for temperature measurement in process plants worldwide ABB’s new non-invasive temperature sensor offers a simpler and safer way of measuring process temperature without the need to shut down a pipeline, drill a hole, or install a thermowell. With its innovative double sensor architecture and specially developed calculation algorithm, the sensor greatly enhances safety and reduces installation costs without sacrificing the quality of the measurement. The device is designed for surface measurement and eliminates the need for a thermowell, avoiding process intrusion altogether and greatly increasing the safety of people, plants,

and the environment. As such, it can be used in a range of applications, including processes with hazardous media, special hygiene requirements and/or stringent cleaning requirements and highpressure processes with high bending loads or use with abrasive media. The non-invasive approach is inherently safe, compliant with safety standards, and simplifies environmental aspects. With the sensor able to be installed and maintained without shutting down a process, plant availability is improved and system costs are lowered, helping to reduce CAPEX costs by at least 30%.

has been developed through direct testing and feedback from key customers in the oil and gas, chemical, and food and beverage industries. The non-invasive temperature sensor is easy and straightforward, from ordering to maintenance, and the common ABB look and feel with text display makes commissioning and handling easy. The device is suitable for different media and

pipe diameters and can be used in all areas of the process industry and power generation. It has also global approvals for explosion protection up to zone 0. Its use with liquid media with low viscosity, high thermal conductivity and/or turbulent flow in metal pipes is particularly advantageous. For more information, email enquiries.mp.uk@ gb.abb.com, or call 0870 600 6122 ref. ‘Non-invasive temperature sensor’.

The new temperature sensor uses innovative technology with proven components, such as standard in-sets widely utilized in industry. It

Process Industry Informer • November - December 2019

Leaders in temperature measurement

Labfacility are the UK’s leading manufacturer of Temperature Sensors, Thermocouple Connectors and associated Temperature Instrumentation and stockists of Thermocouple Cables. Thermocouple Connectors

A comprehensive family of IEC / ANSI / JIS colour coded miniature and standard connectors, accessories, panels, terminal and barrier blocks: all manufactured by Labfacility Plugs & Sockets, / Quick Wire / Panel Mount / Fascia Sockets/ PCB Mounting / Duplex / High temperature

Temperature Instrumentation

Labfacility have always been associated with high accuracy temperature measurement manufacture. L60 Thermocouple & Fine Wire Welder Bench Top Instrumentation Temperature & Humidity Transmitters Data Loggers Environmental Instrumentation & Sensors

Temperature Sensors We manufacture a wide range of temperature sensors to suit your application. An extensive range of Thermocouples, PRT’s, Detectors, Environmental Sensors and Hand-Held Sensors / Thermometers are also available to purchase online for immediate despatch.

Thermocouple & PRT Cable/Wire A range of IEC / ANSI colour coded thermocouple cables / wire and PRT cables / wire to suit various applications. The range consists of the following: PVC, PFA, PTFE & Glassfibre insulated cables. We also offer retractable curly leads and extension leads.

www.labfacility.com Bognor Regis tel: +44 (0)1243 871280

sales@labfacility.com Shefﬁeld tel: +44 (0)1909 569446

Measurement

MmWAVE Radar from Pulsar – Flexibility, Choice and Accuracy Like No Other Pulsar Process Measurement has launched mmWAVE, a compact FMCW RADAR sensor that offers high accuracy, repeatable level measurement and compatibility with Pulsar’s full range of level controllers. That means that Pulsar customers can choose between mmWAVE RADAR and dB ultrasonic measurement without having to make any compromises in terms of functionality - they choose the right control solution and simply pair it with the appropriate measurement technology for the application. Pulsar Process Measurement is a world leader in noncontacting level measurement with tens of thousands of installations worldwide. The success of the business has been built on reliable, repeatable measurement systems that have made difficult or seemingly impossible measurements such as deep, cluttered sewage wet wells or dusty grain silos a reality. RADAR and non-contacting ultrasonic measurement are complementary non-contacting technologies – measuring level by signal analysis but excelling in different situations. RADAR is preferred where there is variation in temperature or changes in gas composition, and extremes of fog, haze, mist or rain, so users can now introduce Pulsar’s sophisticated control functionality into new applications. mmWAVE RADAR is a Frequency Modulated Continuous Wave (FMCW) transducer with

Process Industry Informer • November - December 2019

a 16m range and accuracy of ±2mm. FMCW RADAR offers significant advantages over pulsed RADAR systems - higher resolution, better signal to noise ratio and better target discrimination. A major benefit to customers is that mmWAVE sensors are compatible with existing Pulsar controllers already installed and used in the field, such as Ultra 3 and Ultra 5, meaning that sites can retrofit a RADAR sensor within their existing applications, redeploy Pulsar equipment across a wider range of applications for maximum flexibility, or test the performance of different measurement technologies without having to significantly reconfigure the device. Commenting on the development, Pulsar’s Sales & Marketing Director, Alistair MacKinnon said, “Pulsar is known all over the world for its ultrasonic systems control and communication functions that have been developed over twenty years to meet the needs of a wide range of industries and processes. mmWAVE RADAR now allows us to broaden that approach to new markets and new applications.” For more information visit here or get in touch at: info@pulsar-pm.com | +44 (0) 1684 891 371

SOMETIMES THE CHOICE IS DIFFICULT …

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MEASUREMENT IS EASY: One sensor for bulk solids. Sounds simple, is simple!

RADAR LEVEL MEASUREMENT WITH 80 GHZ Industrial processes are becoming increasingly customized and complex. Now it’s even easier to select the right level transmitter for your needs. For a reliable non-contact level measurement solution, just choose VEGAPULS 64 for liquids or VEGAPULS 69 for bulk solids.

DYNAMIC RANGE

120 dB

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PROCESS FITTINGS FROM

¾"

With small connections and a compact design, VEGAPULS 64 is the perfect fit in the smallest liquid containers.

FOCUSING

3°

No interfering signals from internal installations. A radar beam angle from 3° for liquids and 4° for bulk solids.

ACCURACY

+/-1 mm

Every drop counts with VEGAPULS 64. It really scores points for accuracy, especially with high value liquids.

ADJUSTMENT 80 GHz radar sensors can be adjusted wirelessly with a smartphone or tablet. Did you know? All VEGA level sensors since 2002 can also get Bluetooth. Just click-in a new PLICSCOM display and adjustment module and it’s done!

More information: www.vega.com/radar Phone +44 1444 870055 | E-mail info.uk@vega.com

Measurement

Variohm EuroSensor’s Euro-CMRT micro threaded angle sensor Smallest model now launched for new miniature programmable Hall Effect angle sensor range: Variohm EuroSensor’s EuroCMRT micro threaded angle sensor offers extensive option and customisation selection With a diminutive 10 mm diameter housing, M8 threaded mounting and a 3.175 mm diameter flatted shaft, Variohm EuroSensor’s new EuroCMRT series Hall Effect angle sensors extend its recently launched CMRx range of miniature programmable non-contacting sensors. The durable and robust CMRT series has an IP68 rating and is particularly aimed at long life, high duty-cycle precision angle measurement tasks where space is at a real premium or where its design flexibility allows straightforward mechanical and electrical adaptation to exactly match the customer’s requirements. A choice of single or dual redundant output, with CW or CCW direction, includes ratiometric or PWM signal levels from an industry standard 5 VDC input. Variohm’s Hall Effect sensor technology has been adapted and improved over many angle sensor design iterations and is well-proven for use in arduous position feedback measurement applications that

include motorsports, industrial automation, agricultural vehicles and construction machinery. And now the new Euro-CMRT series is available in its smallest package size to date. The M8 mounting and small envelope will facilitate mounting in the smallest spaces as well as allow custom flange adaptations for form-fit replacements for competitor products and application upgrades for existing Variohm applications. The high grade anodised aluminium housing supports the 316 stainless steel shaft in a durable phosphor bronze sleeve bearing and with no sensor contact, long life – in excess of 50 million movements - is specified. A vibration rating that meets IEC 600068-2-6 and temperature range from -40° C to +125° C, with short term operation to 150° C, further ensures performance for the most demanding environments. The Euro-CMRT complements the new 18 mm PCD flange mounting Euro-CMRS and the puck-andmagnet design of the Euro-CMRK. Thanks to their innovative and modular design, with encapsulated sensor electronics, all EuroCMRx series products boast the same impressive environmental

and electrical specifications with independent linearity to 0.5% of each signal range, and programmable angles from 30â° to 360â° in 1â° increments. Electrical connection for the 3-wire singlechannel and 6-wire dual-channel versions is 500 mm long Raychem 55 cable with connectors and other options on request. Across the new CMRx micro sensor range, whilst the dimensions are the smallest currently available, the modular design offers straightforward mechanical and electrical customisation. This scalability helps to ensure the customer’s installation requirements are both matched and simplified. The Euro-CMRx range is produced at Variohm’s ISO 9001:2015 quality-certified UK manufacturing facility along with many other precision sensor components and measurement sub-systems for position, force, pressure, load, and temperature measurement. Variohm is also a distributor for several other leading sensor component suppliers as well as a supply chain partner for major manufacturers. The specialist provides complete sales and application support across its comprehensive range of sensor technologies for demanding measurement applications in industry, construction, agriculture, motorsports, research and more. A new datasheet is available covering the Euro-CMRT along with complete specification details for the new Euro-CMRx range of customisable Hall Effect noncontacting sensor models on the Variohm EuroSensor website. Variohm EuroSensor’s application engineers are on hand to discuss customer requirements and provide technical assistance from development through to after sales support.

Process Industry Informer • November - December 2019

Feature Article

By Jalal Bouhdada, founder and CEO of Applied Risk

manufacturing

Tips for effectively protecting Operational Technology

Technological developments such as the Industrial Internet of Things and 5G are increasingly bringing connected devices and sensors into manufacturing environments. Yet as industrial businesses ramp up their investment into systems that incorporate connected devices, many of them are opening the door to functional safety, environmental and cyber security breaches.

The manufacturing industry has been hit by a number of cyber-attacks in recent years. Last month, German manufacturer Pilz was victim of a ransomware attack that meant its systems were down for more than a week. This summer in the US, the National Association of Manufacturers (NAM) identified suspicious activity relating to company systems which they believe came from an attack from foreign nation

state. To mitigate cyber security threats like this, organisations must start by implementing strong Operational Technology (OT) cyber security controls, by combining prevention, detection and response tactics to safeguard critical OT systems and valuable intellectual property. Despite the warning signs, we have seen many manufacturing businesses are still not following the

Process Industry Informer â&#x20AC;˘ November - December 2019

most basic cyber security measures. This indicates a lack in the awareness of how severe the impact of a security incident in this sector can be. In most factories that are being retrofitted with real-time remote sensing and analytics, not enough attention is being paid to the secure implementation of systems and devices already lacking basic security measures. The potential dangers need be taken more seriously, and this must filter through all areas of the company. Perhaps, cyber security isnâ&#x20AC;&#x2122;t considered often enough in the manufacturing world because of its complexities, implementing effective processes may seem difficult. By their very nature, industrial environments are complicated, and a large proportion of the security risks come from the fact

that machines which were designed to be deployed in closed networks are now being connected to open IT systems. The additional risks that may result from this, can effectively be assessed and mitigated if suppliers and end users work together to investigate the security of legacy and new connected devices. The following six basic security requirements are recommended when designing and implementing IIoT connected devices: Secure interface It is essential to understand a deviceâ&#x20AC;&#x2122;s architecture and review its associated interfaces, software and hardware, for vulnerabilities. Software/firmware integrity It is crucial that IIoT devices first and foremost 22

Feature Article have the ability to perform updates regularly while maintaining cryptographic checks from a trusted source. Access control Firms must review the various access controls to determine whether a device allows for the separation of roles, strong passwords and the sufficient protection of credentials. Network services Product manufacturers should ensure only necessary ports are available and exposed. Backdoors An IIoT device should not have undocumented functions or hidden entry points that can be easily exploited by the device vendor or any other third parties. Security configuration An attacker will often utilise the lack of granular permissions to access data or controls on a device. Manufacturers must scrutinise devices for sufficient security hardening by restricting user privileges. While there have been few substantiated reports of major attacks in manufacturing plants when compared with breaches in corporate data, that doesn’t mean they aren’t already happening undetected. The concern is that the lack of major headlines, when compared to consumer and corporate data breaches, is actually feeding complacency around the issue. Yet, as we saw in IT, many firms are unaware that their OT networks have been breached, since there’s a general lack of monitoring. 23

The time to get this right is now, not just to mitigate the threat of cyberattacks, but also to allow manufacturing firms the opportunity for enhanced intelligence and streamlined operations, all with minimal cyber security risks. There are also many lessons that the manufacturing industry can learn from other industries. Techniques that are routinely deployed on corporate networks to identify and quarantine anomalous behaviours – identifying attacks early, in other words – must be developed. Fortunately, the most common issues we have encountered in our investigations are relatively easy to tackle. Addressing the OT security challenges that continue to put operations, and consequently, business at risk are essential. Here are our recommendations: Governance Make sure it is clear who is responsible for managing and maintaining the cyber security. By making this the primary task of a number of employees, you can be sure that someone is always working on the protection of your systems. Cyber security is a continuous process: continuous vigilance is necessary – a powerful argument for investing in the professional execution and tracking of your cybersecurity. As well as continuous monitoring, it is important to also have an action plan in place in the event of a cyber-attack. Secure by design Make sure the system is ‘Secure by Design’. Cyber security must be part of the design and procurement of a system, up to and including

the end of its lifespan. The Systems Development Life Cycle (SDLC) principles have proven to provide a reliable method that can be used to develop your systems safely. Cyber security hygiene As with an industry, good cyber security starts with the basics. That means simple things like ensuring good password policy for all users (on-site and remote), administrators and the IIoT devices themselves, where standards of practice still fall short. It continues with asset audits and ensuring that proper network segregation is used to protect vulnerable parts of the infrastructure. Supply chain It is essential that you not only look at your own company, but also to suppliers and other partners. You can have your business in order, but do those you work adhere to the same standards? Be critical and set the bar high. Re-evaluating the entire supply chain and ensuring that business partners thoroughly understand the OT environment and its cyber security risks is essential. Continuously test Make sure cyber security is

tested on a regular basis. We find fire exercises very normal; that should also apply to the practice of a cyber-attack. Let professional hackers try to invade your system and practice the next steps – involve your suppliers here too. KPIs Cyber security (and the potential risks) is not only the management’s concern. Every employee, at every level in the company, must be aware of the hazards and the points of attention. Develop an awareness-raising culture and set it mandatory for all employees. It is not a crazy idea to link the program to Key Performance Indicators. Urgency Fortunately, the importance of cyber security is becoming increasingly acknowledged, but not everyone is taking the measures that are involved seriously enough. Now that more and more new capabilities are emerging for threat actors, digital security needs to be prioritized. By following these steps, you can make things much harder for cyber criminals.

Process Industry Informer • November - December 2019

Columnists

Introducing PII’s newest columnist

Gavin Smith!

THE OTHER SIDE OF THE Climate CHANGE EQUATION: Brief (www.carbonbrief.org) titled “Global coal power set for record fall in 2019”. So, which is it?

I am fond of many quotes from Mark Twain and in the age of social media one is particularly apt:

“If you don’t read the newspaper, you’re uninformed. If you read the newspaper, you’re misinformed.“ As the World Meteorological Organisation (WMO) reports (www.public.wmo.int/en) greenhouse gases reaching new heights, if media reports are to be believed (and I am not saying that they can’t), China is producing circa 70% of its’ energy from Coal powered power stations. Websites such as www.politifact.com have quoted the New York Times article published on July 1, 2017, as saying that “Overall, 1,600 coal plants are planned or under construction in 62 countries.”, however corrected down (“fact-checked”) this number to less than 460, mostly across Asia. Any number in the order of 460 is still a staggering number, especially when it is likely that the economies of China and India will see increased demand for coal generated electricity over the immediate future. The Guardian article of November 2019 “China’s appetite for coal power returns despite climate pledge” lists not only China’s coal-fuelled energy growth, but also how China is helping to fund coal plant construction projects around the world. Whether the number is at, above or below 460 isn’t the key issue given 46 is too many, let alone 460. Cross referencing with the NRP and a statement as to China building “hundreds” (“more than 300” is the number quoted) of coal power stations within China and abroad is front and centre. Following the Guardian report comes the report in the online journal for Carbon

Process Industry Informer • November - December 2019

Coal remains one of the less expensive fossil fuels, one that is readily available and is easy to handle for power generation. The same dialogue could be applied to most other fossil fuels. Coal is just one of many that bridge the gap between renewables and humanities growing energy demands. The scale of mining operations out of Newcastle, Australia is staggering (as is the “economic value”) – so it is somewhat disingenuous to single out the end user without also considering the suppliers. Interestingly, people often look upon the Oil and Gas industry in an opposite way (when it suits) in so far as protesting the operators without considering the many, many end users and products hydrocarbons end up in. Understanding why there is the need for such an expansion of coal fired power stations is as an important question. The Elephant in the room, while we still have Elephants as a living species, it that at a time we need to decrease our carbon footprint, we are seeing an increase in human population. This population increase is driving ever more the need for energy and consumption (and resultant waste and pollution). The irony here is that China is one of the few (if only) country to actively legislate to reduce population growth – oddly something that is often portrayed in the media as a negative despite the overwhelmingly positive impact on climate change. It would seem that the socio-economic forces that drive most of our economies, in 2015 also drove China to announce the abolishment of the one child policy. The problem in China is thus two-fold in that it needs to provide for the food, energy, textiles, etc. for it’s own population it does so also for the wider world also. One could argue that the need for China’s expansion of coal fired power stations is as much globalisation as it is China’s own making. Where would Australia’s economy be without coal exports? Or the many technology industries that import vast tonnages of electronics from China? With increasing population comes increased consumption of both energy and materials. Politicians “promise” a

Gavin Smith (FIChemE) is a graduate from the University of Melbourne in Chemical Engineering. Having started off as a Winemaker, has spent the last 22 years based in Europe (when not in the Middle East or North Africa!) as a Professional Chartered Engineer working in Engineering Management, EPC and technical consulting across the Food/beverage, Pharmaceutical/Biotech, Energy (Hydrocarbons) and Wastewater industries. Former Chief Process Engineer for AMEC upstream Oil and Gas, now working within the Pharmaceutical and Biotech sector.

future “net-zero” carbon footprint, yet don’t address the fundamental economic driver for most economies is population growth and increased consumerism. Is the flaw in that argument not obvious? Governments and environmental groups really need to stop the hyperbole and consider the science and practicable alternatives. If we do nothing about population growth, consumption and globalisation, then we accept that climate change is inevitable unless we radically change consumption and the economic basis that most economies run upon. Surely population growth must be part of this “climate change” discussion given it seems self-defeating to reduce carbon footprint whilst adding 160 million human feet (80 million new humans) onto the planet most years (Reference: UN World Population Prospects 2019)? As someone born in 1970, I read with interest on www.worldometers.info/worldpopulation “In 1970, there were roughly half as many people in the world as there are now.” Whilst overall population growth rates have declines somewhat since I was born, there are still twice as many of us taxing the earth’s precious resources since I was born. This is the other side of the climate change equation that gets little attention and few protests/ activists. 24

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Process Industry Informer • November - December 2019

Feature Article

Tim Broadhurst, chief commercial officer at CooperOstlund

Top tips to perfect your

co-generation performance

In this feature, Tim Broadhurst, chief commercial officer at CooperOstlund, discusses the importance of maximising CHP performance and how a few simple steps can boost your site performance significantly. According to insight from Ricardo-AEA, there is currently some 6.1GWe CHP capacity in the UK. By 2030, this figure is expected to reach more than 65TWh/yr (25% of which is expected to come from entirely renewable resources). Whether combusting biogas in the food

waste recycling market or as part of blended energy programmes for some of the world’s largest manufacturing organisations, CHP is fast-emerging as a key part of our future energy landscape. But while a highly disruptive decentralised technology, CHP is often seen as a one-time purchase. Many owner/ operators are running their plants with the belief that the only requirements for a successful CHP are to engineer and construct the plant, push the start button and reap the benefits of a completed project.

Process Industry Informer • November - December 2019

Operating on this false premise, many businesses do not adequately plan for the extensive maintenance requirements and ongoing capital investments necessary to achieve maximum efficiency in their CHP plants, causing the savings to erode over time. As this happens, many CHP owners become frustrated with the results, try insufficient quick fixes and in some cases choose to turn off their plants and go back to the grid. This is an unfortunate situation, but one that can easily be avoided with appropriate attention and simple changes. It’s

essential to appreciate the long-term requirements of your CHP engine and effectively plan for the future. Failing to do so will not only result in unnecessary engine maintenance issues, but also jeopardise pay-back periods and significantly reduce your site’s financial viability. Step 1 – Maximise maintenance Your CHP needs daily checks, regular fluid topups, periodic servicing and replacement parts to appease general wear and tear. While it is possible to do a number of these tasks yourself, especially if you

Feature Article know your way around an engine, there will always be some responsibilities that are best left to the experts – especially for certain functions made inaccessible by coding technology or manufacturer restrictions. Having a solution in place to manage the day-to-day operations and maintenance of your CHP engine is therefore paramount to its performance, efficiency and longevity. Whether that covers the entire servicing element or simply takes the more complex milestone requirements off your hands, working with an expert will ensure your site maximises performance and efficiency in the longterm. To support this, you need a trusted supplier of spare parts, fluids and everything in-between. What’s more, you need fast response times, expert insight and a consultative approach. Step 2 - Improve your outputs The performance gap between a CHP running at maximum efficiency vs. an inefficient one can be quite significant. For example, equipment availability on reciprocating engines at a well-run CHP plant is typically in the 92 to 94 per cent range, whereas many plants in the industry are operating at levels in the 70 to 75 percent range. Alongside maintenance, there are numerous ways to optimise an older, lowerperforming plant. Electric Turbo Compounding (ETC) – ETC products make gas and diesel-powered gensets work more cleanly and effectively, by recovering 27

waste energy from the exhaust to improve power density and fuel efficiency. The technology is equally suited to new-build and retrofit applications, for engines in the 150kW-2MW range. By integrating ETC technology with your engines, it’s possible to achieve enhanced power generation capacity efficiencies. Organic Rankine Cycle (ORC) – ORC works by harnessing excess heat from your CHP engine and turning it into power. The units capture excess heat, using it in a process of evaporation. As a thermal oil is pumped through at high pressure it begins to boil and turns into gas. The gas flows through an expander, which causes a generator to spin and produce power. The gas is then cooled back into its liquid form to begin the process again. Step 3 – Control your set-up Another factor that often separates the well-run CHP plants from inefficient ones is the ability to measure the key performance metrics as outlined in the operations plan in real time. Best-practice companies have appropriate meters and software in place that enable them to collect

and view the operations and performance metrics that are at the core of the operations plan. By contrast, many companies that fell prey to the green button theory do not have the ability to capture and track the critical trend data over time as it pertains to the performance of the plant. As a result, they have no idea of which steps need to be taken to improve the performance to the desired levels to ensure they are meeting the financial targets that the project was initial approved on. By replacing proprietary control systems with open protocol alternatives, your CHP engine can interoperate without the need for a proprietary interface or gateway. This allows engineers to easily control each setup without the need for specialist support and provides immediate digital access. The added benefit of internet connectivity means engineers can even control engines from an off-site location, which further reduces costs and dramatically improves uptime.

At CooperOstlund, we understand that no two sites are the same, so approach every situation in a completely bespoke fashion – ensuring the utmost care and attention to deliver exceptional results. Alongside providing an extensive range of maintenance programmes, we also offer a wide range of plant improvement technologies to guarantee the best possible return on investment for your site. From open-protocol control panels, to nextgeneration Organic Rankine Cycle (ORC) systems, our capabilities stretch far beyond installing and commissioning gas engines. Through an exclusive agreement with Bowman Power Group, for example, we offer a comprehensive range of Electric Turbo Compounding (ETC) products, achieving an average c.3% increase in output efficiency. Our consultants can even provide independent site audits, to provide external insight into the performance of your setup, and advise a variety of improvement options, if required.

Process Industry Informer • November - December 2019

MAINTENANCE AND HEALTH & SAFETY

DIALIGHT LAUNCH ATEX-CERTIFIED GRP LED LINEAR Dialight Group, the leader in Hazardous Area and Industrial LED lighting, has announced the launch of its new SafeSite® Glass Reinforced Polyester (GRP) linear model for the APAC and EMEA markets. The rugged new fitting has been designed for long-life performance in the harshest environments and specifically for Hazardous Area applications including the upstream and downstream oil and gas, petrochemical, mining and heavy manufacturing sectors It is certified for IECEx / ATEX Zone 2, 21 & 22. Available in 764mm and 1244mm lengths with M25 entries as standard and a lumen output range of 2,785 – 5,750 lumens, the SafeSite GRP LED Linear can operate within the temperature range of -40°C up to +65°C. and comes complete with Dialight’s industry-leading 10-year warranty, providing a reliable, low maintenance solution with triple the lifespan of traditional fluorescents, even in the world’s most demanding conditions. Dialight’s LED lighting also contains no harmful toxins such as mercury.

Process Industry Informer • November - December 2019

Featuring Dialight’s exclusive inhouse designed power supply and thermal management system, the SafeSite also features corrosion resistant GRP housing and stainlesssteel hardware. It is impact resistant and IK08 rated. It is also IP66/67 rated making it impervious to water and dust Ingress. Options include battery backup models with field-selectable durations of 60, 90 & 180 minutes to allow end users to easily conform with local regulations for minimum EM durations for egress lighting purposes. Additional safety features include four stainless steel retention tabs, an optional wire guard accessory, a wildlife, eco-friendly amber solution and a green shower safe and eye wash station option. The new SafeSite GRP Linear range is controls-enabled, offering DALI 1.0 / 2.0 as standard across the range and is dimmable from 100% down to 5% to provide greater efficiency and energy savings.

Dialight’s new SafeSite® Glass Reinforced Polyester (GRP) linear

Fariyal Khanbabi, Dialight Group Chief Executive, commented, “The new GRP linear represents another key advancement in engineering, safety and longevity for harsh and hazardous industrial environments.” “We are justifiably proud to be able to bring our expertise to the market with a superior solution that is optimised for long life in challenging environments and offers one of the widest ambient temperature ranges on the market.” The new SafeSite® GRP Linear is now available. To learn more about the GRP SafeSite and Dialight’s other market-leading industrial LED lighting solutions, visit www.Dialight.com

MAINTENANCE AND HEALTH & SAFETY

NSK K1 lubrication units resolve failures at cereal plant K1 lubrication units extended operating life by 12 months at the cereal plant

The introduction of NSK linear guides with K1 lubrication units has helped a cereal manufacturer overcome contamination issues on its bagging machines, a move that is saving the company almost €65,000 a year. After enduring regular failures across its four bagging machines, the cereal plant decided to call in NSK and leverage the company´s experience in

cereal manufacturer asked NSK to propose a solution.

diagnosing issues of this type. The application review performed by the expert team of NSK engineers revealed that the problem was attributed to dust and cereal particles entering the guide carriage and contaminating the lubricant, leading to premature failures. With the failures occurring on a monthly basis, and faced with high maintenance and lost production costs, the

NEW SAFETY LOCK OUT FOR MAINS CUT OUTS Now available from Martindale Electric – leaders in safe isolation and electrical safety – is the new LOK6W, a simple and effective locking off device for Henley and Lucy mains supply cut outs. Designed to restrict finger access to live contacts and prevent the reinsertion of a fuse whilst maintenance is in progress, the LOK6W is an essential accessory to keep electricians, installation teams and their customers safe in accordance with Electricity at Work Regulations. In common with the LOK6, the new LOK6W features an extendable design which also makes it suitable for larger Red Spot type fuse holders rated at 63A and 100A Manufactured without any metal parts – to reduce the risk of use in live working environments – the LOK6W is constructed from a resilient flame-retardant blend of Polycarbonate and ABS for high strength and long-term durability.

Designed in Martindale’s distinctive yellow casing, to make it easily identifiable, the new locking off device from Martindale Electric is quick to install without the need for any tools. The LOK6W is compatible with a wide range of locking padlocks with shackles up to 7mm wire diameter. Martindale Electric recommends utilising the PAD11R or for added safety the insulated padlock PAD21R, both padlocks are serialised with unique key numbers for safety and simple identification. Also available from Martindale Electric is a full range of locking off kits, voltage indicators, test lamps and proving units for implementing safe isolation procedures in all installation categories up to 1000V CAT IV. For more information, please contact Martindale Electric on 01923 441717 or visit: www. martindale-electric.co.uk

NSK recommended its K1 lubrication units, together with new linear guide and rail assemblies, which the company estimated would extend operating life by up to 12 months. In addition, the cereal manufacturer would be able to reduce maintenance and equipment downtime, achieving significant cost savings. To put the theory into practice, a trial of the NSK solution was carried out at the cereal plant, which indeed showed a minimum of one-year maintenance-free operation. The K1 lubrication unit´s material consists of 70% mineral oil and 30% polyolefin resin, ensuring

Cereal manufacturing creates dust that can penetrate linear guides and cause failures

long operating life under tough lubrication conditions. As well as improved performance, this clean method of lubrication has far less impact on the environment than conventional systems. Now installed across all four machines, it has been calculated that the NSK solution is saving €64,625 per annum for the cereal manufacturer, based on reduced maintenance costs alone. www.nskeurope.com

COMPRESSORS BOGE’s total compressor rental service guarantees industry the air to work BOGE, a leading manufacturer of compressed air systems, is helping businesses across industry to cost effectively meet both short- and long-term demand for compressed air through its total compressor rental service. The highly affordable service offers businesses an alternative to owning and maintaining their own compressors. BOGE and its network of experienced distribution partners specify compressed air systems based on the needs of each business, ensuring customers are consistently supplied with the correct volume of compressed air required. Skilled engineers oversee a fast installation and commissioning process and provide 24/7 nationwide service and maintenance support as part of the monthly fee. BOGE offers a comprehensive range of industrial air compressors, including oil lubricated and oil free screw compressors from 1 to 480 HP. It also supplies a complementary range of compressed air

equipment from filters and dryers to condensate management equipment. This allows businesses to quickly and easily source everything they need from a single supplier. “Renting a compressed air system is proving increasingly popular in sectors like food and beverage, packaging and general engineering, as more businesses begin to realise how affordable it is,” explains Mark Whitmore, General Manager at BOGE Compressors. “BOGE’s rental service is designed to make hiring a compressor as easy as possible. We take care of the specification, installation, servicing and maintenance, as well as all the admin, so customers can focus on their day-to-day responsibilities and have peace of mind that compressed air will always be available when they need it.” Further information on the compressor rental service is available at www.boge.co.uk.

Process Industry Informer • November - December 2019

MAINTENANCE AND HEALTH & SAFETY

ESAB launches first portable wire feeder with ip44 protection class rating for extreme durability ESAB Welding & Cutting Products today introduced the Robust Feed Pro portable wire feeder, the first product in its category with an IP44 protection class rating, which means it is protected against water splashes from all directions, as well as solid objects larger than 1 mm. The completely-sealed Robust Feed Pro has a double-wall design with special impact zones made from a more flexible material to absorb more impact energy. All controls, power and gas connections are inside the case with a dedicated service cover, providing easy access to the electronics.

and offshore, steel erection, structural steel fabrication, hard surfacing and cladding, repair and maintenance, pressure vessels and pipeline. The Robust Feed Pro is compatible with ESAB’s Warrior 500i, Warrior 400i and Warrior 400i MV power sources, allowing operators to adjust voltage and wire feed speed at the feeder. At outputs of 550, 500 and 400 amps, it has a duty cycle rating of 50, 60 and 100 percent, respectively.

“The Robust Feed Pro is the only feeder on the market that you can leave outside in a heavy rain. A heat kit inside the units wards off condensation and keeps the wire dry,” says Arne Lagerkvist, Global Product Manager, Heavy Industry Welding Equipment, ESAB Welding and Cutting Products.

Powerful Drive System The Robust Feed Pro accepts wire spools up to 300 mm, measures 595 x 250 x 430 mm and weighs 16.8 kg. It comes equipped with a new precision wire drive system with enough power to handle up to 2.0 mm solid wire and 2.4 mm cored wire. ESAB minimised the footprint of the 4-roll drive stand while accommodating 38 mm drive rolls, which feature a quick change design and are color-coded for size clarity.

All cable connectors are protected inside of the feeder. There is a robust strain relief for the interconnection cables that makes sure there is no strain exerted on the cable connectors.

The system provides a large range of wire feed speeds (WFS), from 0.8 to 25.0 m/ min, which offers the speeds necessary for solid wires as small as 0.6 mm solid wire and as large as 2.4 mm cored wire.

“You can drop this feeder and drag it through the mud by the cable and nothing happens. There is no strain or risk from shearing off a cable or hose connection,” says Lagerkvist.

“Our design improves accuracy at lower speeds, has the power to feed larger cored wires and the high speeds necessary for smaller diameter hard wires,” says Lagerkvist. “The Robust Feed Pro is truly an all-purpose unit.”

The Robust Feed Pro’s extreme durability, portability and performance are particularly suitable for industrial fabrication operations such as marine

The front of the feeder has crisp, bright, large LED displays that are visible in strong sunlight, as well as backlit

Process Industry Informer • November - December 2019

symbols that makes the unit easy to operate in dimly lit conditions. The front has control knobs for voltage and wire feed speed buttons for wire jog and gas purge. Inside of the unit contains controls for 2T or 4T operation, wire inch, crafter fill and a flow meter for setting accurate shielding gas flow rates. The Robust Feed Pro also incorporates a switch to optimise arc termination for solid or cored wires. In the solid wire position, the switch activates Short Circuit Termination (SCT) technology, which sharpens the end of the solid MIG wire at the termination of a weld. By eliminating the ball that typically forms on the end of the wire, the feeder optimises the wire condition to promote a positive arc start. SCT technology also eliminates the need for the operator to clip the wire. In an operation with numerous weld stops and starts, the time savings will quickly add up. To improve arc starts when using Flux-Cored or Metal-Cored wires, the cored wire setting enables burnback control. Ergonomic Portability The Robust Feed Pro has three comfortable handles — all are crane certified — and two additional lifting points for best-in-class portability and maneuverability. The long top handle provides a way to lift the unit in its center of gravity, with or without a spool inside. Handles on the front and back make it easier to move through manholes and smaller spaces. “This is the only feeder on the market with clearly-marked

Pictured is ESAB’s Robust Feed Pro

crane-rated handles, an important feature for offshore and shipyard applications where they often lift objects into position,” says Lagerkvist. For greater mobility, the Robust Feed Pro has an optional wheel kit that mounts on either the bottom or side of the feeder. To keep digital voltage and amperage meters oriented for easy viewing (e.g., horizontally), the control panel can be rotated 90 degrees with the removal of two screws. “Putting the wheel kit on the side of the feeder creates a low, flat profile that’s more stable,” says Lagerkvist. “In applications such as trailer manufacturing, the operator can easily move the feeder under low objects. In any setting, its low center of gravity enables pulling the feeder past obstacles and across uneven floors without risk of it tipping over.” ESAB Welding & Cutting Products is a recognised leader in the welding and cutting industry. From timehonored processes in welding and cutting to revolutionary technologies in mechanised cutting and automation, ESAB’s filler metals, equipment, and accessories bring solutions to customers around the globe. For more information, visit www.esab. com or call 01992 768515. 30

MAINTENANCE AND HEALTH & SAFETY

Functional Safety Solutions From Moore Industries The FS Functional Safety Series from Moore Industries features instruments that have been designed and built in compliance with IEC 61058, the leading worldwide functional safety standard. Designing instruments in accordance with the standard from the ground up forces the components, firmware and circuit design to undergo additional scrutiny that affords the highest levels of reliability. Selecting products from the FS Functional Safety Series gives safety practitioners confidence that their instruments will perform as expected and when demanded.

STZ Functional Safety Dual Input Smart HART Temperature Transmitter The new STZ offers a dual sensor input that reduces process inter ruptions. Backup and Fail-Over Protection allows either of the sensors or inputs to be designated as the primary measurement, with the secondary input acting as the backup sensor in case of primary sensor failure. The dual sensor input also allows for Average and Differential measurements along with High-Select and Low-Select options. The STZ also features Moore Industries’ Device Intelligence, a series of features designed for smarter control and monitoring including: • An Associated Intrinsic Safety (AIS) option available with the DIN housing allows direct connection of sensors located in hazardous locations without requiring an intrinsically safe barrier. • Sensor drift and corrosion detection that checks and alerts users when the sensor is drifting out of a preset range or when the resistance due to corrosion exceeds set parameters. • Smart range alarms with four HART alarms – set to any input or calculated input – that detect when the variable is within or outside of user preset limits. • A High Availability option enables the selection of how the AO behaves when there is an input failure or outof-range value detected by the transmitter. This helps prevent spurious trips or nuisance alarms in Safety Instrumented Systems (SIS). • Input simulation capability allowing manual input of a direct or calculated value. This simulates a real input, 31

allowing users to test the AO or any HART diagnostic and range alarms – which assists in proof test procedures.

The STZ Functional Safety Dual Input Smart HART Temperature Transmitter family. The STZ is HART 7 compliant with exception-based reporting and dynamic variable mapping. It is HART and DTM programmable with useroriented basic configuration for fast and accurate setup. Utilizing the HART DD, it can be configured and interrogated on the 4-20mA loop via any HART handheld communicator or HART compatible host. To prevent unauthorized or accidental reconfiguration of the STZ while it’s performing its safety function, it has an added security feature to allow users to set HART communication into a Read Only or Off mode. Users can also program or monitor the transmitter with any FDT compliant host or program such as PACTware using the STZ DTM. Other FS Functional Safety Series Products Our FS Functional Safety Series instrumentation gives you layers of protection that reduce risk and deliver reliable performance when you need it most. Key features include: • Designed and built from the ground up for use with confidence in your Safety Instrumented System. • Full third-party certification to IEC 61508 eases the

burden of proven in use on unapproved products. • SIL 2 and SIL 3 capable product family designed to meet your safety loop instrumentation needs. • Instrumentation designed and built for reliable performance.

The award-winning Moore Industries FS Functional Safety Series product line. The FS Functional Safety Series product line also includes: STA Functional Safety Trip Alarm: The exida certified SIL 2 and SIL 3 capable STA Safety Trip Alarm performs as a logic solver and acts on potentially hazardous process conditions in Safety Instrumented Systems (SIS). The STA models accept a signal input from transmitters, temperature sensors and a wide array of other monitoring and control instruments.

2 capable SRM Safety Relay Module provides a high level of availability for safety-critical applications and as a part of Safety Instrumented Systems (SIS). The SRM is a relay repeater model that accepts a single contact closure input from a logic solver such as the Moore Industries STA Functional Safety Trip Alarm. The SRM provides three contacts per alarm input, allowing you to simply and cost effectively add additional alarm contacts to your safety processes. SFY Functional Safety Frequency-to-DC Transmitter with Display: This SIL 3 capable 2-wire (loop-powered) transmitter is ideal for use in Safety Instrumented System (SIS) in a wide range of monitoring applications. It monitors frequency, period, high or low pulse width, and contact closure signals and converts the input signal to a proportional, input-to-output isolated 4-20mA output ready for direct interface with a Safety System, readout instrument, recorder, PLC, DCS, SCADA system.

SSX/SST Functional Safety Isolator and Splitter: These exida certified up to SIL 2and SIL3 capable family of 2-wire and 4-wire Isolators and Splitter provide isolation and signal conversion for your SIS (Safety Instrumented System) needs. These units protect and enhance loops and also pass valuable HART data from the field transmitter to host systems and vice-versa. They isolate your SIS from your Basic Process Control System or monitoring system so disconnections or failures to these secondary systems don’t affect your safety system.

SLD PC-Programmable Functional Safety Loop Display: Features a large integral customizable easy-to-read display showing real-time process status in mA, percent, or any designated 5-character Engineering units (EGU) . Certified as SIL3 capable, noninterfering device for use in a safety loop, the SLD accurately displays process status in a safety loop. Optional Loop Maintenance Zener Diode allows removal from loop without interrupting the safety process.

SRM Functional Safety Relay Module: The exida certified SIL

See all the available FS Safety Series models at www.miinet. com/safetyseries

Process Industry Informer • November - December 2019

WATER & ENVIRONMENTAL

A win-win for the environment and water companies, EloVac®- P, vacuum degassing of digested sludge. ELIQUO is a group of companies operating in the field of municipal water, wastewater and sludge treatment. Together, they provide a comprehensive range of solutions: from EPC contracting in Germany and the Netherlands, to technology licensing and implementation in the UK. In addition, they have developed proprietary sludge technologies, such as EloVac®- P, that provide simple and innovative solutions to the wastewater sector.

An interview with Ulrich Knörle of ELIQUO - the inventor of EloVac®- P. What is EloVac® - P? EloVac®- P is the only vacuum degassing technology with simultaneous phosphate precipitation for digested sludge in the market. What is sludge vacuum degassing and how does it work? Vacuum degassing is a process where a vacuum extracts residual gas from a media, in this case digested sludge. Anaerobically digested sludge releases residual methane and carbon dioxide to the atmosphere – methane emissions from sludge treatment make up 75% of the diffuse CO2equivalent emissions (Gärtner 2017). With vacuum degassing, a pump continuously extracts the residual gasses inside a reactor tank for beneficial reuse such as additional biogas/electricity. The retention time of the sludge in the reactor tank is controlled. The special feature of EloVac®- P is the simultaneous phosphate precipitation in the reactor tank by dosing magnesium chloride directly into the tank. How did you come up with this idea and what does it mean to you? ELIQUO is foremost a water solutions company with the goal to provide technologies to the market that preserve natural water resources. For a long time, I worked in the field of anaerobic wastewater treatment. I was always amazed how these tiny anaerobic microorganisms can produce so much gas to generate Megawatts of electricity. The

methane in the biogas is a valuable energy source, but it can also be a source of potent greenhouse gas emissions; that is where I started thinking ‘how can a water company contribute to reduce greenhouse gas emissions?’ I had the opportunity to investigate how much gas is still contained in digested sludge, and to my surprise, it was much more than I had expected. The answer was clear: we extract the gas from the liquid to make it available for utilisation without releasing it into the atmosphere. Another problem water companies typically face, particularly those with advanced digestion, is the elevated phosphate concentration in the digested sludge, which negatively affects the achievable percent solids in the cake after dewatering. Here, we also investigated possibilities to precipitate the soluble phosphate in the sludge to enhance dewatering and increase the quality of the cake. With conventional technologies, enormous tanks are necessary to allow the growth of the precipitates and finally separate the crystals from the sludge. EloVac®- P’s approach is different: precipitation of the phosphate, no growth of the precipitates and no separation of the crystals. The benefits of this approach are unique: very small footprint (50 times smaller reactor tank), positive effect on dewatering, reduction of polymer consumption and no uncontrolled struvite scaling downstream. In addition, because the miniscule struvite crystals remain in the sludge, the quality of biosolids cake improves as a plant available fertiliser for land application. We recently received a

Process Industry Informer • November - December 2019

nomination for the Environmental Technology Award of the German Federal State of BadenWürttemberg. This is a clear sign that EloVac®- P is on the right track to help address the challenges we are currently facing with climate change and resource efficiency. We also filed for a patent application of the technology earlier this year. What kind of financial and emissions savings can be achieved? From the aggregated benefits of better dewatering, reduced polymer consumption and additional biogas production; and because of the simplicity and compactness of the system, the payback for water companies can be between one to three years. Moreover, based on our experience with the full-scale implementation in Lingen Germany, plants can expect approximately a 25% reduction in their overall carbon footprint simply by implementing vacuum degassing. In what type of plants can this system be installed? Currently, we are focusing on municipal anaerobic sludge digestion. Nonetheless, in addition to the benefits already mentioned, vacuum degassing can also improve the overall sludge digestion process. For example, one area we are currently investigating is how vacuum degassing can improve sludge density and thus

increase digester capacity. Therefore, the benefits are not limited to municipal plants - any type of anaerobic sludge digestion where a certain viscosity of the sludge is not exceeded, can also benefit from vacuum degassing. In which countries are these systems currently being installed? The first full-scale plant is running at the wastewater treatment plant in Lingen, Germany. Outside of Germany, through our sister companies in the United Kingdom, the Netherlands and the United States, the technology will be available, as it has generated a lot of interest. A pilot plant will be available in North America by end of this year. This plant will have a capacity of ca. 20 m³/h, which represents the sludge flow of a municipal wastewater treatment plant with a capacity of ca. 400,000 PE. We are in discussions with various water companies in the UK as well who are interested in piloting the technology, and we are still actively seeking more pilot partners in the UK and across Europe! For more information about EloVac®- P, please contact Ulrich Knörle: ulrich.knoerle@eliquostulz.com or +49 751 359785-11

ADVANCED SLUDGE TREATMENT TECHNOLOGIES

LysoTherm®

EloVac®-P

Patented THP system for small to mid-size treatment plants.

Vacuum degassing of digested sludge with simultaneous phosphate precipitation

Unique technology based on tube heat exchangers and thermal oil:

No need for aeration or any caustic addition

No steam or chemicals needed

Energy positive, efficient and climate friendly Compact, simple, and completely skid-mounted

System is simple to install, operate and maintain Modular, Plug & Play

Improve dewaterability > 5% with lower polymer consumption

Cleaning in place (CIP) system, no odour emission

Avoids struvite scaling

Flexible configuration based on project requirements.

Reduce direct methane emissions > 90%

Laboratory testing available: Discover your carbon footprint reduction and dewatering savings.

The benefits of THP without steam and without chemicals

WASTEWATER MANAGEMENT

CLEAN WATER MANAGEMENT

SURFACE WATER MANAGEMENT

ELIQUO HYDROK LTD I T 01726 862000 I sales@eliquohydrok.co.uk

WASTEWATER TREATMENT

SLUDGE TREATMENT

www.eliquohydrok.co.uk

Feature Article

James Woollard, Managing Director of Polythene UK

Why it’s important to be looking at

plastic packaging alternatives

Here in the UK – and globally – we are facing a climate crisis on an unprecedented scale. Only earlier this summer, Sir David Attenborough told Parliament’s Business, Energy and Industrial Strategy Committee that the crusade against plastic pollution is at an all-time high in the UK, while 16-yearold Swedish environmental activist, Gretna Thunberg, inspired hundreds of thousands of students from around 150 countries to walk out of classrooms on September 20th, as part of a Global Climate Strike to call for greater action against climate change.

play that’s small-minded thinking and unrealistic. What we should be doing is encouraging plastic producers to offer products of the future today. The world is playing catch up in offering sustainable alternatives to harmful plastic products, but, generally speaking, we’ve made milestone movements towards our long-term green goals to ensure future generations live in an eco-friendlier environment.

The swelling international attention on the climate crisis only serves to highlight the severity of the situation, and there is good reason too. One of the biggest culprits of the crisis is plastics, especially single-use plastics and microplastics, the latter getting into everything from our food and drink to the air we breathe. The potentially toxic

properties of plastics are contaminating our oceans, killing wildlife and causing unsustainable amounts of rubbish to be sent to landfill. The reality is; plastic is everywhere. Businesses that work in the plastics sector are being closely scrutinised, and rightly so. Around 40 per cent of plastics are thought to enter the waste

Process Industry Informer • November - December 2019

stream in the same year they are produced which is a harrowing statistic, especially as there are now 5.25 trillion pieces of ocean plastic debris, which is estimated to treble by 2025. It is easy to point the finger at plastic producers and call for the banning of plastic altogether, but in the current state of

Take the plastic packaging industry for example. Plastic packaging accounts for 44 per cent of the plastic used in the UK, but generates an incredible 67 per cent of plastic waste. Environmentalists are calling for supermarkets and shops to ditch non-recyclable plastic packaging on its products as well as the bags offered at the check-out. Even behemoth corporations such as Amazon have recently come under fire 34

Feature Article for using non-recyclable plastic packaging. No-one is immune to the climate crusade. While this is a deeply concerning time for plastic packaging producers, it’s also an exciting one; a time where businesses have a chance to come to the fore and make a change, lead the way in offering innovative alternatives. Major food and drink brands are desperate to avoid the firing line, such as brewer Molson Coors, which has pledged to only use plastics that are 100 percent reusable, recyclable, compostable or biodegradable by 2025 – so there is a market for sustainable plastic packaging producers to operate. At Polythene UK, we offer flagship plant-based packaging alternatives that ensure businesses and their consumers have peace of mind, knowing they aren’t contributing to the plastic pollution pressure cooker. In fact, a recent study by recycling and waste management company, Viridor, found that 65 per cent of Brits are more likely to purchase a product if it is housed in recyclable packaging. Eco-friendly products such as PolycompTM, a starch-based compostable polythene that is designed to break down naturally after use, offers an innovative packing solution that doesn’t need to be recycled. The UK adds more household waste into landfill than any other EU state. The 100 per cent compostable bags aims to change this statistic, 35

being designed to break down within ten days in the right environment, yet are strong and effective during use. In addition, they contain no Genetically Modified Organisms, having been produced free from GMO materials. Other sustainable packaging alternatives include PolyairTM, one of the only 100 per cent recyclable, carbon neutral materials currently available on the UK market. The product has been designed to improve businesses’ green credentials and dramatically reduce their carbon footprint, while also providing a commercially viable alternative to standard polythene. This bio-based material is made from sugar cane waste, and it’s the process of photosynthesis as the plant grows that makes the product carbon neutral, meaning the raw material will remain 100 per cent recyclable. What’s more, the sugar cane actively captures CO2 from the atmosphere, while at the same time releasing oxygen – making the material not just green,

but proactively green. This allows for businesses to meet legislative requirements and deliver improved environmental solutions. It can be used for pallet covers, top sheets, bags, wraps and liners, and in terms of practical use, the material is identical to alternatives made from fossil fuels, except being fully recyclable. Another product, PolyliteTM, is an extremely tough, lightweight polythene material that offers substantial cost savings compared to alternative polythene packaging materials. Typically, by delivering the same strength from a thinner multi-layered product, the material can reduce the weight of a company’s polythene consumption by 20 per cent, reducing the amount of plastic waste going into landfill. Overall, UK businesses have a unique chance to

offer something different to consumers, something they demand in this climate crisis. We’re currently experiencing a fast-paced movement away from using harmful plastics, but there’s still an awfully long way to go to appease the rigid demands of environmentalists, while also ensuring carbon footprints and landfill intakes are reduced to a sustainable level. Alternative plastic packing has undergone a pioneering leap in recent times with cutting-edge products becoming widely available and, more importantly, cost-effective for businesses to pursue. We must continue on this upward trajectory to create a healthy future for businesses, consumers, and ultimately, the planet.

Process Industry Informer • November - December 2019

HEATING

WHERE THERE’S A MILL, THERE’S A WAY:

BABCOCK WANSON PROVIDES URGENT PROCESS HEATERS FOR FLOUR MILLER Babcock Wanson has supplied flour millers Whitworth Bros. Ltd. with two TPC Thermal Fluid Heaters for its flour heat treatment process at its Barlby Road, Selby site. A new customer for Babcock Wanson, Whitworth Bros. had been using another manufacturer’s thermal fluid heater, originally installed in 2004 as part of a complete process install project. “Support from the other company had been very poor over the years” states Alan Boyce, Whitworth Bros. Engineering Manager, “and in August 2018 the heater suffered a catastrophic failure of the heating coils rendering it useless.” With the incumbent company

unable to supply a swift solution, and Whitworth Bros. productivity directly affected, they turned to Babcock Wanson. Babcock Wanson’s Thermal Fluid Heating System rental service proved an invaluable solution. Two ‘plug and play’ TPC 400B Thermal Fluid Heater were delivered to site and set up by Babcock Wanson’s experienced commissioning engineers. “The service from Babcock Wanson was excellent as they helped us out when we could not produce, and thermal oil heaters are not readily available to purchase but are made to order” comments Alan. From here, Babcock Wanson TPC 600B and TPC 1000B

thermal fluid heaters were ordered by Whitworth Bros. These are now in situ and are being used to pre-heat filtered air, which is then used as part of the heat treatment process of flour which changes the baking properties for suitability in different food products, such as sauces, batters etc. “The thermal fluid heaters have performed to our expectations and have proved to be cost effective” states Alan. Thermal fluid heating was selected over other methods for this process due to its lower maintenance requirements, its noncorrosive nature and ability to run at low pressures. Babcock Wanson offers a complete range of products

and services for boiler houses and other process heating needs, from steam boilers, thermal fluid heaters, rapid steam generators and hot water boilers to VOC and odour treatment by thermal oxidation, water treatment or process air heating solutions. The company aims to help optimise customer’s energy production with high quality products and efficient service. For more information, please contact Babcock Wanson on 020 8953 7111 or info@babcock-wanson.co.uk or go to www.babcockwanson.co.uk

EXPERTLY PACKAGED SOLUTIONS Benefits of Fulton’s skid mounted and plant room heat transfer solutions include: · Higher productivity · Reduced construction timescales and year-round construction (not constrained by weather) · Increased build and quality assurance · Design flexibility · Minimised on-site disruption · Reduced wastage · Improved Health & Safety · Built in a controlled environment with designers and fabricators under one roof · High cost benefit against site work

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Process Industry Informer • November - December 2019

+44 (0)117 972 3322 sales@fulton.co.uk 16/01/2019 13:41

Materials Columnists Handling

Sean Moran

The Voice of Chemical Engineering

Freelancing I’ve been working as a freelance for twenty-odd years now. It’s not something which has been imposed upon me. I only worked “staff” for about five years at the start of my career: exactly as long as it took me to get chartered, and learn the basics of what engineering was about. I’ve been a director of one microconsultancy or another since then. The first one had four full-time staff, (which was, it turned out, enough people for there to be for company politics), and when I sold my share in that, I started Expertise Limited, which has only ever had two fulltime staff. The other things I do, such as writing books, are pretty much all done on a sole trader, one contract at a time basis, though I did have a staff job in a university alongside all of this for a while too. Sometimes I work through agencies, though this is uncommon, because so many of their clients want someone who wants to be more like an employee. What’s an employee? It means different things in employment and tax law in the UK, but what it means to me is someone who wants “job security”, with guaranteed work Monday to Friday 9-5 every week, with paid holidays, sick leave, and so on. When I work through agencies, I sometimes find myself in workplaces where they pride themselves on treating staff and agency workers the same. These are not my kinds of places. I’m an aim-oriented guy. I like to get a job done and go home. The idea of spending the next twenty years doing the same job in the same place with the same people does not appeal to me. There used to be quite a lot of people like me, but the trend towards bigger organisations in engineering has made us a poor fit with modern purchasing policies. We tend not to carry £10M of PI cover, or to be able 37

to meet “financial stability” requirements drafted with plc’s in mind. I have survived this trend, but many of my former freelancer competitors have not. They have retired, got staff or agency jobs. This might seem odd, considering the wider trend towards the gig economy, but gig workers aren’t really freelancers. They have very limited autonomy, and their poor pay tells you all you need to know about how much negotiating power they have. Many fairly recent graduates have asked me how they could go about starting up as a freelance, and to be honest I have no idea how they might go about this now. The world has changed since I started up, and I had some lucky breaks early on. I know that those people who write books about how to succeed in business tell the story of their own success being the result of skill, but none of us really know how big a part luck played. We would however usually prefer to believe that we are responsible for our own successes (though few of us are as willing to own our failures). But I digress. I seem to be observing the demise of the freelance, independent engineer, but no-one seems too concerned. I wrote an article on LinkedIn a couple of weeks back about some of the issues surrounding this which drew surprisingly little interest. Maybe I and those other fiercely independent freelancers are dinosaurs. Maybe most engineers want to be employees. But how can they be? Engineering doesn’t work like that. Certainly EPC company engineering doesn’t. The nature of engineering contracts is task oriented.

Businesses employ other businesses to design and build something for them. The businesses that design and build things need to be able to vary the numbers of engineers of various disciplines rapidly, in order to ‘staff up’ for contracts once they have won them. Then, whether these temporary workers are genuine freelancers or agency workers, they will be retained for precisely as long as the contract against which they are billing hours. No amount of giving them a cake on their birthdays can hide this fact. So they are different from the people who have a contract of employment, (although employers can certainly be pretty brutal with those people too, if there is any kind of extended downturn). I have some sympathy with the UK tax authorities who consider many agency workers to be employees, in all but having a formal contract of employment. Maybe all that is happening is that engineering is becoming part of the gig economy. The combination of the loss of autonomy, and the depression of hourly rates would seem to suggest that that is where we are heading. Was this what those promoting the oversupply of engineering graduates were after - making engineers as commonplace, replaceable, powerless and cheap as Deliveroo riders? Process Industry Informer • November - December 2019

Feature Article

Dave Baskett, Technical Strategy Manager for industrial IT solutions provider SolutionsPT

The

Manufacturing Divide David Baskett, Technical Strategy Manager at SolutionsPT, looks at the manufacturing divide already being created by digitalisation and imagines what the future looks like for those who don’t make the change.

UK manufacturing has long needed a boost. Plagued by the perennial productivity problems that have seen the UK workforce unfavourably compared to its worldwide counterparts, a lack of skilled employees and the potential disruption of Brexit, good news for UK manufacturing has been sparse and focused on short term successes. However, digitalisation - or Industry 4.0 – has offered many cause for optimism, promising transformational improvements from the factory floor to the supply chain. Digitalisation is offering a lifeline to British manufacturing, so you’d think manufacturers would be racing to embrace it. Not so. In a session during a recent conference, ARC Advisory Group (ARC) cited its recent research of 157 process manufacturers that found that there were still

barriers in organisational accountability, culture and employee change management that impeded transformation. The research found that although more than 80% of industrial process manufacturers are piloting advanced technology, only 5% to 8% of them are ready for digital transformation today. The finance, insurance, health and retail sectors have rapidly harnessed the Internet of Things (IoT), artificial intelligence and big data to meet the changing needs of their customers, but the manufacturing sector has been slower in adopting new technologies. So, what are the main barriers to adoption? For many, the issue is internal, with a lack of digital-savvy leadership, a shortage of skills to implement and maximise technologies, and

Process Industry Informer • November - December 2019

The business world is littered with big name companies who, despite leading their fields, failed to keep pace with the organisation wide change required by digital innovation and have ceased to exist. In manufacturing, digitalisation is already threatening to create its own class system, with those who embrace the industrial transformation element of digital transformation securing their long-term health, and those who ignore it, their demise.

a generally low awareness of how to build an effective business case for the required investment all proving problematic. Other challenges to adoption often include concerns about cybersecurity, challenges posed by legacy equipment and concerns about the cost – and potential disruption - of change.

offering. The company filed for bankruptcy in 2012. Sony changed the way we listen to music with the invention of the Walkman but didn’t adapt to technological innovations such as digitalisation and eventually lost out to Apple. Closer to home, a failure to acknowledge and embrace e-commerce sealed the fate of high street chain HMV.

But doing nothing is not an option. History tells us that an unwillingness to innovate puts any company at risk of failure but refusing to evolve with the market can be devastating. The examples of those who have ignored the digital revolution are everywhere. Kodak invented the first digital camera but were so focused on film that they didn’t want to tell anybody about a new technology that would deflect from their ‘core’

What’s key here is not the digital invention, whether it be the camera or the iPod, but the fact that these technological advancements came in response to changing consumer requirements. Manufacturers used to be a step removed from the consumer, but changes to the buyer journey have filtered down every part of the supply chain. Mass producing one product for millions of customers is increasingly 38

Feature Article rare; consumers want options, personalisation and customisation, and to do that in an industrial environment requires the technology to dynamically adjust production, dialling up and dialling down, whilst looking for efficiencies and monitoring maintenance requirements. Digital transformation is key to achieving objectives like improving efficiency and quality, reducing costs and waste, and creating innovative products and services. The benefits of digital transformation in the industrial sector are many. Among them are improved asset health that will result in a reduction in unplanned downtime and better asset performance and enhanced incident prediction capabilities that have the power to lower operational risk and protect worker safety. Other digital innovations now available for manufacturers to utilise

include Context Driven Interfaces, which will increase efficiency and enable informed decision making; Artificial Intelligence and Machine learning, which allow the automation of low skilled tasks; IIOT devices that can use sensor technology to deliver low cost, non-intrusive sensing to drive efficiency without impacting control networks; and symbiotic plant and cloud technology, which will enable decision making and control available at the Edge. One good example of a company which has embraced digitalisation is Procter & Gamble with its “decision cockpits.” Acting on the need to empower employees at all levels through data, it has created cockpits which take the form of real-time, onestop screens displaying the current state of the business and any important trends. This data is accessible to all employees

at any time, helping them stay informed and engaged, enabling faster and more accurate decision making and delivering cost savings and operational efficiencies. And Proctor & Gamble are not alone. BMW, Rolls Royce, Schneider Electric, Starbucks, Ikea and even Domino’s Pizza have all digitally transformed their business models to give themselves the competitive edge. Digitalisation is no longer simply a tactical aspect of the manufacturing business – it is becoming vital to pursue end-to-end digital transformation in order to achieve objectives like improving efficiency and quality, reducing costs and waste, and creating innovative products and services. The manufacturing operations we’ll be seeing in 30 years times will be very different than those of today. To be a successful manufacturer of the future, the need to build an effective roadmap

to guide you along the transformative changes of the next five, ten or fifteen years needs to start now. The key is to see industrial transformation not as a one-off implementation project, but as a constantly evolving process designed to add incremental value, a process which encompasses your assets, operations and people. A recent report found that the early adoption of advanced digital technologies by the UK manufacturing sector has the potential to grow the UK economy by £455bn, create 175,000 new jobs, increase productivity and cut CO2 emissions over the next 10 years. It’s for this reason that Industry 4.0 forms such an important part of the UK government’s industrial strategy. This issue is not simply about the performance of each individual company, but how competitive the UK is on a global scale. Perhaps, for some, the scale of what they feel is required for digital transformation is too daunting, but what’s important is to take those first initial steps. Continuously improving even by a small percentage year-on-year – via the use of digital technologies, is much more appealing than stagnation or decline. It’s easy to see how failure to act now will create a huge gulf between manufacturers in the next two to three years. Digitalisation cannot be delayed any longer; the potential of Industry 4.0 must be recognised now. It will play a key role in shaping and enabling the growth of the manufacturing industry in the years to come.

Process Industry Informer • November - December 2019

Drives & MoTors

Electromagnetic Clutches flux distribution, maximizing torque. Different coil voltages available. Although 12 volt is the most common, 24 volts can also be made available. Depending upon the quantity, other specialty voltages can be made.

Designed to function and survive in harsh environments, providing reliable performance in many long-life applications.

High temperature, longer life grease. All models include our special long life grease which has shown a significant improvement in life over other standard high temperature greases.

These are flange mounted, normally a two piece construction clutch typically mounted directly on to the pumps.

E-coating. Where possible, all parts in the clutch are e-coated to give maximum corrosion protection.

Solid forged rotor. A one piece solid forged rotor means no chance of internal parts separation. Our rotors also have an even wall thickness around the coil which gives optimum

High temperature epoxy coil. To help prevent failure from both vibration and outside contaminants, all coils are sealed in the coil shell with a high temperature epoxy coating.

Forged machined pulley. All models in this section use a heavy duty machined pulley. A stronger pulley resists damage due to abusive environments. MMC series electromagnetic clutches are designed for use with hydraulic pumps, many of which are used in marine winch drives. Typically flange or plate mounted, they engage and disengage the pump. »» Torque ratings from 271 to 2033 Nm (200 to 1500 lb-ft) . »» Solid forged rotor & pulley or hub. »» Direct drive or pulley drive. »» 12 & 24 VDC available.» “TC” and “B” type pump mounts. »» Straight or splined bore. »» High temp, long life grease. »» Bi-directional operation. »» One piece design. »» Plated for corrosion protection. »» High temperature epoxy coil. For technical data see page 4 of technical specification catalogue Further information and technical specification catalogue found here

Hire drives keep water flowing for Anglian Water customers A pumping station is repaired within hours following a drive breakdown, avoiding 2,000 homes being left without water Anglian Water avoided a serious interruption to customer’s water supplies following a rapid replacement of variable speed drives (VSDs) after a double drive failure at one of its pumping stations. The pumping station supplies water to some 2,000 households near Ipswich and Stowmarket in Suffolk. Two sets of two pumps are arranged in duty/ assist configurations, supplying different parts of the area. Depending on demand, each set pumps 20 to 30 litres per second from on-site bore holes. Each pump is controlled by a 90 kW VSD, each of which was subjected to overheating and tripping. One Friday evening, the VSD on two of the duty pumps stopped working, placing the onus on the two assist pumps. Should either of the VSDs on the assist pumps fail the site would be unable to pump enough water to meet demand.

A rapid response was vital to prevent major disruption for customers, as well as reputational damage and a potential fine from Ofwat. Anglian Water called ABB Value Provider, Gibbons Engineering Group and within hours the team had installed two ABB 90 kW hire drives. Following test and commissioning, the pumps were operational by Saturday morning. Hiring a drive is a quick, low cost way of keeping critical processes running in the event of a drive failure. It reduces the cost of downtime whilst buying time to either repair the failed equipment or to source and allocate capital for a permanent replacement. For more information please contact: Layla Hewitt Marketing Communications Phone: 01925 741517 Email: layla.hewitt@gb.abb.com ABB Ltd. Daresbury Park, Daresbury, Warrington, WA4 4BT www.abb.com

Process Industry Informer • November - December 2019

www.euromixers.co.uk

SUPER HYGIENIC

POSITIVE DISPLACEMENT LOBE PUMP

Jabsco Lobe Pumps Jabsco Rotary Lobe and Flexible Impeller pumps incorporate the very latest in hygienic design concepts making them ideal for a wide range of food and drink applications and the ever increasing demands for improved cleanability and hygiene. With over 40 yearsâ&#x20AC;&#x2122; experience in the field, Jabsco leads the way in the worldâ&#x20AC;&#x2122;s most demanding markets. Rugged modular design ensures reliability that keeps your lines running. The hygienic rotary lobe pump is 3A and European Hygienic Engineering and Design Group (EHEDG) certified: A clear choice for the food and drink industry.

For UK sales contact 01297 630 230 or visit xylem.com/uk for more information

Feature Article

Peter Smith, Director at Peak Sensors Ltd

Resistance Thermometers versus Thermocouples Thermocouples (TCs) and Resistance Thermometers (RTs) are both contact temperature sensors. They need to be in the environment they are measuring for them to work. Both devices are commonly used in industry and have significant differences which we will touch upon in this article.

Base Metal Thermocouple Assembly with Metal Sheath and KNE head. Typical design for high temperature processes for instance cement manufacture.

So Many Names Resistance Thermometers can be referred to by many names, some of these include Resistance Thermometer Detector, RTs, RTDs, Pt100s, Pt1000s, Platinum Resistance Thermometers (PRTs), Pt500 or Pt200 sensor. A thermocouple is also called a TC, thermal junction, thermoelectric thermometer, Pyro or Pyrometer. Occasionally you may see a reference to the specific type of thermocouple such as T1 T2, K, R or other less common alloy pairs. What is a Resistance Thermometer? A Resistance Thermometer Detector (RTD) is a variable resistor which changes its resistance depending on its surrounding temperature. It creates an internal resistance that can read with a simple circuit.

Mineral Insulated Thermocouple with Standard Plug and Flexible Sheath.

Process Industry Informer â&#x20AC;˘ November - December 2019

What is a Thermocouple? A Thermocouple is essentially a simple assembly based on two different alloyed wires. It produces a reliable millivolt signal when it is in a thermal gradient. The signal is not linear, but instrumentation usually deals with that. The highest temperature thermocouples use Platinum Alloys. These rare metals are very expensive so very thin sections are used. Thermocouples therefore usually rely on an external protection sheath to protect the thin alloy wires from the process conditions. Temperature Sensors Differences Resistance Thermometer Detectors (RTDs) are generally used to monitor temperatures between -70oC and 500oC. RTDs provide a practically linear output for the vast majority of applications. RTDâ&#x20AC;&#x2122;s can be designed into equipment without a specific protection sheath or enclosure. When some stand-alone protection is needed, the smallest practical sheath size is approximately diameter 3mm. Because of lead wire resistance, Resistance Thermometer Detectors usually have 3 or 4 wires and these wires are normally red and white. Thermocouples (TCs) only have two wires and can be very small sensors indeed, much smaller than RTDâ&#x20AC;&#x2122;S. Thermocouples can be made in sheath diameters as small as 0.25mm. TCs are more robust due to their simplicity and can withstand much higher temperatures. Type B will survive around 1600oC with the appropriate protection sheath material. Thermocouples can be more expensive due to the rare metals used within the construction of the sensor. 42

Feature Article Multipoint Resistance Thermometer with Long Length Mineral Insulated Cable and Flange. A very specialised design used within a hot water storage vessel.

Cable Resistance Thermometer with Metal Pocket. Typical four wire Pt100 with a sheath used within a low temperature oven.

RTDs are manufactured as a discreet chip. The chip is made from a very thin platinum wire or layer (hence the Pt in some of the names for these sensors) which is on a ceramic backing or in a ceramic tube. A Resistance Thermometer Detector is more accurate than a Thermocouple due to smaller tolerances. RTDs are usually cheaper to manufacture than TCs as the RTD lead wires are usually copper or nickel, depending on the application temperature. A Thermocouple requires controlled conductor alloys throughout its length, including specialist extension or compensation cables. Thermocouple circuits need to deal with cold junction compensation although the vast majority of modern instruments handle cold junction compensation automatically. An RTD is a discrete device that can easily be put onto a circuit board. If an RTD has significant lead lengths then, 3 or even 4 wires are needed to maintain accuracy. These RTD extension wires must be identical to each other in terms of resistance per meter. Application of Devices Resistance Thermometer Detectors are typically found in medical devices, for example an anesthetic dispenser, used within research, are part of HVAC (Heating, Ventilation and Air Conditioning) devices as well as 43

within OEM (Original Equipment Manufacturing) like electric motors. In high temperature environments, for example within molten metal applications, cement manufacturing, furnaces and ovens, thermocouples are typically used. A high temperature thermocouple must be robust and tends to end up quite large. The diameter increases to give thicker protection sheath sections. Probes end up quite long as connection to plant cables or instrumentation must occur in relatively cool areas. After an extended lifetime, thermocouples usually fail because of contamination that has entered the assembly. It is very common in industrial thermocouples or resistance thermometers that the output in converted to 4-20mA loop powered signal for transmission around a plant. Sensor positioning within a process can be very important. Inadequate immersion will give a low reading temperature error, while a direct line of sight between heaters and sensors may cause a high reading because of radiation error. Mineral Insulated Resistance Thermometer Insert with Block. Used as an insert into thermowells, for example on chemical plants.

Base Metal Thermocouple Assembly with Ceramic Sheath and KNE head. This is a high temperature multipurpose kiln sensor.

Base Metal Thermocouple Assembly with Metal Sheath and ALA head. Typically used for flue gas measurement.

There are a lot of points to consider that are not always obvious when choosing between temperature sensors. A few considerations have been highlighted above. Further consideration can include pressure containment, vibration, ingress protection and of course cost. There is no set answer to what sensor is best as it is dependent on the application and process environment. Our advice as temperature sensor specialists is simple, please just ask us at Peak Sensors and we will be happy to help.

Process Industry Informer â&#x20AC;˘ November - December 2019

Feature Article

Jeff Blair, Offer Manager for level products at Schneider Electric

Easy Radar

Have you noticed when you ask your favorite vendor for help with a new level application, they send you a tedious two- to four-page form to fill out with all necessary process data? Furthermore, they want a sketch of your process and several other bits of information related to your level application. The reason for this is that throughout time, despite its apparent simplicity (“I see the level!”), level historically has been a very challenging application to measure. Greg Shinskey, noted author and ISA Fellow, regards level as one of the toughest applications. He said in his article “The Enigma of Liquid-Level Control” that level can either be one of the easiest processes to control or one of the most difficult. That’s the consensus in talking with end users and specifiers of level instruments it’s very tricky, but it shouldn’t be.

Example of radar beam diameter for different frequencies over identical distances with the same antenna size

Process Industry Informer • November - December 2019

Contributing to level’s complex stereotype is that level is often inferred by another measurement. That is, we measure one variable and convert it to a level reading. Hydrostatic pressure (d/p level) measurement has often been the global preference for measuring level. Most sources of process market information tell us that d/p level continues to be a favorite but loses preference and installed base annually to other non-contact technologies. Buoyant force is

another popular method. Both hydrostatic and buoyancy contact the liquid, measure a non-level variable (i.e., pressure or force), and infer level. Perhaps this is why the widespread process market introduction of free space radar (radar) in the 1990’s was an initial success. Radar is a relatively simple level measurement device that infers level from a distance and doesn’t contact the liquid. There is no additional math or equation involving specific gravity or another variable when dealing with radar – it simply gives an output signal that reflects either the distance to the liquid or the level of the liquid. In addition, radar is one-size-fits-all. There is no specific pressure range span code or displacer force to worry about. The market has grown to accept radar as a common level measurement device. Some surveys even show that for new applications, end users prefer radar. Regardless of why radar is selected over other methods, what is often marketed as simple is often more complex than originally thought – hence the fourpage application data sheets from the vendor. Vendors have various radar frequencies they offer, different antennae that contribute to the 44

Feature Article sometimes-difficult choice of narrowing down a radar selection. Recently released 80 GHz frequency radars allow radar instruments to be used in applications that may have “tripped” up traditional lower 10 GHz and 24 GHz radar technologies in the past and get past the time-consuming pre-application work. Like a properly ranged pressure transmitter or a temperature transmitter with an RTD attached –you put them in the process, and they “just work.” They’re simple, well understood, and easy to use instruments. Using pressure and temperature as models of success, radar is often the same in many applications. It’s simple. Regarded as high frequency, 80 GHz radar emits a signal that broadcasts a much narrower radar “beam” than traditional 10 GHz and 24 GHz radar. This narrow beam avoids previous generation radar issues such as poor installations, getting false levels from obstacles, and weak return signals. Installation issues are avoided thanks to the compact size and small antennae. Most previous generation radars featured large horn antennae and often large, heavy flanges as process connections. They were awkward to install properly. An installation too close to a tank wall would create false echoes and degrade the measurement. The 80 GHz radars feature small NPT connections that can be installed in most locations on top of or, depending on the tank material, outside of a tank. A more focused narrow beam ensures that obstacles and tank walls aren’t seen and treated as potential 45

80 GHz radars with small beam could be installed closer to the tank wall.

Tank height, 0%, and 100% level are entered into an 80 GHz radar during the simple configuration.

false level targets. They are avoided altogether, thereby eliminating the need for “blanking” software that tells the radar to see through or filter parasitic signals. Think of it as avoiding an illness altogether rather than getting an illness and treating it with medicine. The focused signal of 80 GHz also ensures a strong return signal, increasing measurement reliability. In most applications ensuring (1) material compatibility, (2) proper pressure, (3) proper temperature ranges, and (4) dielectric constant that is within the wide applicable range are all that’s needed to use an 80 GHz radar. Once the radar is onsite a typical configuration takes place on the ground using just the pushbutton display to determine the (1) tank height (2) 4mA / 0 % level measurement, and (3) 2mA / 100% level measurement. Foam remains one of the few obstacles that 80 GHz may not be able to overcome. There are several variables (e.g. type of foam, density of foam, height of foam) that determine whether a radar will succeed in an application featuring foam.

M12 or M20 connectors allow time and labor savings when installing a radar.

To complement the simple setup and application of 80 GHz radars, additional features may be considered during the procurement and logistics planning stages. Use of M12 or M20 4-pin connectors for quick “plug and play” style instrumentation wiring helps trim labor costs. Either order the radar with the connectors pre-installed, or work with your local radar or electrical shop to pre-wire the connectors before the radars ship to the job site. After a radar

is installed mechanically, a 24V (or fieldbus protocol) twisted pair cord set merely plugs into the radar to make it operational. No labor and time-consuming conduit connections are needed. During the specification and procurement process, consider ordering online. Many manufacturers have online stores (e.g., www. buyautomation.com) offering direct ordering and tracking capability. However, for first-time applications, or the first use of an 80 GHz radar, take advantage of a local salesperson’s expertise for part number recommendations and technology selections. While the traditional four pages of desired application data is always helpful to have, in most 80 GHz radar applications, it isn’t necessary. The simple “point and shoot” approach of the narrow 80 GHz beam allows a customer fast startup and a lifecycle of onesize-fits-all simple reliable measurement.

About the Author Jeff Blair is Offer Manager for level products at Schneider Electric. He is an ISA Senior Member and past President of ISA St. Louis Section. Blair has a bachelor’s degree from Illinois State University and a master’s degree from University of Illinois at Urbana-Champaign.

Process Industry Informer • November - December 2019

Cooling

Rittal’s RiMatrix Containerised Data Centre DeliversTurn-Key

Solution for Envision AESC UK

Envision AESC UK required a new data centre to support its newly acquired office and production site at their newly acquired Sunderland site. While there was a requirement for additional rack space, the primary driver was space and location. The client chose to relocate an internally based data centre (potentially consuming office or warehouse room), placing it instead externally. Rittal was able to provide a solution consistent with the previous system, in terms of both design and technology. Rittal engineers specified the RiMatrix S, a containerised data centre with a pre-configured design, which meant that no additional design input was required by the customer. Within the RiMatrix S, Rittal supplied 6 x server racks, 1 x networking rack, a fan-based cooling supply, an ABB UPS, a distribution board, fire suppression and 2 x free-cooling chillers.

Process Industry Informer • November - December 2019

Rittal partnered with an M&E partner to manage the installation, meaning that Envision AESC received a wholly managed, turn-key solution. The result is a complete data centre with a small site footprint, with no need for any building work on-site. Envision AESC UK’s Andy Dixon commented “Rittal’s ability to deliver a turn-key solution using a standardised product was a major consideration for us. We are very impressed with the quality of the RiMatrix S product and the associated chiller units. The solution has provided us with the environment we needed to host our critical IT infrastructure’. Further information at www.rittal.co.uk and www.friedhelm-loh-group.com or on twitter @rittal_ltd.

FLUIDS & LIQUIDS HANDLING

Offering the Right Connection Founded in 1916, Dixon is a premier manufacture and supplier of hose couplings, made to order hose assemblies, valves, manifolds, drydisconnects, flame arresters, vents, bespoke fittings and other fluid transfer and control products. The company’s global reach includes a wide range of products for numerous industries, including petroleum exploration, refining, transportation, chemical processing, food & beverage, steel, fire protection, construction, mining and manufacturing. At Dixon Europe based in Preston, Lancashire, we specialise in the support of bespoke engineered solutions from concept and design through to manufacture and delivery. Dixon’s ISO 9001 approved onsite manufacturing and engineering facilities means that new designs, animations and provide 3D modelling can be produced to support our customers coupled with a quality assurance underpinned by international

standards and certifications. Dixon products can be relied upon, as quality control starts at the innovative design stage, and is further supported with technologically advanced engineering and manufacturing processes. Dixon will not compromise on high quality control, utilising assurance standards and inspection procedures at each critical step of the production process.

Open communication with customers and following through with solutions strengthens trust as a supplier of both current and future products. Dixon Europe are driven to provide ‘the right connection’ in meeting specific hose and coupling requirements across all industries. Their strength in service, technical support, training and advice ensure the correct specification of bespoke hose assemblies and couplings.

Dixon has been building a credible reputation for over 100 years, demonstrating that it’s a responsible manufacturer producing and supplying safe, reliable and long-lasting products.

To find out more about how Dixon can help you and the Dixon range head to dixoneurope.co.uk or contact our customer sales department on 01772 323529

Dixon Petrochemical Products

Fluid transfer products for upstream, downstream and refining Products:

• Hoses and hose assemblies • Hose & pipe fittings • No-spill couplings • Safety breakaway fittings • Blow-Out prevention couplings

• Hydraulic Fracturing: Low Pressure Systems • Loading arms • Liquid level sensing • Zero emission valves

Services:

• Global inventory and locations • Sales and technical support worldwide • In-house engineering & design • ISO 9001 accredited • Pressure Equipment Directive (2014/68/EU)

+44 (0)1772 323 529 • dixoneurope.co.uk •

• TE C H NICAL EXPERTISE • U NCOMMON EXCELLENCE • DESIGN • CUSTOMER SERVI CE • I NNOVAT I ON • MANUFACT URI NG • QUALI T Y • T ECHNI CAL EXPERT I SE • UNCOMMON EXCEL L EN

Process Industry Informer • November - December 2019

FLUIDS & LIQUIDS HANDLING

Pertti Kujala, Director, Smart Factory Solutions, Haltian

Factories Can Save Up to 90% in Valve Monitoring Costs With Wireless IoT Sensors Factories and plants in industries – such as chemical processing, pulp and paper, water and waste-water treatment, have seen the benefits of remote valve monitoring. Traditional retrofitted monitoring solutions, however, are costly and slow to deploy for factories with thousands of manual valves of different types. There is a more cost-effective alternative – factories have evidenced a 90 percent reduction in retrofitting investment, by using industry-grade wireless sensors and Industrial IoT technologies. In this article, Industrial IoT specialist, Pertti Kujala, the Director of Smart Factory business of Haltian, talks about retrofit valve monitoring, and explains how factories can save substantial costs. What’s Remote Valve Monitoring? Factories and plants in the chemical process industries, pulp and paper, water and waste-water treatment, and other sectors are, first and foremost - known by the massive networks of process pipelines, controlled by thousands of hand-operated valves. Until recently, the systems have been operating successfully and effectively for many years with different types of hand valves. The remote monitoring of these manual valves is becoming even more critical in process industries as the Industry 4.0 transformation sweeps through the factories worldwide. To maintain future competitiveness – industrial enterprises need to increase production efficiency, optimize processing operations, prevent

unnecessary outages, and improve safety. With the integration of SCADA with field instruments, and also smartphones, tablets, and other mobile solutions, industrial automation and process control is growing rapidly for the greater good. Benefits for Factories and Plants Remote valve monitoring is made up of several components: and it detects the valve position with a retrofit sensor device, mounted on the hand-operated valve. Position sensors are divided into angular position sensors and linear position sensors. The sensor device then reports the position data in a digital format to the factory’s central control system. With an ideal remote monitoring solution, positions of all valves in a factory can be monitored on the central control system in the factory in real-time - from thousands of different points, along the process pipelines. Remote monitoring of process control valves can provide multiple benefits to factories in countless different ways: ● Bring massive cost savings ● Enable faster process recovery after maintenance breaks ● Increase safety at the plant ● Reduce the occurrence

Process Industry Informer • November - December 2019

of errors and quality deviations ● Provide valuable analytics, and help to prevent unplanned downtime. The benefits from remote valve monitoring amid the ongoing Industry 4.0 transformation have propelled the remote monitoring and control market onto a steady growth trajectory with a CAGR of 4.5 percent. It is expected to reach USD 27 billion by 2023 globally. Challenges of Traditional Retrofitting Solutions Many factories and plants hesitate to invest in remote valve monitoring expansions, despite rapid market growth and the significant economic benefits. Retrofitting a monitoring system on thousands of different types of valves - some of which can be very old, often manufactured by different vendors - is costly and time-consuming. The author has compiled a rundown of the main challenges in retrofitting remote monitoring on existing valves. The current valve position sensors in the market often fit only one type of valve, and different valve manufacturers have their own specific position sensor devices. This increases the sensor device hardware

investment for factories, and procurement involving several manufacturers’ products can be time-consuming The traditional field sensor devices use several industrial communication protocols - such as Foundation Fieldbus, Profibus, DeviceNet, AS-Interface, and the HART protocol, for communicating with the factory’s SCADA or SAS system. This can require costly software interface customization, especially if sensors of several different vendors are included in the system. Most current industrial valve position sensors and detector products in the market require physical cabling for electricity and data. When there are thousands of valves in a factory, then the cabling becomes a significant cost, and extends the deployment time to months, and sometimes years. The traditional position sensor devices available currently in the market are built, based on the same extreme industrial standards, as the critical, operational field hardware. This could, however, be deemed to be over-engineering in many industrial applications. The position sensors are typically mounted on top of the primary operational hardware, such as the valves – and the sensors 48

FLUIDS & LIQUIDS HANDLING are not directly exposed to the harshest conditions. This extreme product design practice has increased the sales prices of the traditional position sensor products, but high-quality, enterprise-grade products with a lower price tag are equally fit for this purpose in most use-cases. These challenges slow down the deployments of retrofit remote valve monitoring solutions in global factories. The question that arises is: How can one reduce these investments and make retrofitting easier? A game-changing solution could come from the Internet of Things (IoT) technology sector. Developments with IoT sensor devices and wireless technologies have taken a quantum leap ahead, in recent years. Game-Changing Technology in Remote Valve Monitoring Haltian, the product development specialist and Industrial IoT provider, together with a global process industry company have developed a smart, industry-grade wireless Angle sensor for remote valve monitoring. It combines the latest industry-grade wireless technologies and ultra-durable materials. With this solution, factories can reduce their retrofitting costs by up to 90% - compared to traditional alternatives.

Haltian Angle sensor mounted on a process control valve

clamp that mounts the sensor device onto a pipe. Its rotating position detector disc is attached to the valve lever with a simple clip. Inside the Angle sensor device are magnetic and mechanical sensors to detect the valve’s position, with an accuracy of one degree. It reports any position changes over the wireless connection - to the factory or plant’s central control system. After being switched on, the sensor automatically connects to the other sensor devices using the Wirepas Mesh technology.

What can the Angle Sensor do? The wireless sensor doesn’t need any cabling. This retrofit angle sensor can be attached to several types of manual rotary valves, including ball and butterfly valves.

Whenever required, the Wirepas Mesh wireless protocol in the Angle sensor device can automatically optimize the radio transmission power and frequency band. No base stations or any wireless network infrastructure is needed in the factory – the Angle sensor devices function as access points for other sensor devices and form a fully-meshed network, which transmits data packets, hopby-hop to the right destination.

It is delivered with a mounting adapter kit to make installation quick and easy. There is a

The power-frugal Angle sensor device is able to run for several years with just a battery.

How Can it Benefit Factories? Throughout a multi-year industrial investment horizon, the wireless Angle sensor approach can bring factories and plants CAPEX and OPEX savings. Here are the most prominent lifetime benefits: ● Installation onto your valves is quick and easy – no cabling is needed, and it is delivered completely pre-configured. It reduces the deployment and operational costs, when thousands of valves are involved. ● Works with several types of rotary valves including the ball and butterfly valves made by any manufacturer – reduces hardware costs and makes procurement easy ● Avoid further costly software customization for industrial communication protocols – the Angle sensor integrates straight into the central control system through a simple application programming interface (API). ● The changes in valve position data is reported to your control system – this enables you to adjust factory processes faster to their optimal performance levels. ● With up-to-date information about all valve

positions, you can avoid accidents and increase the occupational safety at the plant. ● Avoid environmental damage by making sure that hazardous substances are not released out of the system. ● Manual valves are typically adjusted by the operation staff. They carry out the adjusting work based on their tacit knowledge – valve monitoring enables you to digitize and store this tacit knowledge. ● End-to-end data collected from all the valves, enables you to measure and optimize the processes. In Conclusion Remote Valve Monitoring provides factories and plants with significant benefits – this translates into cost savings, better safety, and continuous process optimization. However, the digitalization of process control valves has been dragging for too long, due to high retrofitting investments. The new industry-grade Angle sensor and wireless Industrial IoT technologies can change the Remote Valve Monitoring game with an easy, yet robust alternative with up to 90% lower investment!

About the Author Pertti Kujala is the Director of Thingsee Smart Factory solutions at Haltian. After joining Haltian in 2012, Pertti has worked in several IoT leadership positions in the company. Pertti began his career in Nokia in 2003, where he successfully held various mechanical design, engineering, and concepting roles. In the luxury device maker, Vertu, in the UK, Pertti worked as a senior mechanical designer in 2007-2009 and has designed and developed new decoration assemblies with materials such as leather, sapphire, ceramics, and precious metals. Pertti’s extracurricular passions include architecture. Pertti holds a degree of M.Sc. in Mechanical Engineering from the University of Oulu in Finland.

Process Industry Informer • November - December 2019

FLUIDS & LIQUIDS HANDLING

Sine pumps

for high viscous syrup in drinks production At BrauBeviale, Watson-Marlow will showcase a selection of its specialist range of technology for the drinks industry, including Sine pump Certa. The pump’s high performance and versatility has been illustrated with mixer TurboDigi from manufacturer FAMIX-Maschinenbau GmbH. This system uses Certa for metering syrup, providing gentle transfer and excellent CIP-capabilities.

will feature the mixer FAMIX TurboDigi by FAMIX Maschinenbau GmbH. This system for the production of sophisticated drinks combines deaeration, mixing and carbonation in one compact system. The mixing ratios are controlled by a highprecision digital flow meter system. Thanks to the patented FAMIX carbonation and mixing device, the manufacture of drinks either still or sparkling is possible.

Sine pumps are positive displacement pumps. The rotation of sinusoidal rotors creates four equal circumferential chambers, which are displaced as a whole, the chamber volume does not change. The medium is gently carried from the inlet port to the outlet port. The seal from the pressure side to the suction side is guaranteed by a plastic gate located on the rotor. This simple, yet powerful design makes Sine pumps the perfect choice for transferring high-viscosity liquids, easily able to cope with viscosities up to 8 million centipoises. For the drinks industry, this pump principle offers gentle

pumping in a great variety of applications. “In drinks industry, sine pumps are used in all applications, where high viscous media need to be transferred gently, with low pulsation and low shear”, says Watson-Marlow Commercial Manager Christian Paschen. This includes unloading frozen orange juice concentrate from tanker ships, as well as transferring yeast in breweries or handling delicate whey or cream in dairy applications. FAMIX TurboDigi: Innovative all-in-one solution individually customized. Illustrating Sine pump capabilities, WatsonMarlow’s stand in Nuremberg

Process Industry Informer • November - December 2019

The FAMIX TurboDigi uses a Certa Sine pump as syrup pump. “Metering the syrup is a crucial step in the process”, explains Herbert Falterbaum, Managing Director at FAMIXMaschinenbau GmbH. Syrup is not only the most expensive raw material in producing mixed drinks, it is also key to maintain end-product quality and consistency. The Sine pump masters this task with ease: The volumetric positive displacement pump whose flow rate is directly proportional to the speed is flexibly adapting the amount of syrup to the desired mixing ratio and is pumping the syrup gently, with low shear and virtually no pulsation.

The simple but innovative design with just one rotor, one shaft and one seal simplifies maintenance. “Moreover, the pump’s excellent hygienic and CIP capabilities, predestine the pump for use in mixer systems such as our TurboDigi or our multistream system TurboDigiS”, says Herbert Falterbaum, Managing Director at Famix. “An additional advantage is that various viscosities can be handled with the one pump.” Certa reduces the time for CIP cleaning cycles, minimising downtime while offering maximum hygiene for food and beverage applications. All contact parts on the pump are FDA and EC1935/2004 compliant. Providing EHEDG Type EL Class 1 Aseptic certification, Certa can be used in aseptic processes and is bacteria tight without requiring additional steam ports. Further advantage: Certa offers significant energy benefits compared to lessefficient pumps. Depending on the application, power consumption is reduced by up to 50%. The Sine pump is available in seven different sizes offering flows from 100 l/h to 99,000 l/h. www.wmftg.com 50

FLUIDS & LIQUIDS HANDLING

Full FDA compliance of Certa 250 pump enables US exports for leading UK natural healthcare manufacturer MasoSine Certa 250 pump from Watson-Marlow Fluid Technology Group helps natural healthcare manufacturer export products to the US Ease of cleaning and aseptic certification prevent contamination issues and satisfy FDA requirements One of the UK’s leading natural healthcare manufacturers, has integrated the MasoSine Certa 250 pump by Watson-Marlow Fluid Technology Group (WMFTG) into its pharmaceutical creams manufacturing process. The pump satisfies all FDA requirements, with full clean-in-place (CIP) capabilities, successfully enabling the Company to export its natural healthcare products to the US and expand their global presence. Exporting to the US The Company wanted to export its products to the US to expand its global reach. In order to do so, the Company needed to meet all FDA manufacturing regulations and provide the necessary certification for all aspects of its manufacturing process. The pharmaceutical creams processing presented a problem for FDA compliance as the pump previously deployed was difficult to clean and did not offer appropriate certification. The process required a pump which provided both clean-in-place (CIP) capabilities and the ability to transfer creams slowly to prevent air ingress and shear. Certification provides confidence The MasoSine Certa 250 was

selected as it both complies with FDA requirements and provides all the required pump functionality. With EHEDG Type EL Class I as well as EHEDG Type EL Aseptic Class I and 3A certification, the pump provides fully accredited CIP capability, satisfying FDA requirements and the natural healthcare manufacturer to target the US market. Head of Operations at the natural healthcare manufacturer, commented: “As the pump doubles as a high-volume CIP pump, we can now clean the pump and associated hoses with ease. The Certa pump gives us the confidence we need in our manufacturing process in order to offer the highest quality natural healthcare products to US customers.” End-to-end process expertise In order not to disrupt production, ease of integration into the existing production line was essential. Utilising 60 years’ expertise in end-to-end fluid

management across a range of industries, the MasoSine Certa 250 pump is designed to fit into any pathway with a range of available ports. This enabled its seamless integration into the pharmaceutical cream process. The pump has successfully been in use for over 18 months. “The Certa 250 pump integrated perfectly with our existing process, enabling us to progress from conception to validation in under four weeks. Having already used a range of Watson-Marlow products, we were aware of the breadth of their offering and their experience across pharmaceutical and food manufacturing.” Added the Head of Operations at the natural healthcare manufacturer.

Process Industry Informer • November - December 2019

Feature Article

Karim Mahraz, Product Manager, Analytical Instrumentation, Swagelok

EIGHT BEST PRACTICES FOR IMPROVED

LABORATORY GRAB SAMPLING

Enhancing Analyzer Accuracy and Operator Safety for Better Results Grab sampling for offline process fluid analyses isn’t necessarily as easy as grab and go. You must first ensure the sample is representative of the process property or composition that you are trying to measure, so analyzer measurements are accurate and meaningful. You also need to play it safe, as grab sampling carries more inherent risks for system operators compared to online sampling. To help improve your plant’s grab sampling operations, here are eight guidelines for enhancing system accuracy and safety. IMPROVING ACCURACY At the time of lab analysis, captured grab samples must be as representative of the process conditions as possible. That means ensuring the sample itself was fully mixed within the process line and that it won’t become contaminated along its route to the sampling vessel. The following tips

will help you improve sample representativeness – and therefore analyzer accuracy.

Figure 1. In turbulent flow (bottom), fluid moves randomly across the line, encouraging good sample mixing. In laminar flow (top), fluid movement is parallel to the sample line and is often slower. Laminar flow near the line walls may contain higher concentrations of unmixed process fluids, so it’s advisable to use a probe to grab samples from the center of the line.

a turbulent flow that encourages mixing, while the slower-moving fluid has a laminar flow that may contain higher amounts of solid particles (with a liquid sample) or liquids (with a gas sample) than the overall process stream (Figure 1). Therefore, samples drawn from the laminar flow area may not be representative of the process. Instead, industry standards recommend installing a probe at every grab sampling tap. [1, 2] The probe will poke through the tap into the center of the process stream to draw samples from the turbulent, better-mixed fluid.

Avoid Sampling from the Bottom of Process Lines Particles within liquids flowing through process lines are prone to collecting and moving slowly along the bottom of the lines. The same is true for liquids in gas streams. If you mount a grab sampling tap to the bottom of a line, this settled matter will end up in the sampling vessel, creating a nonrepresentative sample. Ideally, all grab sampling nozzles should be mounted horizontally – with a probe – to ensure samples are well mixed and representative. [1, 2]

Use Sample Probes When drawing samples from a process line, faster-moving fluid near the center of the line will likely be better mixed than slower-moving fluid near the line’s wall. The faster-moving fluid has

Process Industry Informer • November - December 2019

Feature Article

Figure 2. In this deadleg configuration, old sample trapped in the tee formation leaks into the main fluid stream, contaminating the new sample.

Remove Deadlegs Deadlegs (Figure 2) represent dead spaces in sampling systems that trap old sample material, which can then bleed into new samples being drawn for analysis. The result is a mixed sample that isn’t true to realtime process conditions. Deadlegs may eventually dissipate without intervention or not. They do not behave in a predictable manner. Generally, deadlegs become more problematic as the ratio of length to diameter increases. In addition, lower flow in the analytical line increases the degree of the deadleg’s effect. Deadlegs may occur at tees, pressure gauges, temperature indicators, and other areas. Minimize or avoid installing such components upstream of the sample bottle or cylinder to prevent new sample contamination. If practical, relocate any upstream tees downstream of the sample vessel, as the resulting deadlegs won’t affect sample integrity there. Use the Right Hoses Some hoses shouldn’t be used in certain areas of sampling systems. For example, a corrugated hose used to connect a liquid sampling station to a bottle runs the risk of old sample material remaining in the corrugations – even following extended purging. That old material can contaminate newly extracted samples, skewing analyzer results. Use a smooth-bore hose instead to ensure drainability and purgability. In addition, ensure hoses are compatible with system media to promote longevity. Fully Purge Cylinders Before Sampling Plant laboratories may not empty 53

grab sampling vessels before returning them to service. Any material remaining inside will not be representative of the current process and must be purged prior to collecting a new sample. In doing so, the sampling system must have a separate purging option or sufficient flow to fully purge the old sample to a vent or a disposal system. Therefore, it’s helpful to install indicators within the system to verify flow. However, the best practice to avoid sample contamination is to follow industry standards that recommend cleaning and drying sampling cylinders before reuse. [1, 2] Even then, it may be wise to purge the empty cylinder to ensure sample representativeness. ENHANCING SAFETY The personal safety of people in and around the plant is the highest priority for fluid processing plants. To address operator safety, plants need to reduce risks associated with both drawing samples and transporting sample vessels. They can also perform preventive maintenance to boost safety. Here are a few ways to enhance safety for your operations. Mount Sample Vessels Properly Capturing and storing samples in cylinders or bottles and transporting those vessels to a lab for analysis carries inherent risks. Both types of vessels often hold materials at elevated temperatures, increasing the risk of burns when grabbing and transporting samples. In addition, cylinders often capture samples at high pressures, exposing operators to potential risk during sampling and analysis.

To enhance safety, mount cylinder supports or bottle shrouds and stirrups in grab sampling stations. These supports securely hold vessels in place, so they don’t hang freely from sample lines. Freehanging vessels place stress on quick-connect couplings, which could potentially lead to a severed connection that blasts an operator with hot, high-pressure fluid. Clamping vessels in place reduces stress on quick connects, increasing their service lives, while also improving operator safety. Use Outage Tubes in Sample Cylinders Operator safety is especially critical when filling and transporting cylinders containing liquified gas samples. The cylinders must have a sufficient volume of vapor space inside to account for expansion of their contents. Without enough space, a small temperature increase can cause the liquid to expand and the pressure to increase dramatically, creating a potential safety hazard. Refer to local regulations and other appropriate guidelines for safe cylinder filling limits for your application. Installed in the top of vertically mounted cylinders, outage tubes enable a defined volume of vapor space to remain inside cylinders when capturing samples. This vapor space allows the captured liquid to expand if the temperature increases. Without using an outage tube, an operator may overfill a cylinder, presenting the risk of a pressure release during transport, analysis, or reinstallation into the sampling system. Properly Install and Maintain Hoses When using hoses to connect a sample vessel to a sampling panel, avoid installations that place undue strain on hoses, which can shorten their service lives or cause failures. Follow these best practices – and inspect hoses frequently for signs of wear – to both enhance operator safety and reduce hose maintenance costs: Process Industry Informer • November - December 2019

Feature Article

Follow Minimum Bend Radius Guidelines: Installing a hose with too small of a bend (Figure 3a) may cause it to kink, reducing its life. Bending a hose too close to the hose/fitting connection (Figure 3b) may cause it to rupture or leak. Install a longer hose to fix either issue.

Avoid Undue Hose Strain: Failing to use elbows and adapters to relieve hose strain on horizontal end connections can lead to leaks (Figure 4). When adding these accessories, you may need to adjust the hose length to maintain the minimum bend radius.

Figure 3b. Image © Swagelok

Figure 3a. Image © Swagelok

Figure 4a. Image © Swagelok

Bend Hoses on One Plane: Avoid twisting a hose or bending it on more than one plane to prevent undue stress on the hose. For a compound bend, use multiple hose pieces or other isolation methods (Figure 5). Replace Damaged Hoses: Replace any hose that has been kinked or has a damaged reinforcement layer. Such hoses could leak or burst at any moment. If damage is limited to the cover and does not reach the reinforcement layer, you can likely leave the hose in place until the next scheduled replacement interval.

Figure 5. Image © Swagelok

I M P R O V I N G O P E R AT I O N S With high stakes for ensuring accurate analyzer readings and plant and operator safety, processing plants should consider following the above recommendations to enhance their grab sampling operations. Through careful system design and operation, they can ensure sample compositions are representative of the original process conditions at the time of analysis, as well as reduce a number of risks to system operators. ABOUT THE AUTHOR Karim Mahraz is product manager, analytical instrumentation for Swagelok Company. He can be reached at karim.mahraz@swagelok.com.

REFERENCES 1. API MPMS 8-1 (2013) Standard Practice for Manual Sampling of Petroleum and Petroleum Products 2. ASTM D4057-12 (2012) Standard Practice for Manual Sampling of Petroleum and Petroleum Products

Process Industry Informer • November - December 2019

Winter 2019

NEWS

Introduction

By Ian Birkinshaw, General Secretary - Solids Handling & Processing Association

in Numbers The Solids Handling & Processing Association has now nearly completed its fourth decade of continuous progress from its initial start in 1981 with only 7 companies it has grown to well over 100 organisations, all focusing on providing the best possible solutions for all aspects of solids and bulk handling. Thank you and congratulations to all those who have been involved in making SHAPA the success it is today. There is clearly something driving this success and that is, or more correctly, they are the end user customers who rely on the expertise and competence of their supply chain. The benefits of SHAPA membership by acknowledged industry experts and suppliers combine to offer proper long-term peace of mind to plant owners and operators.

Well, it is very easy to become inwardly focused, but the risk is losing sight of the main purpose of our very reason for being. Perhaps SHAPA exists solely for the benefit and development of its members, this would be an overstatement and also missing the crucial point. So, what makes SHAPA unique and what is the real purpose of the organisation, how has it survived growth, recession and successive changes imposed by successive governments over the intervening years?

56 | SHAPA Newsletter

To aid end users further in their selection of the right equipment for their installation, SHAPA have developed a Total Cost of Ownership paper, the aim of this document is to provide a framework to enable all stakeholders to qualify the whole lifetime value of equipment so that this can be compared against suppliers rather than just being compared on the basis of the initial capital cost. This document is free to download from the SHAPA website We are generally all in agreement that the application of science serves more reliably and predictably than the so-called black art which for a long time characterised the powder and

granular material handling and processing industry. Fortunately, collective education, technical knowledge and experience have come together to provide a soundly based scientific approach to these disciplines. It is very difficult to achieve all of this in isolation however large a company might be. So, by sharing practical and theoretical engineering knowledge amongst like-minded companies through technical papers and training events, quicker progress is possible, guesswork may be eliminated, and industry standard solutions can be developed, upon which individual member companies may build their advantages and inject cutting edge ingenuity.

Introduction Larger installations may be overseen by project engineering companies, project managers or consultants who require a complete set of equipment, each of which work in isolation and are ultimately combined together to form one complete holistic solution that performs to the overall project specification. These individual items of equipment are quite often procured from several companies with individual expertise to provide the overall solution for the end user. Compatibility of equipment from intake points, batch storage containers, process equipment through to dust-free bagging and out-loading require co-operation throughout the process. This means complete trust amongst the manufacturers and suppliers, knowledge of the machine functions including the required inputs and outputs upstream or downstream from any piece of process equipment and in particular how one element could interact with the next in normal and abnormal conditions. In addition, controls and safety protocols must recognise and take account of the operating conditions of the surrounding environment, plant and equipment. Not until all the finest detail is taken into account can all the information used to provide the most effective long-term solution for the end user. All of this is clearly desirable and indeed essential to maintain the end user in a competitive position in his own marketplace. Furthermore, there should remain scope for later improvements as new techniques, advances in technology and better production equipment are developed and become available. All of this may be more readily achieved if the specialist companies involved can work together successfully, even better if they know each other and have worked together previously. The success any technically demanding, project can be increased still further by being safe in the knowledge that their selected manufacturers and suppliers can demonstrate that they have access to all the best relevant technical, commercial and legal knowledge. With the current push to increase the productivity of manufacturing by the government, many end user industries are turning to use automated bulk storage, handling and

processing equipment. In order to cope with the myriad of powder and granular material types, exhibiting truly diverse properties at all stages of storage and processing is the real reason that solids and bulk handling companies join a technically based trade association and the only major UK based trade association serving the whole range of our industries is SHAPA. Like any company, club or association, SHAPA is a made up of a team of committed individuals, who give their time voluntarily and enthusiastically to run the General Council and the two sub-committees looking after the marketing and technical activities. These groups are continually driving progress to enable all member companies to have the tools at hand to enable them to compete. As we look forward towards our 40th Anniversary the drive for innovation and more science to solids and bulk handling knowledge is undiminished and at SHAPA we have teamed up with an innovation funding partner to allow members to unlock funds from R&D tax credits and Patent box initiatives details can be found on the SHAPA website on the Innovation funding page . SHAPA is about to launch the annual Solids Handling Industry Awards which recognise the successes and innovations within our industry. The awards open on the 1st December 2019 and close on the 29th February 2020. With 2020 being a leap year we can look forward to a leap forward in innovation and knowledge. The award categories for the awards are, Innovation, Export, Newcomer and Company of the year. Speaking of newcomers, we welcome

our next Arkwright Scholar Theo Cains to the association, our last Scholar, Georgina Edwards has now moved on to university and we wish her well in her future studies and career selection. In addition to meetings and training workshops SHAPA offers its members free access to a major consultancy for legal and commercial advice, this can be accessed directly from the SHAPA website and includes over 700 publications which are free to download covering all aspects of running your businesses as well as a phone helpline. Digital marketing is vitally important these days, and is covered by what has now become by popular demand an annual seminar led by Susan Hallam MBE the renowned industry expert. In March 2020 we will be holding our 12th consecutive digital marketing workshop, the things that have changed in the last 12 years in the world of digital marketing is to say the least revolutionary and SHAPA is proud to have a long standing partnership that informs and guides the membership to get the best out of their own digital platforms. So, there is a great deal of activity within SHAPA to promote membersâ&#x20AC;&#x2122; interests. Many member companies work in partnership other member companies, so the regular easily accessible centrally located meetings act as networking opportunities as well as being attractive in their own right with quality speakers invited to update members on topical subjects. We are sure that the following pages will serve to reinforce the value of beginning and ending your search with SHAPA for well informed, well established suppliers and installers of solids handling and processing equipment. Visit www.shapa.co.uk or email info@shapa.co.uk for further information and help. SHAPA Newsletter | 57

Bella XN Mixer

How the Bella Fluidized Zone Mixer Works The Bella fluidized zone twin shaft paddle mixer by Dynamic Air achieves fast, high-capacity, low shear, precision mixing of either dry bulk solids or liquids with solids. Regardless of particle size, shape or density, materials are mixed with a fast, efficient, and gentle action with typical mixing times of 15 to 30 seconds. A weightless zone created by low-speed counter rotating paddles generates very low friction without shear. This makes it ideal for abrasive products and fragile products that cannot tolerate rough handling. Even flakes or spray-dried bodies remain intact. The Bella mixer consists of twin drums which have two counter-rotating agitators with specifically angled paddles. They overlap at

counter-clockwise direction at the perimeter while simultaneously moving both left and right in the center (Figure 2).

Figure 1

the center and completely sweep the entire bottom of both mixer drums and allow it to be started under full load (Figure 1). The material in the mixer moves in a horizontal

Figure 2

The material in Zone B (Figure 1) is in its normal gravimetric state as it is being moved and disbursed. In Zone A, a weightless zone is created which effectively lifts the ingredients to an almost weightless state allowing them to move freely and randomly, regardless of particle size and density. Thus the two zones’ interaction becomes highly efficient as every particle moves rapidly to a highly homogeneous mix, the key to the Bella Mixer mixing technology for fast, precise mixing.

The Bella mixer is available in stainless steel for food applications. Custom sizes, finishes and materials of construction are available upon request. Read more here Dynamic Air Ltd. Milton Keynes, United Kingdom +44-1908-622344 E-mail: sales@dynamicair.co.uk www.dynamicair.com

DMN Westinghouse announces new appointment

Gericke sifters for mills and industrial bakeries

We are delighted to be able to announce that Paul Scott has joined DMN UK as the Sales Manager for the UK & Ireland.

For more than 70 years Gericke has been producing and selling a complete range of flour sifting machines for mills and industrial bakeries worldwide.

Paul has wide and impressive career experience on the system supply side of the processing industries. On leaving school, he joined Portasilo as an apprentice fabricator spending time on the shop floor and in the drawing office. This was followed by an in-house sales role and then Technical Services; a relatively new department at that time which enabled him to develop closer relationships with major customers. After a short spell at Redler as a sales engineer, Paul returned to Portasilo to take up the position of Business Development Manager. This involved foreign travel including India and the Middle East. Prior to joining DMN UK, 58 | SHAPA Newsletter

Paul was Area Sales Manager for Zeppelin. On joining DMN, Paul said: “I am really looking forward to getting started and meeting customers. It’s a great challenge to develop those areas and industries where DMN sees new growth opportunities, while working with the team here to service our existing client base.” Paul lives near York where any available leisure time is spent cycling. For more information on the range of DMNWESTINGHOUSE rotary and diverter valves please phone 01249 818401 or visit www. dmnwestinghouse.com

The purpose of these centrifugal sifters is to remove foreign bodies from the various flour qualities. This allows the flour quality to be kept constant and clean. The success of these centrifugal screening machines in milling is mainly based on 3 points: 1. Very high screening capacity with mesh sizes from 400μm, and flow rates from 1 to 100t/h. 2. Compact devices in terms of throughput and simple design. This facilitates operation and maintenance. 3. An extremely robust construction ensures the longevity of the machines. There are Gericke sifters being in operation for

Gericke centrifugal sifting machine

more than 40 years. This is sustainability. These centrifugal screening machines have been further developed over the years to simplify cleaning and to meet new technical and regulatory requirements: Atex, CE/1935/2004 certification, easy screen change and disassembly for cleaning. We would like to remind you that Gericke manufactures complete dosing, conveying and mixing systems for powders and bulk material. In our pilot stations, all our equipment can be tested on an industrial scale. For further information please do not hesitate to contact us: www. gerickegroup.com

Baghouse performance monitoring for reduced operating costs For optimum performance, fabric filter baghouses require correct and timely maintenance. ENVEA’s UK business (formerly PCME) manufacture a range of particulate monitoring systems, from simple leak to QAL1 certified measurement instruments providing Process Operators with an improved understanding of their baghouse operation. Designed to monitor dust releases from single or multiple filter compartment baghouses, sensors installed in the clean gas output of each filter chamber are able to detect leaks as they develop, even down at very low emission concentrations. Knowing where leaks are developing enables process stoppages and maintenance times to be scheduled saving time and resources by

highlighting which bags require changing prior to potential emission limit excursions. In addition, ENVEA now provide sensors to warn of hopper blockages, often a cause of bag filter abrasion and which can potentially result in explosions within the filter. For Combustion applications which require sorbent injection such as lime or activated carbon, PicoFlow sensors are available to measure the quantity of injected sorbent. Ensuring the correct amount is injected maintains acidic conditions in the filter at the desired level preventing costly damage to the

baghouse and also helps to prevent sorbent over usage and consequent wastage. Further details of ENVEA’s range of Particulate Emission and Solids Flow instrumentation can be found at www.enveauk.global For further information contact Linda Furnell, l.furnell@envea.global

LET’S TALK „… about your individual process solution and why AERZEN Engineering is the key to it.“ Matt Kilgarriff, Special Products Manager

+44 0208 502 8122

matt.kilgarriff@aerzen.co.uk

When it comes to your best solution, you should be as uncompromising as we are: It must be precisely tailored to your requirements, absolutely reliable and highly efficient. With individual assembly configurations and customised services, AERZEN has been serving demanding process applications worldwide for over 150 years. Thanks to efficient compressors and blowers, comprehensive engineering knowledge and pronounced consulting competence, AERZEN can implement your individual customer requirements exactly. The unique AERZEN product expertise ensures you an efficient process solution and sustainable plant availability. www.aerzen.co.uk LT_Processgas_210x148_UK.indd 3

02.01.2019 08:05:07

SHAPA Newsletter | 59

James Miller, Director at Dustcontrol UK

How the food industry can save time, money and resources on cleaning Dust is a major issue in the food industry thanks to the presence of airborne allergens, which, while a problem for workersâ&#x20AC;&#x2122; long-term health, can also pose issues further down the line for consumers.

food industry to ensure the protection of workforces and the quality of products, while adhering to the relevant health and safety regulations. The food industry has special requirements and control of components and equipment used in production is extreme, with a special focus on migratory risk,Â surface finish and antistatic properties.

60 | SHAPA Newsletter

Failing to undertake appropriate cleaning measures and tackling dust in hard to reach areas can affect product quality, while also running the risk of cross contamination â&#x20AC;&#x201C; with potentially fatal consequences in the event of an extreme allergic reaction.

cotton and pollens can cause inflammation of the airways, which can develop into infections such as bronchitis.

For the workers themselves, exposure to fine dusts from flour,

It is therefore essential that efficient measures are put in place within the

Overexposure to hazardous dust for a prolonged period of time can also cause permanent disabilities, and even death.

As a deeper understanding of the harmful properties of dust are better understood, businesses are taking steps to control and confine areas in the workplace where excessive dust is created, but the necessary cleaning required often takes a considerable amount of time, money and resources. Research we carried out found that a third of UK food businesses spent between 11 and 20 per cent of their annual turnover on cleaning, with a further one in six claiming to spend even more than that.

On top of unnecessary costs, we also discovered one in four food companies spent more than 21 hours a week cleaning, while a third assess their cleaning processes at least once a week, on top of the time they spend actually cleaning. It’s a snowball effect - not having the equipment to effectively capture dust at its source, both where and when it’s created, leads to an accumulation of dust, which in turn will naturally increase the time and money spent to combat it. Streamlining cleaning processes and using the optimum equipment for each scenario plays a large part in reducing time consumption, as well as unnecessary costs. Source extraction systems are one of the most effective ways of achieving safe and hygienic food production, as they are designed to ensure food processing areas are the cleanest they can be – keeping the potentially

serious side effects of dust to a minimum. With hygiene requirements within the food industry being extremely stringent, a complete source extraction system can be fully integrated into the production process for recycling or used as a centralised vacuum cleaning system. By combining safe food contact, autoclavable, colour-coded, detectable, antistatic and FDA compliant properties to fully integrate a comprehensive system, food processing companies can yield higher quality products, whilst making savings on factorywide cleaning costs.

food industry, courtesy of strict process and control. With companies spending considerable amounts of time and money on cleaning, it pays to make sure they’re doing it right. Streamlining cleaning processes and using the optimum equipment ensures businesses are utilising resources and saving valuable time and costs on creating a safer working environment.

Overall, cleaning is a serious business in the SHAPA Newsletter | 61

Heavy Duty Butterfly Valve Posi-flate 585/586 butterfly valves feature seats and discs for application pressures up to 10 bar. The design improves on existing 485/486 seats to provide the same incredible valve life at even higher pressures. The 585/586 valves are designed to fit PN 10 flanges, and come in sizes 80mm to 600 mm.” The Posi-flate Series 585/586 butterfly valves are designed for the most the most severe of applications. They are ideally suited for very abrasive materials which can reduce valve life. The inflatable seat design provides a better seal by utilizing air pressure to expand the seat against the disc, providing more sealing area and an even pressure distribution against the disc every time. The seat automatically compensates for wear when it inflates against the disc, extending valve life considerably.

Because the Posi-flate disc only makes casual contact with the seat during opening and closing, torque requirements are substantially lower. This ease of movement also allows the disc to come to a perfect 90-degree position every time. Additionally, the smooth profile of the disc helps material flow easier and reduces build-up. For unique fail-safe monitoring, a pressure switch can be utilized to verify a perfect seal. The Posi-flate 585/586 butterfly valves are available in a wide variety of construction materials including stainless steel and lightweight aluminum. Read more here Posi-flate Milton Keynes, United Kingdom + 44 1908 622366 E-mail: sales@posiflate.co.uk www.posiflate.com

Dust Control for Processes; one day short course for industry An examination of the different methods for dust minimisation, capture and extraction.

Fine particle content can lead to flow or dust emission problems The capture of airborne particles is a requirement that can span a wide range of industries. At a low concentration the fugitive material can take the form of airborne dust whilst at the other extreme the separation of particles from the air occurs with much higher concentrations (i.e. reception vessels for pneumatic conveying

62 | SHAPA Newsletter

systems or systems vents). For either type of application good disentrainment efficiency is of paramount importance. Aspects of control of fugitive particles or capture There are four potential sequential approaches that can be employed. These are: • Prevention during handling • Containment • Suppression • Extraction and Collection Learn more about these strategies and technologies at the Wolfson Centre for Bulk Solids Handling Technology. Contact Caroline on +44 (0) 20 8331 8646 wolfson-enquiries@gre. ac.uk or book on line

Posi-flate butterfly valve

Consultancy and Short courses for the Process Industry: Bulk solids handling technology

We support industries that are seeking to resolve process problems, develop design schemes for plant expansion, or simply improve product quality.

Consultancy services

Some of our Consultancy services include advising on: Storage and Discharge of bulk materials Pneumatic Conveying of bulk solids Spoiling of materials in storage and in transit Plant and Equipment design/redesign Ship Unloading/ quayside operations Control of plant wear Dust control Bulk Materials characterisation ATEX/DSEAR compliance Expert Witness services

• • • • • • • • • •

Short courses for Industry

We also provide a range of short courses to help delegates identify potential bulk materials handling problems and advise on how to avoid and/or overcome these issues.They fall under 4 main categories Pneumatic conveying:

storage of bulk materials:

•Pneumatic Conveying of Bulk Materials • Pneumatic Conveying System Design • Rotary Valves; Design, Selection and Operational Issues • Commissioning and Troubleshooting ‘Hand’s On’ Pneumatic Conveying Systems

general bulk materials handling:

• Storage and Discharge of Powders and Bulk Solids • Design of Equipment for Storing and Handling Bulk Materials • Biomass Handling, Feeding and Storage (can be adapted to

other materials such as waste, recycled goods, pellets)

sPecialist areas of concern:

•Overview of Particulate Handling Technology • Dust Explosions - How to demonstrate DSEAR/ATEX Compliance • Port and Terminal Operations for Bulk Cargoes Measurement of the Properties and Bulk Behaviour of Particulate Materials • Introduction to Processing Dry Solid Materials

• Caking and Lump Formation in Powders and Bulk Solids • Undesired De-blending and Separation in Processes and Equipment • Electrostatics in Powder Handling • Numerical Modelling of Solids Handling and Processing • Dust Control in Processes Powder Handling and Flow for Additive Manufacturing

bulksolids.com

Lyn Bates, BMHB.

The need for a

‘USER GROUP’

of Companies handling loose solids.

The economic benefits offered by continuous processing over batch is driving the pharmaceutical industry to follow the route of food, chemical and mineral industries in adopting this method of production, (1).The historical mindset of management to employ batch processing is reinforced by the need to change in design methodology from a unit operation to a systems approach and recognise the consequent importance of the physical properties of the bulk material to the handling of the product. Research and design importance are rightly directed to the constituents and process of production of a suitable product, but it is separately important that the production method is reliable and does not adversely effect the quality of the output. (2). This was dramatically illustrated in other Rand reports that highlighted the wide relative inefficiencies of plants handling solids and those handling liquids and gasses. (3). This discrepancy was attributed to the lack of data relating to relationship between the physical properties of the components and their handling characteristics. Unresolvable segregation issues were also reported as responsible for the failure of a $300,000 pharmaceutical project.

The need for a wider understanding of the handling characteristics of bulk solids is not confined to the pharmaceutical industry, but is virtually universal, (4). However, whereas there are at least three trade organisations of manufacturers of solids handling equipment in UK alone, (5), there is no organisation that represent the vast number of manufactures that use bulk solids within their production facilities or co-ordinates research in the subject, either at universities or on behalf of industries with common interests. The paucity of teaching powder technology in the syllabus of many universities does not currently favour a significant change in the level of support available to design improvements. It is noticeable that, apart from Andrew Jenike’s contribution to hopper design, most advances in equipment design has originated from equipment manufacturers than university research.

The UK Government has currently many others priorities and an early effort in 1959, (6), as part of Harold Wilson’s “White heat of technologies” splurge. Despite sterling work in bulk technology, the laboratories were sold off to form a car park in a Heseltine economy purge. Government will not give attention to this, so it is up to a major manufacturer to take the lead and support The British Materials Handling Board in the formation of a ‘Bulk Users Association’, which was set up by the Government for these objectives.

Refs. 1. ‘Modernizing Pharmaceutical Manufacturing: from Batch to Continuous ’Production’, Journal of Pharmaceutical InnovationSept. 2015, Volume 10, Issue 3, pp 191–199|.. 2. ‘ Linking R & D to problems experience in solids processing’. Merrows. E. Rand Report 1984. 3. ‘Understanding Cost Growth and Performance Shortfalls in pioner process plants’, Rand Report. Merrows.E. 1981. 4. ‘The Global status of Bulk Materials Handling’. BMHB 5. SHAPA, MHEA, PPMA 6. Warren Spring Laboratories, 1959 – 1994.

64 | SHAPA Newsletter

PROTECT YOUR DUST FILTER AGAINST FIRE AND EXPLOSION

Fireflyâ&#x20AC;&#x2122;s unique Spark Detection System is based on true IR spark detectors that are insensitive to daylight. They are designed to detect all dangerous ignition sources, such as hot dark particles, sparks and flames within milliseconds.

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SHAPA Newsletter | 65

Lyn Bate of Ajax Equipment

Cost effective benefits of cooling screw design Screw feeders and conveyors are widely used for the handling of bulk materials in situations where it is beneficial for the product to be subjected to heating or cooling, in some cases this being the prime function of the equipment. A feature of this form of material transport is that there are a range of independent design options that influence to efficiency of heat transfer that are disproportionately in the cost of manufacture. A degree of heat transfer can be secured very economically, but fabrication cost increases according to the form of change, so an optimum cost/ effective solution requires a degree of design expertise.

The choice of â&#x20AC;&#x2DC;Uâ&#x20AC;&#x2122; trough or circular casing depends on various factors, such as access for cleaning, containment and heat transfer efficiency. Similarly, the selection of heat transfer media independently rests on factors such as the availability of resources, thermal task and range of temperature change. Options include: ambient or chilled water, oil, hot or direct fired gas or electric. However, the thermal benefit

and cost of design differences in the machine construction increases in the following generate manner, although not in similar proportions. - Fit rotatory glands on the screw shafts for heating or cooling media. - Continuous heavy weld both sides of the screw flights. - Fit thicker flights - Fit shorter pitch flights - Use larger centre tube. - Fit jacket to casing. - Minimise flight tip clearance by matching casing to screw deflection. - Select oversize screw running slower. The use of screws to extract material from the outlet slots of heat transfer hoppers enables extra cooling by adapting the screw for heat transfer by one or more of the modifications listed. In these circumstances there is an important additional design criterion as the overall heat transfer efficiency of the system is radically influenced by the uniformity of the discharge velocity profile along the outlet slot. An uneven rate of discharge from different regions of

66 | SHAPA Newsletter

11186 PPMA Directory_273x90

the hopper results in a variation in residence time. Overall heat transfer is less efficient than when the outflow is uniform, but unfortunately uniform extraction to produce an even flow rate is rarely achieved. (1). It is well appreciated that a screw with flights of a constant pitch will preferentially extract product from the first section of the hopper to which the screw is exposed. However, a common misconception is that screws which vary in pitch will give a reasonably even feed, whereas the variation in feed rate is usually massive. (Fig 1.). This assumption probably arises from the false concept that the axial transfer capacity of the screw is fixed by the swept volume of rotating, whilst it actually varies as the geometry and surface friction of the product in the inclination of the flight, which changes from where it is adjacent to the centre shaft up to the flight outside diameter. (2). The variable flight helix affects the efficiency of axial transfer capacity, as does the frictional drag of the centre tube, so a ‘mean effective helix angle’ of flight must be assessed for extraction calculations. A basic impediment to uniform extraction is that the

initial ‘draw’ extracted from the hopper by the first flight will extract and axially transfer its full capacity, but subsequent sections of the screw can only transfer their differential increase in transfer capacity. This impediment to even extraction is addressed by a feature of feeder design, as Ajax reg. Design No. 6038827. Some design expertise is then required to exploit the relative merits of design change of flight pitch, shaft size, flight thickness and the face friction. Changes in screw construction are theoretically required for every flight, but this number may be more than halved and change doubled in effectiveness by fitting right and lefthand flights to a central outlet. The extra reduction of over 50% of the effective outlet length follows from the requirement for a central insert to prevent direct leakage of the hopper contents. This insert must stimulate mass flow and the final two exposed flights prior to the inlet has.to extract material from directly above and half that resting above the insert. The dynamic shear strength of the flowing media can be exploited to some extent, especially with short pitch flight sections, to mitigate minor theoretical velocity differentials.

References 1. Bates.L. “Capturing the elusive benefits of uniform extraction rom hoppers” Proc. Ind.Infom. Dec. 2019. 2. Bates.L. “Entrainment pattern of Screw Feeders”. J. Eng. Ind. May 1969, 91(2): 295-302

POWDERS

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Versatile Mixing Machines, the Complete Range from 2 to 25,000 litres Helical Blade (ribbon): Sugar Paste to Herbs Delta Blade (plough): Cookie Mix to Flavours Rotary Drum: Tea to Muesli Paddle Blade: Viscous Pastes Coaters: Herbs, Spices, Flavourings Batch machines or Continuous Complete mixing plant design to commissioning Test mixers available for production development Production scale machines for short or long term hire Get more from your existing plant Existing Mixers and Systems can be refurbished and upgraded Contact our applications engineer for an assessment T: +44 (0)1260 272894 www.jrboone.com e: sales@jrboone.com J.R.BOONE Ltd., 18 Silk Street, Congleton, Cheshire, CW12 4DH, England

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SHAPA Newsletter | 67

Fit for Liquids Under the banner “Fit for Liquids“ UWT is proud to launch a brand new product series in the field of liquids measurement. The new capacitance measuring sensors for continuous and point level detection offers new options for the UK and international market. With the new UWT liquid level detection range, pin-point accuracy and total reliability, UWT offers continuous and point level detection in liquids, pastes, foam and slurry as well as interface measurement. The UWT sensors work with the combination of the capacitive measuring principal and the change in frequency of the sensor which has a far greater switching accuracy than just the capacitance when the probes are submersed in liquid. This allows the probe to also maintain its high accuracy when it comes to viscous media like syrup or honey as the sticky build up on the probe does not affect the switching output signal. This ensures the best possible dry run detection of any system.

Another further advantage is the ability to measure interface between liquids – water and oil, foam and beer – with high repeatability and accuracy. All devices are equipped with potted electronics and work with the unique “Inverse Frequency Shift” technology. They provide a robust, certified construction and offer suitable solutions for a wide variety of liquids, pastes and foams – whether to be used for aggressive chemical applications, within the demanding food industry or in wastewater handling. Through a variety of metal rope, cable, rod and pipe extensions the units can be easily adjusted to single conditions of the process vessel. Thanks to the integrated “Tip Sensitivity” technology the Capanivo® range with the CN 7 and CN 8 level detectors guarantees high reliability for products that cause caking. The Capanivo 7000 delivers a very compact design for limited space, available as enclosure or integral cable version as well as synthetic model.

The Capanivo® 8000 on the other hand is a universally applicable all-round talent due to its range of process connections, hygienic versions and the high safety standard. UWT has expanded the RF limit switch line with the robust Rfnivo® 8000 that includes a hightemperature version for a wide temperature range from -40°C to +400°C and pressure resistance up to 35bar. The PFA isolation ensures high degree of chemical resistance. The NivoCapa® 8000 measures the continuous level in conductive and non-conductive materials with complete accuracy. At the same time the LCD display with control buttons and diagnostic function make the level sensor very userfriendly. The integrated “Active Shield“ technology found in the RF and NC devices ensures precise measuring results even when detecting media that tend to stick to the probe.

For further information contact UWT on: 01743 718883

sales@uwtuk.com www.uwtuk.com

68 | SHAPA Newsletter

HSE Requested Information Regarding LEV SHAPA along with the HSE and others are part of the Industry and Regulatory Forum on LEV, we are collectively working together to promote a safe environment in the workplace. In order for the HSE to better understand the current state of LEV in the workplace they are gathering information to support a project into the ‘Investigation of Critical Factors for the Safe Use of Recirculating Local Exhaust Ventilation’. Can you please help in this process by providing answers based on your experience to the following questions (you can download these questions here) 1. What types of filters are commonly used in industry sectors for LEV systems? · Bag; or · Cartridge 2. What filter media and/or filter standard and class (e.g. EN 779 F9, ISO 16890 ePM1 80%, EN1822 H13, etc.) are commonly used in: · Main or primary filter? · Secondary filter (if any)? 3. Should filter media be specified for particle form, size and chemical composition? 4. Should LEV filters be required to be tested against a standard and meet a defined filter class? 5. What marking should be required for filters? 6. Should all recirculating welding fume devices be type tested against the welding equipment standard (EN15012-1)? 7. What criteria should be used to decide when type M and H vacuums are used for on tool extraction? 8. Are the device and filter standards fit for purpose for LEV systems? Could you please forward your answers directly to Robert Ellis who is leading the initiative from the HSE robert.ellis@hse.gov.uk

Capanivo ® Compact & flexible

Clever capacitance level detection of liquids, pastes, foam & interface measurement Use in non-metallic containers possible!

CN 7000 The pocket-sized one Compact design Enclosure version or integral cable version Synthetic version available Chemical resistance Optional PVDF probe SensGuard protective sleeve 2-wire instrument ” tivity ensi y S p i g “T nolo Tech

CN 8000 The allrounder Pipe and cable extension Range of process connections High safety standard Hygiene versions Very high sensitivity Digital version with LCD

(Download the questions here)

UWT (UK) Ltd • 01743 718883 •

sales@uwtuk.com www.uwtuk.com SHAPA Newsletter | 69

Vibratory Sieving Dust

Containment and Control Sieving and screening powdered products greatly contributes to dust generation, not only when product is poured or dumped on to the sieve screen, but when the sieve applies high powered vibration to the mesh screen. the sieve, minimising impact on the operator and generation of airborne dust from dispensing the product. A dust-tight seal to the sieve is maintained thanks to the metal detectable silicone diaphragm seal. The hood is available with a pneumatically assisted door that can be closed when the sieve is in use to supress dust as powdered product falls into the vibrating sieve below. This helps keep the dust contained and prevents it from entering the surrounding atmosphere, protecting the operator, preventing loss of product and mitigating the risk of contaminates entering the sack tip station when not in use.

Farleygreene are all too aware that dust control has become an ever-increasing concern for manufacturers in a variety of industries where product processed in bulk can produce a large amount of dust. Regulatory standards are also becoming increasingly tight as inhalation of airborne dust particles are contributing to poor health of operators. Heavier dust particles that settle on equipment also add to the risk of fire and explosion, as well as contributing to unnecessary maintenance and a shorter lifetime for costly equipment. DUST CONTAINMENT Farleygreene have developed a range of different solutions that 70 | SHAPA Newsletter

help control dust when sieving and screening. Their Sievmaster range offers a variety of different sieves designed to handle various requirements within manufacturing. The most popular product for plant operators is their Slimline sieve, available in four different diameters depending on the throughput requirement. The two smallest Slimline sieves are also sold with a sack tip option, as the â&#x20AC;&#x2DC;Sievmaster Easiliftâ&#x20AC;&#x2122;, designed for processing powders in bulk from sacks or containers. Providing a sack rest table and hooded enclosure, sacks up to 50kg can easily be cut and emptied into the sieving compartment. When in use, the sack tip hood remains vibrationally isolated from

DUST EXTRACTION The standard dust hood is fitted with a Ă&#x2DC;150mm dust extraction port, ready for connection to an external extraction system to draw air-borne product into the hood and away from the operator during sack tipping. Alternatively, local dust extraction units can be built directly into the dust hood itself. These are available in two varieties; either with an electric fan or a pneumatically powered vacuum pump. Both draw air through a set of filters and feature reverse jet purge cleaning. This means that when the dust hood door is closed, a powerful pulse of air is sent back through the filters, blowing any trapped product off them to fall down to the sieve, minimising loss of product.

concerns as equipment can be more difficult to keep clean. Therefore, a significant advantage of a combined sieve and sack tip station is that transfer between separate machines is eliminated, reducing the risk of contamination or product leakage.

EXPLOSIVE RISKS In order to prevent any explosive risks from powder generated during processing, Farleygreene Sieving equipment conforms to the latest ATEX requirements and can be certified for Zones 20, 21 and 22, depending on options. Several Earthing options are also available including, 430 Chrome steel earth clips and food-grade conductive mesh ring gaskets. However, one of the more popular options is the direct mesh earthing bar which screws directly into the mesh ring through a slot in the body of the sieve. This offers a way of ensuring the mesh is properly earthed without having to open the sieve. HYGIENE CONCERNS Particularly for the food industry, the generation of excessive dust can also contribute to hygiene

Earlier this year, Farleygreene released a new product to their sack tip range, the Easilift Ultra, designed specifically for the hygiene conscious food industries. The hood on the Ultra version is rounded with fewer crevices, improving product flow and cleanability. The externally mounted sack tipping table mitigates the risk of contamination of the product from the outer surface of the sacks or containers, and folds away when not in use to minimise surface areas prone to dust collection. The door has also been designed without welding to reduce deformation and provide a flatter sealing surface, ideal for dust suppression. It is also worth noting that this more hygienic style hood is also available with the pneumatically assisted door and integrated dust extraction system.

Nearly all materials handled in bulk generate dust, but these containment and control solutions offered by Farleygreene can help manufacturers take preventative action to keep operators safe. Farleygreene have been designing and manufacturing sieving equipment at their UK factory since 1976, supplying machinery to some of the worldâ&#x20AC;&#x2122;s largest manufacturing companies. To learn more visit farleygreene.com, email info@farleygreene.com or call +44 (0) 1256 474 547.

SHAPA Newsletter | 71

INVESTMENT CASTING SAND

AND FLOUR CONVEYED FROM BULK BAGS AUTOMATICALLY, DUST-FREE O’Fallon Casting is a major manufacturer of thin-walled, nonferrous investment castings.

The company’s commitment to automation has helped it grow. Examples include installing robots to move the patterns through its slurry and sanding steps, and converting from manual bag dumping to automated discharging from bulk bags using Flexicon bulk bag dischargers and flexible screw conveyors. Bulk-Out® model BFC bulk bag dischargers unload three varieties of sand which flexible screw conveyors transport to the drum sanders. A cantilevered hoist and trolley lift each bag into the discharger frame.

72 | SHAPA Newsletter

Converting from manual dumping to automated discharging The investment casting process can be labour-intensive. It begins with a wax pattern, which is identical in shape to the final casting. This pattern is dipped into a slurry, which partially drains away. Next, the slurry-coated pattern passes through rotating vessels, called drum sanders, each of which coats the pattern in a different type of sand. After the slurry hardens, the wax is melted away and replaced with a molten metal to make the casting. As the wax patterns move through the slurry and sanding steps, they consume the fine powder used to make the slurry—called flour—and three varieties of sand. For years, operators had replenished the slurry vessel and drum sanders by hand, carrying and emptying 23 kg bags into them. In 2007, O’Fallon began buying the materials in 1,360 kg bulk bags and adding them automatically by machine. For this, the company chose equipment from Flexicon,

which supplied four BFC bulk bag dischargers and a combination of single-run and interconnected flexible screw conveyors. One dischargerconveyor system is devoted to delivering flour to the process, while the other three deliver sand to four drum sanders. Systems promote bulk bag evacuation, contain dust Bulk bags are delivered to each discharger by forklift and then loaded into the frame using a hoist and trolley that travels on a cantilevered I-beam. Next, a SPOUTLOCK™ clamp ring atop a TELE-TUBE™ telescoping tube is raised pneumatically and secured to the bag spout. This serves to both contain airborne dust and maintain continual downward tension on the bag as it empties and elongates, promoting discharge from the bag. While each sand variety flows freely from the bulk bags and hopper, the flour tends to bridge, according to Matt Cavins, metallurgical engineer. As a result, the flour discharger includes

Once the bag spout is secured by the Spout-Lock™ clamp ring, the Tele-Tube™ telescoping tube applies constant downward tension as the bag empties and elongates to promote complete discharge and contain dust.

Flexible screw conveyors moving sand to each drum sander terminate at a discharge adapter and downspouting.

In delivering ‘flour’ to the process, a lifting frame, cantilevered I-beam, trolley and hoist place the bag in the discharger frame. Flow-Flexer™ bag activators (top corners, lower half of frame) promote flow as the flour tends to bridge.

two additional mechanisms to promote flow: FLOWFLEXER™ bag activators which raise and lower opposite bottom edges of the bag into a V shape, and a vibrator mounted on the hopper wall. “Those features were major considerations for us,” Mr. Cavins explains. “We wanted to make sure that it was discharging from the bulk bag smoothly and that there wasn’t a lot of dust created where the hoppers are.” One of the benefits of receiving the sand and flour in larger bulk containers is efficiency for O’Fallon’s operation as it enables supplying the powders to multiple locations from a common bulk materials location. To achieve this, flexible screw conveyors automatically transport the materials through openings in the walls to the slurry vessel and drum sanders. Since the design of the flexible screw conveyors is well suited to complex equipment layouts, the series of conveyors allows the Flexicon bulk material handling system to feed the powders to varied locations. In O’Fallon’s layout, powder use points are anywhere from 2.1 m

One of three varieties of sand on its way to the drum sanders.

to 13 m away from the bulk bag dischargers. Further enhancing efficiency, the material conveyance is automated. These additions are weight-based, with a scale beneath each vessel signaling a PLC when to start and stop the conveyors. Automation cuts downtime, manual effort O’Fallon uses about two bulk bags of flour per day, and each of the sand lines consumes about two bulk bags per week. The materials are heavy and abrasive, and the conveyors handle them well, Cavins says. “We really haven’t had many issues. It’s been almost 10 years in operation now, at least on the sanders, and we’ve replaced maybe one drive, and that’s on three systems with multiple drives. Two conveyor tubes have been replaced in that 10-year span, he said. The polymer tube on the flour conveyor is more prone to wear than the steel tubes on the sand conveyors...but it’s really not enough to switch to a steel tube,” Mr. Cavins says.

Robot dips wax patterns in the slurry vessel before sanding. O’Fallon is a leader in thin-walled nonferrous investment castings.

“We have more uptime and a safer working environment.” Flexicon (Europe) Ltd Whitstable Kent CT5 3RB +44 1227 374710 sales@flexicon.co.uk www.flexicon.com O’Fallon Casting +1 636-272-6176 www.ofalloncasting.com

SHAPA Newsletter | 73

Jim Lenihan, President of Gemco Valve Company

Valve Options Powder/Solids processing valves present more performance challenges than gas or liquid valves and therefore often require more consideration of available options and customisation. Before we detail the two most common options, readers may find it useful to review the basic factors to consider when specifying solids processing valves in our article Valves for Powders. High Temperature Options Soft seated valves with elastomers are typically limited to around 200C. Valves are considered high temperature when they are exposed to temperatures above this for extended periods. Some elastomers may handle momentary exposure to higher temperatures but this is generally not well defined and systems should be designed for worst case process conditions. This is different from upset

conditions where after an out of normal limits event, the process is shut down and the equipment is inspected and maintained before restarting operations. For temperatures between 200C to 330C, FFKM (Perfluoroelastomer) O-rings such as KalrezÂŽ 7075*1 may be used for valve body and valve stem seals. However, metal seats are recommended since soft seats will degrade and erode quickly and will not

provide a reliable shut-off. Metal seated valves have a tendency to jam as the valve heats and expands and are often set with a predefined clearance between the seat and shutoff disc at ambient temperature. Of course this affects shut-off class and is not acceptable in some applications. Spring loaded seats that allow for thermal expansion are an option in smaller sizes. Carbon/Graphite based flange gaskets such as Flexicarb*2 are common in these applications. These gaskets are typically not reusable. Graphite stem packing such as GarlockÂŽ 1306*3 is typical for high temperature and some can go to 455C/850F in atmosphere and 650C/1200F in steam. Inconel wire reinforcing in expandedâ&#x20AC;&#x201C; graphite yarn is an additional option that provides more rigidity and dependability to the packing. Extreme Temperatures For bubble tight shut-off at extreme temperatures above 450C, static seals may be the best option. These can vary from standard ANSI or DIN flanges with gaskets and fasteners to Spider Clamps that allow for quicker mounting and removal. Cleanliness is critical to this process so seal faces and gasket surfaces need to be inspected and any contamination removed on every use.

74 | SHAPA Newsletter

NASA’s ISRU (In Situ Resource Utilisation) Technology Development Project for hydrogen reduction of regolith. The valves were used in ROxygen field tests on Mauna Kea, HI in 2008. High Temperature Actuators. While some actuators are available with high temperature O-rings/seals, the preferred method is to isolate the actuator from the process temperature. This can be achieved by insulating the valve and process piping and/ or providing a heat shield plate mounted between the actuator and valve. Another option is to provide a drive stem extension and add radiation fins to the housing extension to dissipate the heat. Flush Mount Options Most discharge valves for vessels and processors leave a dead space where the valve mounts to the vessel. Dead space is defined as the volume between the valve shut-off element and the inside wall of the vessel. This can be an issue for mixing and processing applications where the product in the dead space remains unmixed or unprocessed.

For smaller valves - up to approximately 80mm - a mounting pad on the vessel allows the shut-off disc or ball to be close enough to the vessel to minimise the dead space to an acceptable level for most processes. This often requires the actuation package to be mounted at an angle to avoid interference with the outside wall of the vessel. Most ball valve manufacturers offer this option. For segmented ball/ spherical disc valves, angled stems are not available. Instead, an extended stem and valve mounting bracket can place the actuator outside the interference area.

As the discharge valve increases in size from 100 to 300 mm the solution is more challenging depending on the amount of dead space that is acceptable to the process. To minimise the dead space, a mounting neck piece or pad is welded into the vessel wall and bring the diameter of the ball segment/spherical disc flush with the inside of the vessel.

However, to eliminate dead space, the ball segment and seat need to match the form of the inside of the vessel which can be flat, radius or conical. This customisation requires 3D modeling and manufacturing with CNC equipment. The geometry of the ball segment means that the shut-off disc will penetrate into the vessel as it opens and closes. If the processer has paddles, vanes, ribbons or other moving parts then interference with the ball segment needs to be avoided. The can be achieved by interlocking the controls so the valve will not operate in the interference condition. This design and build to order comes with added costs and is only justified in exceptional applications. Shown is a model of a retrofit, flush mount, valve design for a major producer of food ingredients who wanted to improve the mixing quality of an existing blender. The project involved removing an existing butterfly valve and discharge cone and replacing it with a spherical disc valve and weld neck. The seat and spherical shut-off disc were manufactured to match the inside radius of the blender and eliminated the dead space.

*Gemco Valve Company mentions these brand names as examples only and receives no consideration from the owners. There are many completive products available. *1 Kalrez® is a DuPont brand and is available in a wide range of grades. *2 Flexitallic Industrial gaskets supplies a range of high temperature gaskets. They do state “Flexicarb will oxidise over time. Care should be taken when considering the use of Flexicarb foil for applications above 650°F (343C).” *3 Garlock® packing is available in a range of materials and grades. SHAPA Newsletter | 75

Boone Mixers

are at the centre of BASF’s New Rodenticides Line Boone Mixers have supplied two Horizontal Helical Blade Mixers (HHBM) to BASF in Widnes for their new production line, manufacturing rodenticides with a marzipan-like texture to meet the growing demand world-wide for alternatives to warfarin as rodents develop resistance and traditional rodenticides become less effective. BASF have developed a rodenticide that combats the increasing problem of evolving drug resistance, while being very palatable to encourage the animals to consume the bait. As customers world-wide take up the new product, BASF needed a new production line and following extensive tests the new Boone HHBM mixers were selected as a key part of that development. The base of the product is a simple mix of fat, sugar and flour, mixed

in the Boone HHBM mixer with the ‘active’ components. The mixed product is a crumb mix that is then formed into small blocks and packed for use. Although the end products may be very different, in some ways the challenge of mixing the product is very similar to any other crumb, even crumble dessert topping. It has to be thoroughly and homogenously mixed, including micro-ingredients, while not over-working the mixture, which would compact it and make it difficult to form. Boone HHBM accomplishes this using a low mixer speed and omega shaped mixer shell with a unique, high efficiency interrupted spiral mixer blade configuration. This has a low surface area mixer blade that reduces energy input to the mix and is easy to clean. The omega shaped mixer

shell is ‘short and tall’, so end-to-end mixing is optimised, and the mix fully discharges through a knife gate for packaging. Boone also designed and supplied the liquid oil spray feed system to match BASF’s specification which together with a heating and cooling jacket to control mix temperature and extend the range of products that can be made in the HHBM. Because of the ingredients used, the mixer, inlets and outlet are designed for ATEX internal/ external Zone 20/22. The Boone Standard ATEX Mixers and ancillary equipment are designed to meet that standard. According to Benjamin Charnock, Facilities manager at BASF, ‘Production is ramping up, and we need to respond to the demand. The Boone mixer is helping us to do that, and we are planning to build and add another line in the very near future.’ (HHBM are also known as Ribbon Mixers)

JR Boone Ltd 18 Silk St, Congleton, Cheshire CW12 4DH, United Kingdom Tel: +44 (0)1260 272894 e-mail:sales@jrboone.com www.jrboone.com

76 | SHAPA Newsletter

GROUND-BREAKING NEW PRODUCT FROM

SEMI AUTOMATIC EASY CLEAN 12000 GAUSS ROTARY MAGNET WITH ATEX 20 APPROVAL Greenwood Magnetics are proud to launch a ground-breaking new rotary magnet approved for use in ATEX Zone 20 internal environments.

The 12000 Gauss Semi-Automatic Easy Clean Rotary magnet ATEX 20 is approved by notified body Intertek:

and construction of products intended for use in potentially explosive atmospheres given in Annex II of the Directive”

“Intertek Testing and Certification Limited, Notified Body number 0359 in accordance with Article 17 of Directive 2014/34/EU of the European Parliament and of the Council dated 26 February 2014, certifies that the product has been found to comply with the Essential Health and Safety Requirements relating to the design

The design is protected by registered design number 007214622 Real-world performance The Greenwood Easy-Clean Rotary Magnet is an inline magnetic separator used in vertical process lines for the extraction of ferrous and paramagnetic particles from dry product. It has been designed specifically for products susceptible to bridging such as milk powder or starch. The centrally mounted grid gently rotates extracting fine ferrous and semi– ferrous particles whilst ensuring that the product remains free flowing, avoiding bridging or clogging. Class-leading safety The risk of explosion when handling and processing fine powders is well known. We believe the new Greenwood Rotary Magnet is the first to combine 12000 gauss magnet strength with easy-clean technology in a unit that is approved for use in ATEX 20 environments where dust/powder explosion risk is highest. Class-leading magnet strength The new rotary magnet also offers class leading strength. Many suppliers of industrial magnet systems quote the internal gauss of magnets in their products. This is the maximum available magnetic strength of the SHAPA Newsletter | 77

magnets inside the magnetic tubes. However, this means the actual strength is reduced on the contact surface. The new rotary magnet from Greenwood uses a â&#x20AC;&#x2DC;scraper-plateâ&#x20AC;&#x2122; design which means that the easy clean magnetic tubes have a magnetic strength of 12000 Gauss- tested and certified on THE CONTACT SURFACE. Greenwood Easy-Clean technology Greenwood Easy-Clean system allows the magnets to be readily extracted from the rotary unit so the ferrous and paramagnetic particles fall into a collection tray for easy removal and analysis. This delivers a better, faster method of cleaning, improving operator safety and efficiency. ATEX 20:ISO9001 Integration Intertek has also audited Greenwood Magnetics ISO

78 | SHAPA Newsletter

9001quality management system and confirmed it integrates fully with ATEX under Annex 1V in accordance with article 17 of the Directive 2014/34/EU. Real-world success Greenwoods have already received their first order, even before the official launch of the product. For more information about our new ATEX-certified rotary magnet, other bespoke magnets, manufactured to requirements or if you would like us to test and certify your existing magnets, please do not hesitate to contact us: Greenwood Magnetics Tel: 01706 645824 Email: sales@greenwoodmagnetics.com Web: www.greenwoodmagnetics.com

Christian Dunne, Global Head of Sterile Solutions at ChargePoint Technology

How new technologies are influencing

advanced aseptic

are becoming more stringent, with increased emphasis on using the best available technologies and performing comprehensive, sciencebased risk evaluations of procedures. The industry is seeing significant developments in technology in response to the hazards involved in aseptic processes, as product sterility must be ensured and contamination prevented to avoid potential consequences to patient safety.

Introduction Recent years have seen significant improvements and innovations in technologies used in aseptic processing. With the rise in demand for small batch, novel therapies, manufacturers are looking to develop more vigorous and flexible containment strategies using new and innovative solutions. The regulatory requirements around sterile manufacturing

Current market landscape Containment technology experts are continuing to innovate to meet the evolving requirements of the sterile product manufacturing sector. This is one of the factors driving growth in the global advanced aseptic processing equipment market, which is set to reach a CAGR of 3.8% between 2017 and 2024 [1]. Current regulations for aseptic processing are rigorous, especially in the case of guidelines around cleanroom areas for the manufacture of sterile

products, which must be classified according to the necessary characteristics of the environment. These environments must meet strict classifications in accordance with ISO14644 in order to be categorised as grade A, B, C or D. More personalised therapies that are targeted to meet specific requirements, such as those of a small group of patients, are becoming increasingly popular, generating the need for an increased amount of small batch manufacturing. Equipment for the production of sterile goods must be cleaned, decontaminated and sterilised between batches to prevent contamination of the following batch. If this is not handled correctly, a manufacturerâ&#x20AC;&#x2122;s start up and shut down process can be significantly delayed. This is a particular challenge for the growing number of contract development and manufacturing organisations (CDMOs) that must be agile enough to handle multiple products for multiple clients within their facilities. SHAPA Newsletter | 79

Existing cleanroom technologies Sterile manufacturing environments are open to many sources of potential contamination, and thus potential hazards during the manufacture of sterile products, if they are not managed correctly. Patient safety could ultimately be put at risk should microorganisms, particles or endotoxins enter the manufacturing environment. One of the main sources of contaminants in the cleanroom environment is the operator as the average human carries a multitude of microbes and bacteria. Other potential sources of contamination include the equipment and raw materials used as well as the environment itself. Multiple technologies have been developed in response to the need to ensure the safe and sterile transfer of APIs and formulation ingredients during aseptic processing. One such development is isolator technology: isolators provide an airtight barrier around the aseptic processing line and can be employed in cleanroom environments to minimise the risk from contaminants. Current isolator design incorporates unidirectional airflow into the enclosureâ&#x20AC;&#x2122;s chambers and can provide a specialised environment tailored to the needs of the product; humidity, oxygen, temperature and pressure levels can all be adapted. Restricted access barrier systems (RABS) are also often used in sterile manufacturing environments. Several elements must be in place in order for a RABS to be fully functional, including properly designed equipment, management oversight, a quality system and proper surrounding room design to maintain ISO 5. [2] Recent years have seen RABS technology become more widely used, as it provides a barrier between workers and processing lines while 80 | SHAPA Newsletter

offering operators the opportunity to interact with products as necessary. High-efficiency particulate air (HEPA) filtered airflow is also incorporated in RABS technology, significantly reducing the â&#x20AC;&#x153;probability of a non-sterile unitâ&#x20AC;? (PNSU). RABS can be opened to allow process intervention and has also been found to yield similar PNSU data to isolator technology, which must remain closed during operation. Challenges associated with current technologies Despite their benefits, both isolators and RABS have disadvantages. Manufacturers using isolator technology may face difficulties when transferring materials in and out of the chamber. A docking isolator may need to be used and the interior may need to be sterilised before materials are transferred, delaying the shut down and start up process between batches. Isolators also have slower start-up times in comparison to RABS, meaning product changeovers are often less efficient. In comparison to isolators, the closed solution provided by RABS technology is less robust, providing lower integrity chambers. Where isolators can be decontaminated through an automated process, which allows for a high level of biocontamination, RABS rely on manual cleaning processes. All product or process contact parts within a RABS must be sterilised or steamed-in-place (SIP) prior to use, which creates a more complicated cleaning process than in a traditional sterile area. As the demand for aseptic processing continues to grow, the disadvantages associated with both technologies pose considerable challenges for the industry. New technologies are now being investigated by pharmaceutical manufacturers as they look for ways to improve efficiencies,

lower costs and reduce the risk of contamination. Many of these technologies work alongside isolators and RABS set-ups, which can allow firms to integrate them into their aseptic processing lines. This can generate significant cost savings for firms that may otherwise have had to overhaul their processes entirely. The advent of new technologies In response to these challenges, the industry is starting to implement single use technologies and systems. The boost in efficiency and ease of use that disposable parts can provide has led to these technologies being adopted by the industry. Split Butterfly Valve (SBV) technology, for example, has been developed further to create a single use solution for contained materials transfer using a single use passive, a disposable version of the passive mating half of the SBV, and ChargeBag single use packaging. SBVs are made up of an active half and passive half and enable the transfer of a product from one container, process vessel, isolator or RABS to another without compromising sterility. As well as being used as part of an isolator or RABS set-up, the technology also provides an alternative to traditional barrier techniques and is often considered a more practical option to achieving guaranteed product sterility. The technology can also offer improved ergonomics and reduce reliance on cleanroom environments. When used, the active half of the SBV is attached to the receiving vessel, while the passive half is attached to the flexible bag or discharging drug container. When the two halves of the disc are brought together a single plate is created, which allows product to flow on the interior surface of each half. This means that when the two halves are detached, the external faces remain clean and can be exposed to the process environment safely. When the valve of the SBV is sealed, an opening is created between the discs, which means decontaminating gas can be flushed through and

decontamination can take place in a closed environment. Validation occurs using chemical indicators, which confirm full coverage of the enclosure has been attained. This is followed by biological indicators, to ensure a 99.9999% reduction (or 6-log reduction) in bacterial spores has been achieved. The disposable passive half of the valve, known as a Single Use Passive (SUP) now exists with SBVs. Once docked with the active unit the SUP can be opened, ensuring new single use products are compatible with existing SBV systems in the field. The need for cleaning and sterilising the passive half of the system is eliminated through the use of these disposable products, which allows for increased productivity. Due to the importance of ensuring sterility during product manufacturing, there is also growing use of new smart technologies. Wireless monitoring solutions such

as the VERIFI SMART monitoring technology can provide firms with vital equipment performance data when installed onto an SBV. Maintenance teams, as well as compliance and health and safety teams, can make informed decisions on the management of their maintenance programmes armed with the necessary information provided by monitoring technology. In addition, multiple manufacturing locations are also now being used by pharmaceutical companies. Much of the development, manufacturing and packaging of products is entirely outsourced, and shipping between countries is often involved as more drug products are moved between facilities. Technologies that ensure the integrity of sensitive products while in transit are now being investigated by manufacturers, as current solutions often pose significant challenges. For example, the use of solutions like fibre or plastic drums with flexible liners

can pose challenges around the filling, sealing, handling and emptying of packages. Final thought Current technologies such as isolators and RABS offer substantial benefits to manufacturers, but advances in the industry have seen manufacturers looking to develop their containment strategies to remain competitive and ensure compliance. The industry has seen an influx of innovative new technologies, such as single use technologies, smart monitoring and multi-location solutions, in response to the specific manufacturing and handling requirements of sterile products. As regulations continue to tighten and the need for flexible manufacturing facilities becomes more prominent, the industry will no doubt continue to innovate and use technology to improve their manufacturing processes, so they are fit for purpose now and in the future.

[1] https://www.marketsandmarkets.com/Market-Reports/aseptic-processing-market-53206289.html [2] https://a3p.org/wp-content/uploads/2015/03/article_regulatory_2015_RABS-definition.pdf

SUPPORT

SE RVICE

SALES

TRAI N I NG

DMN UK Ltd

dmn@dmnuk.com

www.dmnwestinghouse.uk SHAPA Newsletter | 81

Leslie David, Conveyor Belt Expert

CONVEYOR BELTING

Who sets the standards? In this special feature for Process Industry Informer, conveyor belt specialist Leslie David explains who sets the standards and defines the test methods. For those choosing conveyor belts for specific applications he also provides enlightening insider knowledge as to how to not be misled by the claims of belt manufacturers and traders and end up making expensive mistakes.

Who sets the standards? In the world of processing, conveyors continue to be an indispensable method for moving all manner of materials and products from A to B. The conveyor belt industry itself is a huge, highly competitive, cut throat market. Although there is an abundance of manufacturers and traders, such competition does not necessarily benefit the end-user. As in any market, the relentless pursuit of orders can and does lead to compromises in safety, quality of performance and operational lifetime. From the buyer’s perspective, mistakes when purchasing conveyor belts frequently prove to be enormously expensive in more ways than one. Although they might seem to the uninitiated as simply super-sized rubber bands, conveyor belts are surprisingly complex and highly technical pieces of equipment. There is an enormous variety of destructive materials and demanding operating conditions that conveyor belts have to cope with plus, of course, environmental and safety considerations. As a consequence, there are many different belt types of conveyor belt construction and an even wider range of 82 | SHAPA Newsletter

rubber compounds designed to protect those constructions. This includes everything from straight-forward wear & tear, rip and impact damage to exposure to heat, oil, chemicals, ozone & UV, extreme cold and fire. With this multitude of requirements comes a bewildering range of test methods and quality standards. European and International standards Globally there are a number of different quality organisations who set standards for conveyor belting but the most widely accepted standards (for all types of conveyor belt) are those used in Europe. These are EN standards (European Norms), which are maintained by CEN (Committee European de Normalization) and ISO standards (International Organization for Standardization). Both CEN and ISO are independent, nongovernmental organizations and are the world’s largest developers of voluntary international standards. ISO membership consists of the quality standards organizations representing 168 countries. The prefix EN ISO refers to ISO standards that have been adopted in full as a European standard.

In many parts of Europe some specific and longer established DIN standards continue to be more commonly recognised and accepted. This is especially so in the case of abrasion resistant belting. The letters ‘DIN’ stand for ‘Deutsches Institut für Normung’, which means ‘German Institute of Standardization’. They develop norms and standards as a service to German industry and are a highly respected non-profit organization that has been based in Berlin since 1917. A great many DIN standards have been converted into EN or even ISO standards. Standards for conveyor belts vary between different countries. However, members of CEN are obliged to implement EN (European standards) as their national standards without modifications and withdraw any of their own national standards that may conflict with them. It is worth bearing in mind that the standards applied to manufacturers in countries that are not members of CEN are frequently found to be significantly inferior or outdated. Test methods and test standards are not the same When assessing quality credentials it is essential to differentiate between what is simply an approved method

of conducting a particular test (test method standard) and the actual quality or performance standard attained during that test. The fact that a belt has been tested according to a certain method actually means very little. The most important thing to look at is the actual level of performance achieved during the testing compared against the minimum acceptable level of performance dictated by the test standard. In other words, what was the actual performance? Did it even achieve the minimum requirement? For example, in the case of the ENISO 4649 abrasion resistance testing method, the performance would typically be measured against the performance standards set within ISO 14890.

initially used was “EC Mark” but was replaced by “CE Marking” in the Directive 93/68/EEC in 1993. When a manufacturer places a CE marking on a product they are declaring, on their sole responsibility, conformity with all of the legal requirements to achieve CE marking. The manufacturer is thus ensuring validity for that product to be sold throughout the EEA even though the mark does not mean that the product was actually made in the EEA. This, of course, is dangerous. Some conveyor belt manufacturers, especially those in the Far East, deliberately use the CE mark to create an illusion of quality and safety based on the likely assumption that goods with CE marking is proof that the product meets strict EU standards even though no such standards exist.

What to watch for

When choosing which belt to buy it is essential that the technical datasheets provided by manufacturers and traders are used in the decision making process. However, the fact is that manufacturer’s technical datasheets almost invariably only show the minimum standard demanded by a particular test. Unless stated otherwise, the data shown does not reflect the actual performance achieved during the test and therefore in no way indicates the level of performance that the buyer can expect. And if they only show the test method reference number then they are pretty much worthless; a fact that applies to the technical datasheets provided by the vast majority of suppliers.

What to watch for

Rather shockingly in my view, a very similar CE mark can frequently be seen that most consumers understandably but mistakenly believe is a genuine CE mark of European conformity. In this case it actually means “China Export”, meaning that the product was manufactured in China.

Designed to mislead? Genuine CE (Conformité

CE Marking Compliance with CE quality standards is increasingly being stipulated by purchasers of industrial conveyor belts even though CE accreditation does not actually apply to conveyor belts. This is because they are not a product category subject to specific directives that are required to be CE marked. Nevertheless, it is still worth having a basic understanding of the role of CE quality standards and how they can be used to mislead. The letters “CE” used in the CE Marking are the abbreviation of French phrase “Conformité Européene”. This literally means “European Conformity”. The term

Européene) mark and ‘China Export’ mark

Dimensions and tolerances In terms of dimensional standards and acceptable tolerances such as length, width, thickness etc, all textile fabric ply construction conveyor belts are subject to ISO 14890:2013. These specify the dimension requirements for rubber (and plastic) covered conveyor belting for general surface use on flat or troughed idlers. Different tests for different demands As mentioned earlier, there are many different types of belt and an even wider array of different types of rubber covers, which are most commonly referred to as either cover

grades or cover qualities. The outer covers protect the belt carcass from whatever they are carrying. The primary rubber cover grades used in processing industries are: • Abrasion (wear) resistant • Rip & tear resistant • Oil resistant • Fire resistant • Ozone & UV resistant There are often a combination of factors, such as resistance to fire and oil. However, one that is common to all is the ability to resist abrasive wear. Abrasion - standards The ability of a conveyor belt to resist abrasive surface wear is usually the single most important factor that will determine its operational lifetime and consequently its cost-effectiveness. There are two internationally recognised sets of standards for abrasion, EN ISO 14890 (H, D and L) and DIN 22102 (Y, W and X). As mentioned earlier, in Europe it is the longer-established DIN standards that are most commonly used. Generally speaking, DIN Y (ISO 14890 L) relates to ‘normal’ service conditions and DIN W (ISO 14890 D) for particularly high levels of abrasive wear. However, DIN X (ISO 14890 H) is regarded as the most versatile because in addition to resisting abrasive wear it also has good resistance to cutting, impact (from high drop heights) and gouging, usually caused by heavy and/or sharp materials such as ceramics. Abrasion – testing The test method for abrasion (ISO 4649 / DIN 53516) is actually quite simple. Resistance to abrasive wear is measured by moving a test piece of rubber across the surface of an abrasive sheet mounted on a revolving drum. It is expressed as volume loss in cubic millimeters. For example, in the case of DIN Y (ISO 14890 L) it is 150 mm³.

ISO 4649 / DIN 53516 abrasion testing SHAPA Newsletter | 83

The key thing to remember when looking at abrasion test results is that higher figures represent a greater loss of surface rubber. This means that there is a lower resistance to abrasion. Conversely, the lower the figure then the better the wear resistance will be. Rip and tear resistance – testing Rip & tear resistance is not a cover grade in its own right. However, the ability to withstand the forces that rip and tear belts can often be more important than any other physical attribute. Even the strongest, heaviest belts can be punctured and ripped by a foreign object becoming trapped. A ‘tear’ is best described as what happens when a section of belt is pulled apart in opposing directions. In contrast, a ‘rip’ is what happens when a sharp object punctures the belt and cuts the belt longitudinally as it is pulled against the trapped object. There are currently no internationally accepted test methods or standards for testing rip resistance. Manufacturers in the USA such as Fenner use a round pin that is pulled through the belt whereas Dunlop in the Netherlands pull sections of belt through a rightangled piece of metal, which they have fondly nicknamed ‘Jack the Ripper’.

Dunlop’s ‘Jack the Ripper’ rip test in action

Fortunately, there is an international standard for tear strength. The ISO 505:2017 test method measures the propagation resistance of an initial tear in textile conveyor belts, either in full thickness or of the carcass only. This test is intended for application to textile belts in installations where there is a risk of longitudinal tearing.

ISO 505 tear testing 84 | SHAPA Newsletter

Although the method of testing is defined there are, as yet, no standardised performance requirements. The test basically consists of mounting two cut ends of a test piece of belting in the jaws of a tensile testing machine. An initial tear is made in a test piece, which is then pulled apart in opposing directions. The force necessary to propagate the tear is then measured. Examination and analysis of the multi-peak tear resistance test traces are made in accordance with ISO 6133.

What to watch for

Perhaps not surprisingly, most manufacturers, primarily those manufacturing what are euphemistically referred to as ‘economy belts’ make little or no mention of rip and tear resistance. Unless specifically designed to resist ripping and tearing, even the thickest, heaviest belts will rip like paper because the type of fabric ply used in the carcass simply is not designed to cope with such forces. Oil resistance Many bulk materials, especially grain and biomass, contain oils and resins. When oil of any kind penetrates rubber it causes it to swell and distort. This results in serious tracking and steering problems, premature wear and ultimately premature replacement. Oils are divided into two distinct sources – mineral and vegetable/animal. The two best recognised test methods for oil resistance (both of which involve almost identical test procedures) are ISO 1817 and the comparable, slightly less elaborate but equally tough American ASTM ‘D’ 1460. Even some of the biggest manufacturers of belting in the world use the DIN reference number 22102 G when referring to oil resistant belting. This is very misleading because the letter ‘G’ simply denotes oil (or grease). However, the truth of the matter is that DIN 22101 G does not actually contain any requirements, test methods or limits that are specific to oil resistant belting. This is yet another classic example of how simply displaying a test method reference number is designed to

provide reassurance to the buyer but in reality is meaningless in terms of actual performance. Oil resistance test methods The ISO 1817 and ASTM ‘D’ 1460 test methods are both used to measure the effect of oil (and other liquids and chemicals) on vulcanised rubber. Samples of rubber (eg. 100mm X 1.6mm X 2mm strips for the ASTM test) are fully immersed in the relevant test liquid for a specific period of time. The duration of immersion and the temperature at which the liquid and sample are kept can be varied but the most common is either 3 or 7 days at ambient or 70°C.

ASTM ‘D’ 1460 testing

The ambient temperature of the environment is controlled within specific guidelines. Changes in the geometry and dimensions of the specimen caused by absorption are then measured when the samples are removed.

What to watch for

Although there are no actual performance standards in existence, it is still important to look for actual references to the test methods used by the manufacturer/supplier. I find it quite disturbing to note that only one manufacturer (Dunlop again I have to say) makes any mention whatsoever concerning the actual test methods used to determine the oil resistance qualities of their belts. Fire resistant belting Although fire safety is an enormously important issue, it is quite amazing that such little care and attention is paid during the selection and buying process. Sadly, it often seems that having paper accreditation and certification to avoid culpability is sufficient reason to buy. There are numerous safety classifications,

international standards and many different tests used to measure the self-extinguishing properties of conveyor belts. Test methods and performance standards vary enormously depending on whether a belt is for use above or below ground. For the processing industry I have focused purely on the requirements for belts being used above ground.

ISO 340 testing

Basic testing The basic test for belting used in normal ‘above ground’ industrial applications is EN/ISO 340. This standard makes the distinction between fire resistance with covers and fire resistance with and without covers. The relevance of “with and without covers” is that over time, wear reduces the amount of fire resistant rubber protecting the inner carcass, which most commonly consists of flammable polyester/ nylon fabric plies. Although no longer used in the current EN ISO 340, the market still commonly refers to grades ‘K’ for testing with covers attached and ‘S’ for testing both with and without covers. This originates from DIN 22103 which was used as the basis during the creation of EN ISO 340. EN/ISO 340 tests involve exposing 6 individual samples of belt to a naked flame causing them to burn. The source of the flame is then removed. A current of air is then applied to the test piece for a specified time after the removal of the source of fire. The time it takes for the belt sample to self-extinguish after the flame has been removed is then measured. The duration of continued burning (visible flame) should be less than

15 seconds for each sample with a maximum cumulative duration of 45 seconds for each group of six test samples. This determines how fire can be carried along a moving belt.

What to watch for

The buyer should still exercise caution even if a manufacturer states that their belt has passed the ISO 340 test. A burning conveyor belt can spread fire a considerable distance in 15 seconds. The real measure of a good quality, safe fire resistant belt is the time it typically takes to selfextinguish. This could and should be as quick as one second. If you are at all unsure of what level of fire resistance you need then it is best to seek expert advice. Ozone & Ultra violet resistance Although not commonly known (or even mentioned by most manufacturers) an absolutely essential quality that all rubber belting should have is the ability to resist the damaging effects of ozone and UV. Although not an actual cover grade in its own right, there is no question that all rubber belts need to be fully resistant to ozone and UV light. This is because at ground level, ozone becomes a pollutant that attacks rubber by increasing the acidity of its carbon black surfaces and causes reactions to take place within the molecular structure of the rubber. This has several consequences including significant surface cracking and a marked decrease in the tensile strength. Likewise, UV light from sunlight and fluorescent lighting also accelerates deterioration. This is because ultraviolet produces photochemical reactions that promote the oxidation of the surface of the rubber, resulting in a marked loss of mechanical strength. Ozone and UV combined really are invisible belt killers. EN/ISO 1431 international standards To scientifically measure resistance to ozone, samples are placed under tension (eg. 20% elongation) inside the ozone testing cabinet and exposed to highly concentrated levels of ozone for a period of time (eg.up to 96 hours).

Ground level ozone and UV exposure causes rubber to disintegrate

Samples are closely examined for evidence of cracking at two-hourly intervals and the results carefully measured and recorded. Experience has shown that for the rubber to be adequately resistant the pass criteria needs to be that there are no signs of cracking after 96 hours (@ 40°C, 50 pphm and 20% strain) inside the ozone cabinet.

What to watch for

As I mentioned earlier, despite its crucial importance, ozone and UV resistance is very rarely, if ever, mentioned. This is almost certainly because costly anti-ozonants need to be used during the mixing process of the rubber compounds. A recent series of samples of rubber belt originating from Asia revealed that every single sample had virtually nil resistance to ozone and ultraviolet. My advice is to make ozone & UV resistance a constant requirement when selecting any rubber conveyor belt. Conclusions Quality standards and testing in the conveyor belt industry is a huge and often complex subject. What I have endeavoured to do is simply provide a basic guide. Never assume that seeing the presence of test method reference numbers or the logos of quality organisations necessarily means what they are designed to indicate. It is always worth taking the time and trouble to ask questions and request evidence of best practice and, above all else, actual performance. Raw materials alone make up some 70% of the cost of manufacturing so in the case of conveyor belts, highly attractive pricing should start the alarm bells ringing. Taking that little bit of extra care could easily save your company an enormous amount of time and money. SHAPA Newsletter | 85

Considerations when sourcing

When clients first consider Pneumatic Conveying as a method for handling bulk material and hear the principle of air blown into an enclosed pipe, they often expect the process to cause particle turbulence and potential damage. This initial view is far from the truth, if the right type of Pneumatic Conveying technology is specified for your process, as well as the material it will convey.

The purpose of this article is to outline the basic, but yet very important considerations, for when approaching a supplier to provide Pneumatic Conveying technology. Types of Pneumatic Conveying Pneumatic Conveying has predominately two category types – Lean Phase and Dense Phase Conveying. Core Differences

The type of conveying method chosen will determine how the materials travel through the process plant. Although the pipes are totally enclosed, through extensive process and formalised material characteristic testing, an understanding on how different materials react between the two types, can be demonstrated by an experienced supplier. There isn’t a ‘one process’ suits all.

Lean Phase Lean Phase Conveying uses a large volume of air and higher velocity, to move in comparison, a small amount of material. As a result, the material is effectively carried through the pipe, while being suspended in air. Typically, this method is preferable for short distances and non-abrasive materials, either powdered or granular in nature.

With either Pneumatic Conveying categories, material is commonly transferred from a single collection point to either a single or multiple reception points and when installed as a full system, will include various components, such a range of pumps, valves and pressure vessels, depending on the material and distances conveyed.

The design of Lean Phase Conveyors offer the benefit of being compact, therefore utilising less space than Dense Phase Conveyors, as well as providing quicker installation. For the operator, the equipment is simple to use and carry out maintenance on – an important factor if the material handled causes regular ‘wear’.

86 | SHAPA Newsletter

Fragile materials that are conveyed through a Lean Phase Conveying system can often become degraded or damaged, leading to an increase in dust within the conveyor and also further down the process. Depending on the process, this dust may change the properties of the material being conveyed, or become a potential explosion risk, often in both cases due to segregation. Such dust generation concerns can be mitigated or avoided by using a Dense Phase Conveyor. Over a period of time, the higher conveying air velocity of Lean Phase Conveying may also cause ‘wear’ on the pipes if the material is not suited to this method of processing. When the wear is excessive, premature failure of the plant could occur, resulting often in lost production,

environmental dust release and expensive maintenance. With the correct application evaluation, it is possible to remove or mitigate all of these risks. It is therefore very important to seek consultation from a specialist who can confirm that the material handled is appropriate for this method of Pneumatic Conveying. Other aspects to factor-in are the design of the pipeline and choice of bends and valves. Where possible, keep the pipeline simple and accessible. Quick access for cleaning and maintenance needs to form part of the overall layout. Quality pipeline divertors, correctly selected for the application, such as the ProDV bypass valve or parallel tunnel diverter PT45 valve, will provide peace of mind on the exact, reliable control of the shut-off/ supply of material. Dense Phase In comparison to the process of Lean Phase Convening, Dense Phase Conveying uses higher levels of pressure, but lower volumes of air, across a much longer pipeline. Consequently, the material is pushed through the pipe and bends, in a slug/pluglike behaviour. This results in the material being conveyed at much lower velocities than Lean Phase Conveying - often of the order 3 to 5 times lower.

Dense Phase Conveying is suitable for a variety of materials, ranging from fine cohesive powders, abrasives such as pulverised coal through to coarse granular products. One of the most important considerations for Dense Phase Conveying is ensuring the conveying velocity at the start is set correctly for the material being conveyed. If the pressure and air volume is not set appropriately, it could lead to a poorly performing conveying system. Industrial scale conveying trials in pipelines with a bore of at least 80mm and a distance at least half of the intended distance for the users application, should be carried out to ensure a welldesigned, long lasting system. Typically, Dense Phase Conveyors experience minimal wear on the pipe and bends, allowing for less maintenance and long system life performance. Often the wear in Pneumatic Conveying Systems is quoted as being proportional to the velocity3. For the case where the material is Dense Phase Conveyed on average at a velocity 5 times lower than the Lean Phase System, then the wear will be 53 = 125 times lower. This is often over looked, but of course means that bends that last only 1 month in a Lean Phase System, could last 10 years in a Dense Phase

SHAPA Newsletter | 87

one. Experienced providers will be able to assist the user with the correct choices according to the operating requirements. Schenck Process UK is home to our Clyde Process Dense Phase Pneumatic Conveying systems, part of the ProPhase® range and are regarded as one of the world’s leading product brands for this technology. What differentiates the Schenck Process range of Dense Phase Pneumatic Conveyors is the continued research and development of our products and solutions, a live and extremely busy industrial scale testing centre, as well as our 40-year experience in specialist design, testing and engineering. All of this allows for: Simplicity, Reliability and Flexibility. In nearly all cases, each system is engineered to be bespoke to the process requirements, using standard, proven components, products and design approaches.

Before Schenck Process embark on any project, we will work with clients to truly understand their process needs, what issue they are encountering, what materials are handled, test the material characteristics and ensure we engineer a system that provides optimum performance and longlife operation.

Schenck Process is a global and trusted supplier of bulk handling industrial equipment, who support a variety of sectors including Food, Chemicals, Plastics and Pharmaceuticals. Mining, Steel & Metals, Sand & Gravel, Cement & Gypsum, Grain & Agriculture, Transport & Automation and Utilities.

• Full consultancy and engineered design • Material and process inspection, as well as testing • Introduce quality processes that removes a customer’s ‘anguish’ • UK, trusted Clyde Process product brand, supplied globally by Schenck Process • Focused on offering efficiency, reducing maintenance and overall operational costs • Project management available from start to finish – world wide • Service packages and user training

Providing New Equipment, as well as Maintenance and Testing Services, with Systems for Conveying, Weighing, Feeding, Screening, Powered Processing, Automation, Air Filtration, Bag Filling & Discharging, as well as Components and Spares. For more information on Schenck Process systems, please contact: enquiries@ schenckprocess.co.uk | www. schenckprocess.com/uk

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Dr Rob Berry, Senior Consultant Engineer, The Wolfson Centre for Bulk Solids Handling Technology

A review of the

pros and cons

of different types of conveyor and their suitability for transporting materials with different bulk flow properties.

Overview of different conveyor types There are seven principally different forms of bulk conveyor as described below; • Belt conveyor, a continuous belt nominally rubber on which the bulk solid is deposited transported and discharged at the end of the belt assisted by a scraper. • Screw conveyor, a screw in an open trough, whereby rotation of screw causes bulk solid to slip down the front face and avalanche forward ahead of the screw, to a discharge port at the end of the trough. • Chain (or En-masse) conveyor where a continuous flighted metalic chain in a casing is used to drag a bed of bulk solid down an enclosed channel to a discharge point. • Vibratory conveyor, a metallic tray, that is vibrated at a high frequency low amplitude in a diagonal forward motion, to cause particles to vibrate along the tray to a discharge point. • Pneumatic conveyor, a closed pipe down which bulk solid is conveyed in air, using either a positive pressure or a vacuum to discharge into a receiving hopper with a filtration system to separate the air and solids. System can be lean phase high air low solids, low pressure or dense phase high solids low air at high pressure. • Air slide, an air permeable membrane (with a pressurised plenum chamber below) in the base of a channel, which is filled with bulk solid that is fluidised by the air flow causing gravity flow down a shallow decline (1 to 15°). • Gravity chute, a declined chute at an angle slightly steeper than the wall friction angle of the material that relies on gravity to cause flow to a discharge point. 90 | SHAPA Newsletter

Fundamental bulk flow properties affecting the different conveyor types There are several bulk flow properties that effect the flow behaviour in the different types of conveyor, and these are explained below. The key flow properties are the: • wall friction angle, i.e. the angle that a surface covered in bulk solid can be inclined too (see fig 1a), before the material slips down the wall. This can be measured in a wall friction test and is presented as a wall friction locus (see fig 1b). The blue wall locus is typical of a free-flowing low wall friction bulk solid with a friction angle of 12° that is independent of stress level, or depth of fill on surface. The red locus represents a fine “sticky” bulk solid, where friction angle varies with stress, with a friction angle of 90° for a fine layer reducing to 35° as bed depth increases to create a hydrostatic stress of 8kPa. • wall adhesion or “stickiness” i.e. the potential for a material to stick and build up on a surface, which is measured as the intercept of the wall friction locus with the shear stress axis (see fig 1b). Here a wall adhesion of 0.5kPa would require a layer thickness of 0.05m for a bulk solid of 1000kg/m3 bulk density to discharge from a vertical wall under itself weight. • fluidisation properties are significant for air assisted conveying, an aeration column is used to measure bed expansion and observe fluidisation behaviour. The Geldart Chart (see fig 2) gives a brief summary of the effect of particle size and difference in solid and fluid density on the fluidisation behaviour. Note while this may be useful for air slides, for

pneumatic conveyors, full scale trials are essential for reliable system design. • flow function, the result of a shear cell test, to measure the flowability (cohesive strength) when a bulk solid is sheared internally see fig 3, shows the standard flowability indices and compares these to approximate limits for handleability of various conveyor types. Generally pneumatic conveying is best suited to freeflowing materials, screw and chains for free and easy flowing materials and belts for cohesive bulk solids. • angle of repose (dynamic) effecting the inventory that will be stored in the width of the belt (see fig 4a), the volume advanced by a screw (see fig 5). A freer flowing material forms a shallower angle than cohesive material. A fluidised material will form a horizontal surface.

Fig 1 Wall friction a) slip down a wall and b) Wall friction loci

Fig 2 The Geldart chart describing fluidisation behaviour as a function of particle size and the density difference between solid and fluid

Fig 3) The flow function and suitability of different conveyor types Pros and cons of the different conveyor types: Gravity chutes require height but are otherwise low cost and can provide good containment. Key issues are; limited ability to control feed rate, potential for material to build-up on the chute surface if bulk solid is very cohesive or “sticky” leading to blocking and flooding/ flushing for free flowing aeratable materials.

Belts provide; low operating cost transport over short to long distances (10 to 10,000m), gentle handling suitable for a wide range of flow properties and are relatively easy to clean. The downsides are; routing restrictions and poor containment, straight line and slight inclines between transfer points, the high capital costs of all components, need for careful setup for reliable operation and the presence of a return path that must be cleaned. Note that special belting solutions such as pouch belts see fig 4b can route round corners and give good containment, but with a significantly reduced transport capacity per unit length of belt. For elevation, the contact friction against the belt rubber (in presence of vibration) limits conveying angle, but textured belt surfaces can increase this. Steep elevation angles can be achieved with sandwich belts, walled belts or bucket elevators. Metallic apron conveyors can be used for high temperature environments. In terms of material flowability belts can handle the widest range of materials issues are sticking and cleaning problems for very cohesive materials and dust emissions at transfer points plus windage (for open belts), for free-flowing materials. Screws provide; good containment, a minimum of moving parts, no return path and ability to convey against a positive pressure or high temperature environment. The downsides are; limited conveying distance (30m per screw), straight routing restrictions and are not fully selfclearing (material retained in trough screw clearance). Screw conveyors can be used to elevate materials at up to typically 30° (usually with a reduced pitch to increase the helix angle). When elevating, screw conveying efficiency is reduced as incline increases (see fig 5b) because the helix angle reduces, so friction against flight face lifts more material over shaft to drain back to the previous pitch, whilst the dynamic angle of repose becomes closer to horizontal reducing forward motion. Note that highspeed screws (rotating above the critical “wall of death” speed) can be used to elevate materials vertically. The material issues are the potential for; particle degradation and poor conveying of high friction “sticky” materials, that adhere to the screw flight turning with the screw. Chains (see fig 6a) provide; conveying over relatively long distances (100m +), good containment, low particle degradation as flights contact a relatively small area of the transported bulk solid and can feed elevated temperatures. Downsides are; metal on metal contact of chain links in product that could cause contamination, a return path that is difficult to clean, routing restriction (horizontal with transition to an incline or vertical rise) and high capital cost of all components. Regarding flow properties, friction between moving bulk solid and channel walls effects conveying efficiency and drive power. Vertical/elevated conveying achieved by increasing flight area in contact with bulk solid in the channel (see fig 6b). Vibratory trays (see fig 7a) provide; conveying over relatively short distances (20m per conveyor), low degradation, can operate at high temperatures and SHAPA Newsletter | 91

elevation can be achieved with a spiral tray. Regarding the bulk properties, are suitable for free flowing non segregating materials (i.e. larger particles convey more efficiently than fines). Cohesive materials tend to stick to conveyor over time, with potential to then discharge as agglomerated lumps. Pneumatic conveyors provide; effective conveying in a lean phase for a wide range of material flow properties (except very â&#x20AC;&#x153;stickyâ&#x20AC;? solids) over distances of up to 100 - 300m, good containment of the product and can feed into high pressure or temperature environments. Inert gas can be used for conveying explosible materials. The downsides are high capital and running costs. Dense phase gives lower running costs, but only a limited range of bulk solids will convey in this mode (generally, freer flowing materials with narrow particle size distributions). Care must be taken over pipe routing to avoid an excessive number of bends, and to ensure pipes are either horizontal or vertical (no inclines), with enough

horizontal straight prior to bends or vertical rises to first accelerate particles to fully suspended flow. Other issues are the potential for either particle degradation (and fine particle generation) or pipe wear at bends depending on whether the particles are harder than the pipe wall. For very sticky or plastic particles, bend impacts can lead to particle adhesion to the pipe wall, gradually reducing pipe bore increasing the conveying velocity and build up rate until eventually the conveyor becomes blocked. Air-slides (see fig 7b) provide; gentle handling, good containment, and are suitable for conveying over distances of 10m plus, per slide. However, technique is only suitable for materials that fluidise easily, Geldart groups; A and B (see fig 2). The former group requires less air but maybe difficult to control or subsequently pack as slow deaeration may cause contents to settle in pack over time, leading to underfilling and pack stability issues if stacked.

Fig 4 Belt conveyor a) angle of repose and idler configuration control volume transported per m of belt and b) Pouch conveyor

a) 92 | SHAPA Newsletter

Fig 5 Mechanics of screw conveyor for; a) horizontal (fill level at approx. 45%) & b) inclined transport (fill level reduces with increasing inclination angle e.g. 30% at 30Â°)

Fig 6 chain conveyor a) b) different flight configurations for inclined conveying of different materials

Fig 7 a) Vibratory conveyor and b) air slide Summary There are a wide range of bulk solid conveyors available, for free-flowing materials it is often equipment wear, particle degradation or dust issues that provide potential challenges. However, for poor flowing bulk solids, where cohesion maybe generated either through the presence of; surface moisture (that binds particles together), or fine particles (below typically 100Âľm diameter where interparticle forces start to dominate over gravity forces), a knowledge of the bulk flow properties is usually essential for the design of efficient trouble-free conveyors. SHAPA Newsletter | 93

Following the success of our 2019 event, we are delighted to announce our 2020 categories. These awards are open to all UK registered member and non member companies and institutions operating in the Solids Handling Industry. Application forms are available direct from the website and winners will be announced and presented at the awards ceremony in the evening of the 22nd April 2019. Closing date for applications 29th February 2020.

Shapa Awards Now Open

Solids Handling Industry Awards 2020 AWARDS PRESENTATION 22nd April 2020 BROOKLANDS - WEYBRIDGE,SURREY

Export Award Innovation Award Newcomer of the year Award Company of the Year Award Solids Handling and Processing Association

For more information visit www.shapa.co.uk or email info@shapa.co.uk