Process Industry Informer September 2015 by Process Industry Informer

www.processindustryinformer.com

SEPTEMBER 2015 Volume 11 No. 5

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

In print | Online | Mobile - The UK’s No.1 Media for the Manufacturing Process Industries

CONTENTS.

4-8 News & Events 11-16 Applications 35-37 Fluids & Liquids Handling (incl. Pumps & Valves)

38, 43, 46 Process Measurement & Instrumentation 46 Test Measurement 47 Compressed Air 47 Gas Detection Systems

21 BPMA News

TAKING A LIFE CYCLE APPROACH

CARBON BRUSHES

FOOD GRADE THERMAL FLUID ESSENTIALS

47 Health & Safety 47 Enclosures 50 Inspection & Vision Systems 50 Calibration 51 Products & Suppliers Directory

A PRACTICAL GUIDE TO IMPROVING TEMPERATURE MEASUREMENT

HOW EFFICIENT ARE YOUR MOTORS REALLY?

MAKING THE MOST OF YOUR IT INFRASTRUCTURE

EDITOR Phil Black: philblack@piimag.com PUBLISHER/ADVERTISING MANAGER Peter Ullmann: peterullmann@piimag.com SALES & MARKETING MANAGER Guy Ullmann: guyullmann@piimag.com SUPPLEMENTS MANAGER David Harling: davidharling@piimag.com OFFICE MANAGER Diane Ullmann: dianeullmann@piimag.com ART DIRECTION Talita Soncini talita@piimag.com

STAYING CYBER SAFE IN INDUSTRY

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All product announcements published in Process Industry Informer are paid for. All copy submitted for publication in Process Industry Informer must be legal and must comply with the British Code of Advertising Practice and is accepted for publication, or not, at the publishers’ absolute discretion. When deemed necessary all copy may be edited and classified at the publishers’ discretion. All material contained in Process Industry Informer is published in good faith, but it is emphasised that the publishers do not in any circumstances accept responsibility for the accuracy or otherwise of any advertisement or message published (nor is any kind of warranty 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

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EDITOR’S COMMENT

A NEED FOR A NUCLEAR EXPLOSION – PEOPLE THAT IS!

he governments current target for building a further 5 nuclear plants has moved from 2025 to 2030 – okay it’s a considerable and costly programme and no doubt along the way there will be hiccups, but one thing that it ensures is a considerable number of jobs for the building industry which is of course great. However, in the meantime there is an enormous mountain to climb; that of finding the expert staff to manager them. Sadly today there is a decline in the graduate uptake across the whole of the process industries and the traditional manufacturing industries; chemicals, pharmaceuticals, food & beverages etc are suffering as more attractive options open for them, areas such as the automotive and aerospace industries for example and this is compounded as older & experienced engineers become fewer. With the industry continually developing and introducing new technologies and with a lower graduate base to follow on, will robots become even more dominant? There will be great opportunities in the ‘new nuclear age’ but where will the ‘new’ batch of qualified engineers come from to man these new establishments? Let the campaign to find them start now!

PhilBlack - Editor

NEWS & EVENTS HYDRAULIC ENGINEERING COMPANY GROUP HES CELEBRATES 50 YEARS OF OPERATION 2015 marks an impressive fifty years in hydraulic engineering for Group HES. The Group has grown to become one of the leading fluid power companies in the UK with offices nationwide with products and systems in use worldwide. From its humble beginnings in 1965 in a disused rail wagon in Cheltenham repairing tractor hydraulics, the company is now a multimillion pound success story employing over 70 people and comprising of 5 divisions: Hydraulic Equipment Supermarkets, Branch Hydraulic Systems, HES Tractec, HES Lubemec and HES Automatec, the new Automated Controls division. With a reputation for innovation, the company needed a website that fits their high-tech profile so a new easy-to-use and customer-friendly site has been launched. Please visit the site www.grouphes.com & if you have any feedback please email whatsnew@grouphes.com or call 01452 730774.

ABB’S SAFETY EXECUTION CENTER IN CZECH REPUBLIC CERTIFIED BY TÜV ABB’s Safety Execution Center in Ostrava, Czech Republic has been certified by TÜV as having in place and applying a functional safety management system (FSMS) for the delivery and implementation of safety system projects in accordance to international industry standards. These standards include IEC 61508 and IEC 61511 for integration and implementation of safety instrumented systems. In Czech Republic, ABB’s Oil and Gas business has implemented numerous safety systems for safety related applications covering all types of protective and mitigation safety instrumented systems (SIS) such as emergency shutdown (ESD), process shutdown (PSD), fire & gas (F&G) and burner managements systems (BMS), etc. TÜV certification recognizes that ABB’s FSMS complies with international standards and best practices for its products, engineering and project teams and installation methods. It meets all relevant sections of the international standards including system configuration, application programming, test and front end safety consulting for specific industrial safety applications.

For more information please contact: ABB Ltd, Eaton Socon, St Neots. Tel: 01480 475 321 E-mail: oilandgas@gb.abb.com Web: www.abb.com/oilandgas

PROCESS INDUSTRY INFORMER September 2015

NEWS & EVENTS PULSAR PUSH FURTHER INTO EXPORTS WITH A KEY PROMOTION Non-contacting ultrasonic level measurement specialists Pulsar Process Measurement have promoted experienced Internal Sales Engineer Ashley Vickers to the role of Sales Support Manager to oversee the export business within Pulsar that now represents more than half of the company’s sales. One key focus for Ashley is to spearhead the company’s growth in the important South American market, working with existing distributors and appointing new outlets throughout the region. Ashley is a fluent Spanish speaker and has worked for Pulsar for more than seven years, though his involvement in the ultrasonic industry goes back more than two decades. To ‘replace’ Ashley in the internal team, Pulsar has appointed Robert Aylen to the position of Internal Sales Engineer. This is an exciting time for Pulsar as they approach their twentieth anniversary. Pulsar now has a product range that runs from self-contained dBi Intelligent Transducers and Blackbox ultrasonic components, right the way through to the Ultimate Controller which offers a complete pumping station controller with RTU and asset management system in one high-specification package. Pulsar’s distributors throughout the world have a great range to choose from, and can find products that are ideal for the needs of their local market. Evidence of this was the recent deal that Pulsar’s distributor down under, Bintech, struck with Australia’s largest water company for Pulsar Ultra 3 pump control systems right across Western Australia. Reliability and performance were key, but so was the system of distributor expertise and Pulsar’s support that have seen Pulsar equipment used in thousands of applications all over the world. For more information contact Pulsar Process Measurement Ltd, Tel: +44 (0) 1684 891371 Fax: +44 (0)1684 575985 E-mail: info@pulsar-pm.com Web: www.pulsar-pm.com

NEW ESAB MAGAZINE LAUNCHES NEW PRODUCTS & SYSTEMS SOLUTIONS ESAB Welding & Cutting Products announces the release of the Summer 2015 issue of Launch, a new magazine that presents ESAB’s new products and systems solutions for industry. Launch showcases ESAB branded systems and product combinations that work together to optimise performance and profitability – a Total System Performance approach. ESAB bundled solutions improve productivity, performance and profitability while lowering total cost of ownership. “Launch magazine does more than highlight new products across our entire family of brands, it demonstrates how these products can be integrated into a complete solution that not only meets the customer’s specific needs but offers unmatched cost and performance benefits,” says Ken Konopa, ESAB’s Vice President of Marketing & Product Development. The Summer 2015 issue of Launch features 20 pages of ESAB’s latest solutions. Included in the magazine’s premiere issue are solutions for industrial welding productivity featuring a multi-process welding system with new wire feeder options, a complete welding package with advanced process capabilities for high volume applications. Also detailed is a new series of manual plasma cutters designed to deliver portability, more power per pound and more punch for cutting thicker materials, as well as cutting automation solutions for smaller shops and first-time automation users. Launch magazine is available for download at http://www.esab.co.uk. For a printed copy of the magazine contact 0800 389 3152 or info@esab.co.uk.

COCA-COLA AWARD FOR BRAMMER Commitment to driving efficiencies and uncovering energy-saving opportunities has secured a coveted Coca-Cola Enterprises (CCE) Supplier Award for Brammer, the UK’s leading supplier of industrial maintenance, repair and overhaul (MRO) products and services. Key to Brammer’s recognition in this important category has been its close collaboration with CCE’s teams in identifying opportunities for energy and water savings, and its ability to implement solutions which have successfully reduced resource consumption and carbon emissions. CCE also pointed to Brammer’s commitment to reducing its own emissions as a major factor in the award win, with its Europe-wide 35% carbon footprint reduction in 2014 highlighted as a key achievement for the business in CCE’s announcement. Brammer has partnered with CCE as preferred MRO supplier since September 2009, currently trading with all 17 of the soft drinks giant’s European plants. Over the past six years Brammer has partnered with CCE on its carbon reduction targets, delivering impressive cost savings. To date, more than £3m in validated operational cost savings projects has been achieved across more than 1,000 value-adding projects. Brammer’s dedication to helping its customers to reduce emissions and energy consumption, as well as the company’s own efforts at its NDCs, branches and other premises, has been recognised. In notifying Brammer of its success, CCE explained: “We have also been impressed by your response to CCE’s carbon expectations and how you are challenging your own carbon footprint of 35% reduction 2014, whilst growing your business, your lowest ever reported ratio.” For more information please visit www.brammeruk.com

VEOLIA WATER TECHNOLOGIES’ VISION OF THE FUTURE Veolia launches Vision - a smarter water management customer portal Veolia Water Technologies has built an unsurpassed reputation as the No 1 service provider for water treatment systems in the UK. With the largest number of highly trained, field based technicians of any water treatment company, Veolia has the most comprehensive national coverage and fastest response time in the industry. To meet a rapidly growing demand from industry for new ways to manage their water treatment systems. Veolia has launched its new customer portal – Vision. Vision is a totally secure, easy to use portal that allows customers to manage the servicing of their water treatment systems more efficiently, including multi-site locations. Its also an instant single point of access for all documentation related to the customer’s water treatment system, including datasheets, manuals, order details and service reports. It even allows its customers to book a service engineer and renew a service contract, all at the touch of a button. Those customers whose water treatment system is critical to their business operation can upgrade to Vision Air. This enhanced platform puts the control in their hands, giving them the capability to monitor their water treatment system remotely. Veolia developed Vision Air in partnership with Sierra Wireless, the global leader in M2M connectivity with a proven track record in providing safe and secure data connection for the financial services, automotive, energy, healthcare, scientific and many other industries where secure communication is a core requirement. For more information contact Veolia Water Technologies, Tel: + 44 (0) 1628 897000 Web: www. veoliawatertechnologies.co.uk

PROCESS INDUSTRY INFORMER September 2015

NEWS & EVENTS SPIROFLOW AT THE DOUBLE WITH COMPANY OF THE YEAR AWARDS Spiroflow Ltd is celebrating a double achievement after winning two Company of the Year Awards in a matter of months, adding the Food Processing magazine accolade in June 2015 to the prestigious SHAPA Company of the Year Award it was presented with earlier in the year. The Lancashire business beat off incredibly strong competition for the SHAPA title - given to the UK organisation that has achieved the most in any category, relative to their size, by promoting best practice, setting aspirational industry standards and increasing sales. No sooner had the dust settled on celebrations for this award when it was announced that readers of influential publication Food Processing magazine had voted for Spiroflow as their Company of the Year 2014, edging out the other finalists in a hotly-contested category. Success for Spiroflow is nothing new. Sales have rocketed in recent years, with the company reporting a 35% increase between 2011 and 2014 and are on target for a further 20% increase in 2015. The company trades on a solid reputation in customised powder handling equipment. The gross profit has allowed for investment in infrastructure, namely IT, Health and Safety and training as well as taking on more staff. Marketing Director Cathy Podevyn, says she’s thrilled with the awards: “It’s made me realise just how much we have achieved over the last three years. Good profits, steady sales From left to right: James Podevyn, Cathy growth (particularly exports), Podevyn and Ben Ayrton receiving their a solid and growing bank of award. key customers, and a new technology centre for testing and machine demonstration.” She added: “Above all I am grateful to the strong team of long-serving colleagues who have made our success possible through good times and not so good, and for the young team that will propel us forward in the future.” Spiroflow has experienced a busy year, with the opening of its new state-ofthe-art technology centre, close to its head office in Clitheroe. Here Spiroflow is able to offer services which really make the company a cut above the rest. Clients can benefit enormously from Spiroflow’s unique powder characterisation and testing laboratory. It actively encourages customers to use the fully equipped test centre before purchasing any of its Flexible Screw Conveyors, Aero Mechanical Conveyors, Tubular Cable and Chain Drag Conveyors, Vacuum Conveyors, Bulk Bag Dischargers, Bulk Bag Fillers or Ingredients Handling and Weighing Systems. Whether equipment is required for efficiently conveying food ingredients such as flour, cereals and coffee granules or accurately controlling the flow of materials for the chemical and water treatment sectors, Spiroflow can reassure customers that the wide range of dust-tight systems that they can supply provide optimum performance and offer value for money. As well as providing a comprehensive range of equipment and testing facilities, an outstanding level of customer service is part and parcel of the Spiroflow experience and is one of the reasons why companies in the food, chemicals and process industries return again and again to Spiroflow for their filling, discharging and conveying needs. Recruiting graduates from universities in the area, Spiroflow provides opportunities for aspiring design engineers in the region as well as training a new generation of sales engineers, marketing and IT staff. Cathy Podevyn says the intake is hugely beneficial for the company: “It’s one of the most rewarding aspects – the recruitment of young, energetic personnel. Their questioning minds, tenacity and fresh ideas have altered the dynamics of the company. They bring with them mind-blowing IT skills. We can now boast a team ready to take on the future with drive and confidence, with the support of experienced long-serving personnel.” For more information on Spiroflow’s products and services visit www.spiroflow.com or call +44 (0)1200 422525.

PROCESS INDUSTRY INFORMER September 2015

SPECIALIST CDM FOR THE PROCESS & CONSTRUCTION INDUSTRIES A new company specialising in the supply of Construction (Design and Management) services for the process engineering and construction sectors is reporting a huge demand for their services following the changes to the CDM regulations that came into force on April 6. HFL:CDM Ltd was established in July 2015 as a direct response to customer demand for CDM consultancy for process engineering projects but has already been selected to provide these for Bio Products Laboratory (BPL) Ltd, the Elstree-based producer of human plasma products in a three year alliance, and several other clients in the chemical, petro-chemical and pharmaceutical sectors. HFL:CDM Ltd’s Managing Director, Wayne Baxter, commented, “Our sister company, Haden Freeman Ltd, had provided Health & Safety advice to the process industries from its formation in 1984, including CDM specific support since the regulations were introduced in 2007. This included the provision of CDM Coordinator, a role in which we worked for a large number of our process industry clients, in addition to our expertise in HAZOP, HAZID and Functional Safety projects.” “Following the changes to the regulations in 2015, however, and the resultant increasing demand for CDM advice and services within the construction and process industries, HFL-CDM was set up not only for general construction clients but also for those undertaking new build or expansion schemes to their production and processing plants. – a niche field requiring construction, engineering and H&S expertise and experience. This includes the provision of the all-important Principal Designer role.” “Process Engineering projects differ from normal construction in several critical ways, foremost of which is the specialist knowledge of various engineering disciplines required to understand the total project – civil, structural, mechanical, chemical, electrical, control systems, instrumentation and safety engineering are involved in most process industry projects whereas normal construction projects require a less broad range.” “However, where we might differ from other providers of such services, is that we are not just professional H&S providers but rather bring real, practical experience of large complex construction projects which enables us to dramatically reduce risk for our clients via tried and tested lean management principles. There are many firms offering resources which explain the new regulations but we are one of the few that has real multi-discipline expertise and experience to enable us to offer almost a ‘one-stop shop’ to both the process and construction industries.” For further details, please contact Wayne Baxter by E-mail: wbaxter@hadenfreeman.com.

ABB’S SAFETY EXECUTION CENTER IN POLAND CERTIFIED BY TÜV ABB’s Safety Execution Center (SEC) in Wroclaw, Poland has been certified by TÜV as having in place and applying a functional safety management system (FSMS) for the delivery and implementation of safety system projects in accordance to international industry standards including IEC 61508 and IEC 61511 for integration and implementation of safety instrumented systems. ABB continues its programme of developing in-country safety execution centers with TÜV certification for FSMS delivery and implementation and has more incountry accredited certification than any other supplier in the industry. These centers are located in every region of the world. Seventeen of ABB’s SECs have so far been certified by both TÜV Rheinland and TÜV Sud, the leading world specialists in the assessment and certification of organisations and products to relevant safety standards. The programme managed by the ABB safety lead competency centre continues with a further 8 additional safety centers working towards the same goal. For more information contact ABB Ltd, St Neots, Cambs. Tel: 01480 475321 Web: www.abb.com/uk

NEWS & EVENTS Q8OILS RESTRUCTURES UK OPERATION FOLLOWING SUBSTANTIAL INVESTMENT Q8Oils has announced a reorganisation of its European lubricants manufacturing following the recent completion of a £100 million investment to upgrade its European blending plant in Antwerp. Having doubled capacity at its Antwerp plant, which is now capable of producing 250 million litres of blended product a year, Q8Oils has moved its UK blending operations to Antwerp and is investing in a new purpose-built UK headquarters in Leeds. Explaining the changes, UK managing director Andy Dixon stresses that this is a positive step for the UK and that Q8Oils is now focusing on expanding its business in the UK market. “This move is part of our plans for a long term commitment to the manufacturing, automotive and energy sectors and the restructuring includes new headquarters in Leeds that opened on 3rd July.” Andy also confirms that Q8Oils has announced the appointment of new business partners, IBL Bulk Liquids, Reynolds Logistics, Potters Logistics and Clarke Transport, to manage the company’s bulk storage and pack operations in the UK. All new UK distribution partners are established experts in packaging and distribution; and the Q8 products delivered will be the same as those already sold in the UK, with products being processed in Antwerp and delivered to Q8Oils’ UK partners. Andy Dixon states: “The important message to Q8Oils’ loyal UK customers is longevity and optimisation and, through better utilisation of European assets, the UK business is already creating long-term commitments, including new area sales manager appointments and recently signed major contracts, all of which demonstrate an on-going commitment to the UK.” For further information contact: Naomi Palmer, Q8Oils, 2nd floor, Marian House, Colton Mill, Bullerthorpe Lane, Colton, Leeds, LS15 9JN Tel: +44 (0)113 235 0555 Fax: +44 (0)113 248 5026 E-mail: Naomi.Palmer@Q8Oils.com Web: www.Q8Oils.co.uk

SMITH FLOW CONTROL EXHIBITED SUCCESSFULLY AT SPE OFFSHORE EUROPE WITH TRITON ENGINEERING Smith Flow Control (SFC), global leader in the design and manufacture of mechanical interlocks and valve management systems, exhibited at SPE Offshore Europe Conference and Exhibition in Aberdeen on 8-11 September, 2015. SFC exhibited with its distributor Triton Engineering. SFC’s products greatly enhance safety and efficiency and are specified by the world’s biggest oil, gas and petrochemical companies. Its comprehensive range of process safety products reduce the scope for operator error and ensure safe continuous plant operation. Its range of key operated interlocks can also be customised to implement a safe sequence of events in any process activity. SPE Offshore Europe offered the perfect framework for visitors to meet and discuss their valve operating problems; SFC offered valuable one-to-one discussions with its experts on all aspects of process safety, valve interlocking and valve management. At Stand 3D210, managed by SFC’s Project Sales Manager, Simon Read, was joined by representatives from its Aberdeen distribution network, Triton Engineering. Triton is a specialist provider of engineering consultancy services to the upstream oil and gas industry, with its core business being pipelines and risers. The company’s expertise ranges from Front End Engineering Design (FEED) studies, including risk-based decision making, through to delivery management, integrity management and ongoing operational support and related site services. Visitors to the stand were able see SFC’s latest innovations: - SmartTrap+, a product which incorporates signals from sensors into the interlocking sequence - EasiDrive, portable valve actuator, providing easy operation of multiple hightorque or high-turn valves - TorkDrive, the ultimate valve protector, which safeguards a valve from excessive torque For more information contact Smith Flow Control Ltd (UK) Witham, Essex Tel: +44 (0)1376 517901, Fax: +44 (0)1376 518720 Email: enquiries@ smithflowcontrol.com Web: www.smithflowcontrol.com

HBM AT SENSORS & INSTRUMENTATION EXHIBITION 2015 Stand: E26

HBM – a leader in the field of test and measurement – will be exhibiting its powerful new solution for eDrive testing, together with a range of data acquisition systems and sensors, at this year’s Sensors and Instrumentation Exhibition; the exhibition for Test, Measurement and Control on the 30th September and 1st October at the NEC Birmingham. The new eDrive Test System from HBM is a robust, integrated system for measuring the performance and efficiency of electric motors and inverters. The system incorporates an intuitive eDrive software GUI which has been developed exclusively for electric motor and inverter testing and for noise immunity. Mike Hoyer, HBM Applications Engineer says “HBM’s new eDrive package is the only completely integrated test solution on the market that allows engineers to record, verify and study both electrical and mechanical parameters under dynamic conditions”. Also showcasing will be HBM’s range of data acquisition systems and sensors, including its range of force sensors, which are used to measure static and dynamic tensile and compressive loads – with virtually no displacement, and its new FIT7A digital Load Cell. Specifically designed to meet the needs of demanding requirements of weighing in modern manufacturing lines. Visitors are also invited to attend two presentations at the Sensors and Instrumentation Exhibition. For more information on the new integrated eDrive Test System for Electric Motor and Inverter Analysis, Dick Eberlein, HBM GmbH Product Manager for DAQ Systems, will be looking at, “What drives electrical machines and inverters: More efficient analysis with eDrive Testing by HBM”. Mr Thomas Kleckers, HBM GmbH Product Manager for Force Sensors, will be discussing the main influences of measurement uncertainty in a force measurement chain and the possibilities to optimise the measurement chain, in his presentation, “Key factors of measurement uncertainty with force measurements – what are the key factors?” For further information contact HBM on Tel: +44 (0) 20 8515 6000 Email: info@uk.hbm.co.uk or Web: www.hbm.com

PROCESS INDUSTRY INFORMER September 2015

With 300 + Exhibition Stands & a wide range of Seminars the

2015 PPMA Show at the

NEC Birmingham 29th September – 1st October is a must…

As growth in the UK’s manufacturing sector continues to accelerate, with manufacturers reporting a rise in sales and indicating plans for expansion1, industry professionals are gearing up to visit the PPMA Show 2015, the UK’s premier, free-to-attend complete production line event for processing and packaging machinery – set to be the largest of its kind in recent years.

esults from the Manufacturing Advisory Service (MAS) Annual Barometer revealed that over 95 percent of manufacturers expect to maintain or increase their investment on machinery, premises and new technology, demonstrating a commitment to continuous improvement and making the PPMA show the ideal place for processing and packaging professionals to discover the latest technologies and product launches from across the UK’s manufacturing industries. Returning to the NEC, Birmingham, the show will run over three days (29th September – 1st October) and will be opened by Lord Digby Jones, former director General of the CBI and Trade and Investment Minister. With exhibitor space up by more than 20 percent compared to preparations for the 2014 show, this time last year, the event is quickly becoming the processing and packaging show that must be not be missed.

ROBOTIC AND INDUSTRIAL VISION ZONE SHOWCASES POTENTIAL FOR AUTOMATION

New features to the 2015 exhibition include a Robotics and Industrial Vision zone which will showcase the latest inventive and quirky uses of robotic technology including robots that can dance, pour drinks and even play snooker. Highlighting just how robotics and automation has come since the first industrial robotic arms were integrated into production lines, Rich Walker, Managing Director for the Shadow Robot company will demonstrate the ‘Moley robotic kitchen’ – capable of cooking chef quality meals using a normal kitchen. Walker will also speak as part of this year’s seminar line-up (Wednesday) to reveal what robotics could hold for the future of food manufacturing.

JUSTIN KING TO TAKE CENTRE STAGE AT SEMINAR THEATRE

A leading figure in the FMCG and Grocery retailing sectors, Justin King CBE is set to headline this year’s PPMA Show seminar theatre. Taking to the stage on the opening day, Justin will discuss the future for multiple retailers, how the growing market shares of discount retailers will affect the supply chain and how the continued emergence of supermarket convenience outlets is shaping the market. Also confirmed for the 2015 exhibition; TUESDAY: Keith Thornhill, Business Manager for Food & Beverage at Siemens will present the case for technology and data analytics for the digital factory of the future; Peter Evans, Compliance engineer with the CE Marking Association will update CE Marking machines and the new 2016 changes. Chris Hurst makes the case for ‘Achieving overall equipment effectiveness (OEE) success in pharmaceutical manufacturing.

WEDNESDAY: Dr Craig Leadley, Team Leader in Food Manufacturing Technologies

discusses the need contain the waste of food in his presentation ‘ Stoping the rot – by considering the future of food preservation’. Mike Cosby, Finance Director for Burts Potato Chips will examine how sales targets and profitability have soared thanks to continued factory investment and new technology and Rhys Herbert, Senior Economist at Lloyds Banking Group will explore what’s in store for the manufacturing sector.

PROCESS INDUSTRY INFORMER September 2015

THURSDAY: Andrew Love, Management Strategist, Leader & Author will discuss

‘The latest developments, technologies and strategies in pharmaceutical anticounterfeit and tamper-resistant packaging’. Andrew Manly, Communications Director – Active & Intelligent Packaging Industry Association (APIA) will make the point of ‘The end of ‘the best before’ & ‘sell by’? and how new packaging technologies can write their obit! John McKeon – Technical Director – Portalis Limited appraises ‘The Falsified Medicines Directive – Comply or die’

MANUFACTURING SKILLS GAP UNDER THE SPOTLIGHT

The topic of the current manufacturing skills gap will be addressed in more detail at this year’s seminar theatre following the launch of the PPMA BEST initiative, a new charitable trust aimed at recruiting more young people in the industry. The new division will highlight and promote the benefits of apprenticeships throughout the industry, highlighting how the skills shortage can be resolved through improved engagement between the industry and the UK’s academia. Addressing the ingredients for success and highlighting the opportunities for an engineering future in food and drink, (Wednesday) Sam Kelly, Electrical Engineering Apprentice for PepsiCo and Hannah Whall, Graduate Project Engineer for Nestle will provide an up-to-date insight into the opportunity in engineering in the largest industry in the UK. Representing two of the routes open to young people, including apprenticeships and graduate schemes, Sam and Hannah will share their personal stories as their build a career in the UK’s food and drink manufacturing industries. In an effort to further encourage young engineers into the sector, the PPMA Show will also welcome the return of the Ones to Watch Awards which recognises the contributions of processing and packaging professionals under the age of 35. Sponsored by Festo, the awards are chosen by a select group of industry specialists from the PPMA Group Industry awards judging panel, with colleagues being urged to nominate outstanding candidates to the Demonstrating the future trends in manufacturing Attendees at the NEC in September can also find out more about the latest trends and innovations taking the industry by storm. With the productivity puzzle still proving an issue for four fifths of the UK’s smaller manufacturers, visitors can visit stand E90 where Festo, the innovation leader in pneumatic and electric drive technology will be showcasing a number of its exciting new developments, concepts and solutions for the food and beverage sector. Visitors to the stand will be able to discuss how they can increase productivity in different ways by considering efficiency, simplicity, security as well as accessing Festo’s key competencies.

To register your attendance at the show please visit: http://bit.ly/PPMA2015. For more information on the PPMA Show 2015, please visit www.ppmashow.co.uk or join the conversation on twitter (@PPMAshow #PPMAShow or the PPMA Show LinkedIn group.)

PPMA 2015

Stand A21

RED LEDGE TO EXHIBIT LATEST FAST-DEPLOYMENT MANUFACTURING PRODUCTION SYSTEM AT PPMA 2015 • Asset and warehouse management systems also on show • Red Ledge exhibiting on partner Fairfield Group Stand A21 Software application and engineering company Red Ledge is to exhibit its latest, fast-deployment manufacturing production system on business partner Fairfield Group’s Stand A21 at the PPMA 2015 event. ‘Red Ledge Manufacturer’ is an innovative new manufacturing production system that uses pre-designed, pre-defined production processes to allow faster, more cost-effective deployment for any manufacturer say Red Ledge. The system uses barcode or RFID technology to track every stage of production, and enables KPI reporting for manufacturing targets. It can be integrated with all mainstream ERP systems. Also on show, ‘Red Ledge WMS’ can be added to Red Ledge Manufacturer to extend its scope for users wishing to integrate their manufacturing and logistics processes. This system can also be deployed standalone. At PPMA 2015 Red Ledge is also exhibiting the latest version of its ‘Red Ledge Asset Management System’ (AMS) mobile distributed solution. It can be run remotely, in real time using RFID technology that requires no line of site, and is suitable for any organisation with widely distributed assets on multiple sites. “Our company motto is process perfect” says Red Ledge managing director Andy O’Donnell. “We hope that visitors to the show will benefit from our smart technology to make cost-effective improvements to their own production, logistics and asset management processes.” For more information contact Red Ledge on Tel: +44 (0)7775 513938 / +44 (0)1484 500226 Email: Andy.ODonnell@Redledge.co.uk

PPMA 2015

Stand E83

CORI-FILL®, a compact fluid dosage and filling assembly based upon extremely accurate mass measurement, on-board software and integrated batch counting, and direct control of a closely coupled shut-off valve, proportional control valve or pump is available for flow rates from 50 milligrams per hour through to thousands of kilograms per hour. CORI-FILL offers all this functionality in one compact footprint and from one supplier, with single point responsibility and without the need for complex programming of additional hardware. In addition, Bronkhorst will be showing their range of gas flow meters and controllers for flow rates from 0.014 ml/min through to 187,000 LPM, their pressure meters and controllers for vacuum through to 700 bar, their low to ultra-low flow meters and controllers for liquids and their humidification systems for controlled atmospheres. Please visit us at The PPMA Show on Stand E83 for more information.

Schematic of compact sequential dosing system featuring more than forty CORIFILL assemblies.

Stand A02 Hall 5

WHEN IT COMES TO MIXERS – COME TO JOHN R. BOONE John R. Boone will demonstrate several powder, granule and paste mixers including the New Tilting Helical Blade Mixer for sugar paste and delicate fruit cake & pastry mixes. Other uses include thick gel mixes, building adhesives, spice and flavours, meat mixes, and breakfast cereals prior to extrusion. Batch Sizes from 2 litres to 10,000 litres. This is one of the highly efficient Industrial Mixer ranges, which guarantees Mixing Process improvements by matching Innovative design with the latest power saving drives and process control to deliver custom built equipment to meet individual customer requirements. Other equipment on the stand will include: The Rotary Drum Blender a Low shear drum blender for Tea, Coffee, Cocoa, Spices, Muesli, Rice Flakes, Seeds Confectionery, Gelatine, Salts, Vegetables + spray coating applications. Batch Sizes from 2 litres to 25,000 litres. The Horizontal Delta Blade Mixer a high shear plough for Catering Mix, Cookies, Molassed Sugar, Adding Minor liquid additions to powders without agglomeration, breaking down soft agglomerates and cohesive powders when mixing . Batch Sizes from 2 litres to 7,500 litres. To speak to our sales team your either contact us on Tel: + 44 (0)1260 272894 or E-mail Chris Boone: chris.boone@jrboone.com Peter Youds: peter.youds@jrboone.com Helen Eite helen.eite@jrboone.com or Sales@jrboone.com for any other enquiries or visit Website: www.jrboone.com

PPMA 2015

CORI-FILL® FOR ACCURATE MASS MEASURING & SIMULTANEOUS DOSING

For more information contact Bronkhorst UK. Tel:1223 833222 E-mail: sales@bronkhorst.co.uk Web: www.bronkhorst.co.uk/

PPMA 2015

Stand G22

FARLEYGREENE WILL BE EXHIBITING THEIR INNOVATIVE SIEVING EQUIPMENT AND TECHNOLOGIES ON STAND G22 AT PPMA 2015. At the heart of their show this year Farleygreene will launch their new Sievgen series of machinery. This new range represents the companies next generation of sieving equipment and commitment to moving the technologies forward for the future. The first piece they will be launching is the Sievgen SG400 unit, which is aimed directly at the additive manufacturing sector. After supplying machinery to some high profile end users in the industry, they have incorporated all previous project requested features and designed a single simple to use package that addresses the feeding, ultrasonic sieving and container filling of high value powders ready for re-use in 3D printing machines. The fully enclosed system has been built to ensure it is aesthetically in tune with the intended operational environment. The stand will also be showing machines from the existing Sievmaster range. These cover all aspects of sieving and screening, from entry level small batch check sieves, to high capacity vibratory and centrifugal check units. They will also be showing a grading separator which has an integrated metering feed hopper and a new updated version of the SM553-STS sacktip check sieving station. As well as these exciting launches Farleygreene have a lot more to offer and exhibit, pop along to the stand where you will be greeted with knowledgeable and experienced staff who will be happy to discuss any of their machines and advise you on how they can meet your specific requirements. Please also have a look on their website prior to the show. www.farleygreene.com or give them a call +44 (0) 1256 474547.

PROCESS INDUSTRY INFORMER September 2015

Stand G36

PPMA 2015

SPIROFLOW WILL UNVEIL NEW FLEXIBLE CONVEYING SYSTEM AT PPMA Award-winning Spiroflow will be at the PPMA Show demonstrating its latest conveying and weighing technology. Spiroflow is a world-leading manufacturer of conveying, weighing, filling and discharge systems. It has a wide range of cost-effective solutions for handling bulk materials where the most rigid standards in hygiene and containment need to be met and maintained. The Lancashire business, which has won two Company of the Year Awards in 2015, recently adding the Food Processing magazine accolade to the prestigious SHAPA Company of the Year Award, is promoting flexible screw and vacuum conveyors. Also on show is a hygienic bulk bag discharger Taking centre stage will be a multiple flexible screw conveyor demonstration set-up, complete with sack tip station, product agitators and loss-in-weight feeders, demonstrating their versatility in terms of feed rate, throughput range, consistency and accuracy of output, angle of elevation and quick release features. Spiroflow’s technical team will also be on hand to demonstrate the advantages of the vacuum conveyor, which is able to negotiate lengthy and tortuous routes and hygienically transfer materials. The bulk bag discharger Model T2 on show is a market leader, with options including loss-in-weight product feed, patented massage systems to promote flow from bags, hygienic spout sealing device, integral hoist and other devices to ensure controlled and dust-free emptying of 1-2 tonne bags. This impressive line-up of material handling systems at the show will enable visitors to see for themselves why sales of Spiroflow’s equipment have rocketed in recent years, with the company reporting a 35% increase between 2011 and 2015. Spiroflow’s marketing manager, Ben Ayrton, said: “We are delighted to be demonstrating fully working examples of our totally hygienic conveying systems at PPMA. While our new flexible screw conveyor is certain to attract attention, our line-up of equipment shows that we can offer a wide range of standard and customised material handling options for both small and large volume users. Whether equipment is required for efficiently conveying food ingredients such as flour, cereals and coffee granules or accurately controlling the flow of materials for the chemical and mineral sectors, Spiroflow can reassure customers that the wide range of dust-tight systems that they can supply provide optimum performance and offer value for money. As well as providing a comprehensive range of equipment and testing facilities, an outstanding level of customer service is part and parcel of the Spiroflow experience and is one of the reasons why companies in the food, chemicals and process industries return again and again to Spiroflow for their filling, discharging and conveying needs. In addition to Flexible Screw Conveyors, Vacuum Conveyors and Bulk Bag Dischargers, Spiroflow is also a manufacturer of Bulk Bag Fillers, Aero Mechanical Conveyors, Tubular Cable and Chain Drag Conveyors, Bin Activators, Ingredients Handling and Weighing Systems. The company’s technical and engineering expertise has led to it developing an international reputation for an unrivalled range of products with stateof-the-art control systems. For more information on Spiroflow’s products and services visit www.spiroflow.com or call +44 (0)1200 422525.

APPLICATIONS NOV SUPPLIES MORE MONO™ PUMPS TO MAJOR ANAEROBIC DIGESTION OPERATOR NOV has provided two of its Mono™ progressing cavity pumps which are now helping manage some 12,000 tonnes of material each year, including 7,500 tonnes of food waste, at a major recycling plant in Weston-super-Mare. An EZstrip™ transfer pump and a Compact C range pump were installed as part of an Anaerobic Digestion (AD) process operated by the award-winning waste management company, Cory Environmental. Three other EZstrip pumps are also in use at the plant. “We are one of the UK’s leading waste management companies, and our customers rely on us to provide them with reliable and efficient waste management and recycling services,” says Alistair Holl, Director of Cory Environmental Resource Management. “Our existing Mono equipment from NOV had performed well, and that was a major factor in our decision to use two additional Mono pumps to handle the depackaged organics which go into our AD process. This is mainly food waste which can be quite aggressive on the rotors and stators of any pumps involved, so it was also important that we chose equipment that we knew would deliver in this sort of demanding application.” NOV’s focus on developing pumping solutions which are designed to meet the specific requirements of specialist industries such as AD made the company an ideal pump provider for Cory Environmental. For more information contact Nov Mono, Tel: 44 (0)161 339 9000 Web: www.mono-pumps.com

PROCESS INDUSTRY INFORMER September 2015

NOT SHAKEN, NOT STIRRED… BUT MIXED Maximising the benefits of renewable energy continues to be the focus for an increasingly diverse range of companies who are continuing to invest in the anaerobic digestion (AD) process and a new bio-energy plant at the Glendullan distillery is a good example. Diageo Scotland Ltd, have a number of distilleries in the ‘Whisky Trail’ area located in Speyside, Perthshire and have invested around £1bn in increasing production capability and enhancing their bioenergy facilities. Mixing is an essential part of the AD process and SYSTEM MIX LTD who market the Rotamix Dual Zone Mixing System, have made an important contribution in supplying mixing equipment to both the Dailuaine and Glendullan distilleries. The mixing system installed at the Dailuaine Bioplant consists of a single Vaughan HE10R12-381 horizontal end suction chopper pump driven by a 37 kW rated motor and 4 internally floor mounted double nozzle assemblies to mix a 24.5m diameter digester tank. The success of this initial AD project was an important factor in the decision to upgrade the Bioplant at the Glendullan distillery, where another single pump mixing system is operating successfully. As the sole UK suppliers of the bespoke design ROTAMIX (Digester Mixing) and STM (Small Tank Mixing) tank mixing systems using the integral VAUGHAN chopper pump, System Mix are making an important contribution to the success of AD plants in the ‘food’ waste sector. For example, problems such as solids settlement are commonplace reducing active digester volume and can result in a significant reduction in output, leading to failure of compliance requirements. Also compressors in ‘traditional’ gas mixing systems and submersible in-tank propeller systems are often associated with labour intensive maintenance issues, resulting in process downtime and associated costs. For more information contact SYSTEM MIX Ltd Tel: +44 (0) 1487 830123 E-mail: andy@pumpmix.co.uk Web:www.pumpmix.co.uk

APPLICATIONS NEW VEGA LEVEL SENSOR REACHES PARTS OTHERS CAN’T! Another success for high frequency contactless radar level sensor E&JW Glendinning is the largest independent supplier of quarry and concrete products both to the trade and direct to the end user in Devon and Cornwall. Over recent years, they have embarked upon an expansive programme of modernisation and automation, creating a state-of-the-art aggregates processing and supply facilities, which is essential to their business goals and to compete in the modern aggregates market. As part of this they need high-tech sensor solutions to deliver the automation and control philosophy they are seeking. They make high demands on equipment to get the best performance out of their plant. The secondary crusher at the heart of the screening and grading plant in the quarry is typical of this requirement. The feed hopper above it is a critical process control point, this is where the majority of aggregate comes through at some stage. It is a noisy, dusty environment, with unpredictable flow patterns and material behaviours. The crusher itself is capable of processing up to 400 tonnes an hour and the whole plant 4000 tonnes a day. With this level of throughput, its vitally important to get accurate information and control to optimise productivity, energy consumption and product quality from the crusher. Originally, as is the case with most sites in the sector, non contact ultrasonic level sensors were installed. However, the noise, dust and product build up regularly delivered unreliable performance for the control they required. This single measurement problem resulted in regular production halts, poor process and energy management and resets of the sensors to clear the problem. The ultrasonic units required regular maintenance: from cleaning transducers, adjusting angles and tweaking software to try and make them perform as they wanted. Their engineers needed to improve the plant performance to a level that satisfied both their customers and themselves. To achieve this they turned to VEGA to trial one of their new VEGAPULS 69 radar level sensors in this tricky, critical control point. The application consists of a feeder hopper over 8m high and around 5m square at the bottom two sides slope down onto a central crusher feed. The hopper can be fed from any one of three different conveyors, which can be simultaneous, and the stone size feeding in can be from dust up to 250 mm, as the majority comes from the primary crushing plant. Inside the feed silo it gets a heavy build up of stone on the ‘shoulders’ of the coned section, forming a narrower ‘rat hole’ to the bottom. This material rarely moves, so it was important for the sensor to be able to reliably read down past this point. The VEGAPULS 69 was installed in the existing mounting position of the ultrasonic sensor, very close to the main infeed into the bunker. It was commissioned by the plug-in programmer on the top of the device. As soon as it was installed on the empty silo, with no extra adjustments, the sensor was able to read right down to the bottom of the bin to the outlet conveyor, which boded well. Then, with just a few minor adjustments to optimise the performance of the sensor and its output, the radar has worked successfully without incident for over 3 months, providing a smooth level output to enable operators to effectively control crusher throughput and the conveyor speeds. This without need for extra maintenance work and a reduction in downtime caused by measurement problems, a first for this area of the process. So why is this radar so different? VEGAPULS 69 works with very highly focused 79GHz microwaves, not sound waves, to provide a very small beam angle (3.5°), along with optimised sensor performance for solids handling. This, combined with radar’s natural immunity to inflight dust, filling noise and air turbulence, means it promises to be one of the most capable and versatile solids level sensors ever. It is now proving itself in difficult unmeasurable applications. The site engineer said “We like VEGA sensors, as we install them, fit them and they get on with their job. We don’t have to keep going back with minor tweaks”. He added, “We also like the continuity of the programming system, all that is needed to set a sensor up is the PLICSCOM display/programmer that simply slots onto the housing that enables access all of the information and gets a sensor up and running quickly and easily and only need one programmer for all devices.” E&JW Glendinning are now confident enough of the radar devices’ performance, that they have embarked upon a schedule of installing them across the plant, replacing ultrasonic sensors. For more information contact VEGA Controls Ltd, Tel: +44 1444 870055 Fax: +44 1444 870080 E-mail: info.uk@vega.com Web: www.vega.com/uk

MONO™ PUMP from NOV SET TO REPEAT 30-YEAR SUCCESS

COLCHESTER ZOO PUMP OVERHAUL

A Mono™ Compact C progressing cavity pump from NOV has replaced a previous Mono pump that had operated without any problems for over 30 years. The new pump is being used in fertilizer production by GrowHow – a leading UK fertilizer manufacturer, and a major supplier to the chemical process industry. The original SH80 pump had given good effluent transfer service for over three decades. “It was still working well, but GrowHow decided to upgrade to a new pump,” explains NOV’s Paul Green. “We proposed a Compact C range pump as the modern alternative.” “We needed something which combined excellent suction lift performance with the ability to handle high suspended solids content,” continues GrowHow’s Chris Smith. “It also had to withstand the very aggressive nature of the effluent, so that it could provide a high level of reliability. The new pump has fitted the bill perfectly and is providing even better performance than the old SH80 unit.” The new pump is driven by a fixed-speed gearbox, operates at 245rpm, handles a 3.25 bar pressure and provides a 19 m3/h capacity. It draws the effluent from an interceptor pit on a 3m lift, and transfers it over 100m to a holding sump.

Gibbons Engineering Group conducted an overhaul of the two main 55kW water pumps serving the Colchester Zoo sea lion enclosure. This was because vibration readings were exceeding ISO recommended levels, while the mechanical seals required replacement. Gibbons’ comprehensive package of work included the lift and shift of the pumps which were returned to our premises for The sea lion enclosure at overhaul and re-instated on completion. The project also included the replacement Colchester Zoo of the bearings plus removal and reinstatement of the coupling assembly. For precision alignment, the coupling was set up using our state-of-the-art laser aligner. The refurbished pumps and motors were set to work and checked for running current and vibration levels before returning to normal service.

For more information contact Nov Mono Pumps, Tel: 44 (0)161 339 9000 Web: www.mono-pumps.com

For more information contact Gibbons Engineering Group Ltd, Tel: 01621 868 138 E-mail: matthew@gibbonsgroup.co.uk Web: www.gibbonsgroup.co.uk

Laser alignment of the coupling assembly

PROCESS INDUSTRY INFORMER September 2015

APPLICATIONS SENSONICS DELIVERS CRITICAL PROTECTION TO NUCLEAR POWER PLANT IN UAE Condition monitoring specialists SENSONICS have delivered the first tranche of machinery protection systems to the Barakah Nuclear Power Plant project in the UAE (United Arab Emirates). Following a two year design and production phase, the equipment delivery, made up of 92 (ninety two) Sentry G3 4-channel protection modules and over 300 channels of vibration analysis across three cabinets, is currently undergoing commissioning as part of the Unit 1 construction phase. The instrumentation will monitor and protect 45 machines, the balance of plant equipment for Unit 1, consisting of various fans, pumps and chillers in support of the steam turbine. The fully programmable Sentry G3 equipment is utilised to monitor bearing and shaft vibration in addition to thrust wear and speed. The specification includes dual redundant power supplies in each rack with redundant Ethernet communications to the main plant systems for trending of overall vibration levels and the reporting of alarms. A condition monitoring package is also integrated with the G3 equipment to provide real time analysis of the vibration signals. All data is stored on a local server which provides live machine Mimic’s in combination with offline analysis of historical trends. This major overseas contract for the Korean Electric Power Corporation is another example of Sensonics’ commitment to developing the most innovative and robust solutions for vibration, position and speed instrumentation for critical machine condition monitoring applications in power generation, petrochemical, paper production and process manufacturing industries around the world. For more information contact Russell King, Sensonics Ltd, Tel: +44 (0) 1442 876833 Email: sales@sensonics.co.uk Web: www.sensonics.co.uk

TOP SAFETY ACCREDITATION FOR ECOTILE FLOORING Ecotile Flooring Ltd has been awarded accreditation from Safecontractor for its commitment to achieving excellence in health and safety. Safecontractor is a leading third party accreditation scheme which recognises very high standards in health and safety management amongst UK contractors. Employing 24 people, Ecotile manufactures the market leading range of PVC interlocking floor tiles currently in use by companies such as Rolls Royce, Siemens, Toyota, TK Maxx and Royal Mail. The company’s application for Safecontractor accreditation was driven by the need for a uniform standard across the business. John Kinge, technical director of Safecontractor said, “Major organisations simply cannot afford to run the risk of employing contractors who are not able to prove that they have sound health and safety policies in place.” “More companies need to understand the importance of adopting good risk management in the way that Ecotile has done. The firm’s high standard has set an example which hopefully will be followed by other companies within the sector.” For further information about the Safecontractor scheme, contact: Sinead Parsons Safecontractor E-mail: marketing@safecontractor.com Tel: 029 2026 6750 For further information contact: Ecotile Flooring Ltd, Luton, Beds. Tel: 01582 788232 E-mail: lucinda@ecotileflooring.com Web: www.ecotileflooring.com

PROCESS INDUSTRY INFORMER September 2015

INDUSTRIAL PERISTALTIC PUMPS REDUCE THE COST OF OWNERSHIP FOR PAPER AND PACKAGING MANUFACTURER Challenge A leading paper and packaging manufacturer in Australia was using Air-Operated Double Diaphragm (AODD) pumps to deliver 4-colour ink to its printers. The on-site AODD pumps were using considerable amounts of compressed air and required constant maintenance due to the wearable parts (seals and valves). This was resulting in unacceptable long downtimes and high cost: for repair and purchase of new parts. The customer requested for pumps that could offer increased durability and low maintenance, reducing the cost of ownership by lowering repair/service costs. In addition and more importantly, the pumps needed to deliver shear sensitive inks to the printers without foaming or separation. Solution After assessing the process, Australian Verderflex distributor, Global Pumps were able to recommend the Verderflex Rapide R8 Peristaltic Industrial Tube Pumps to replace existing AODD pumps. The Rapide R8 belongs to the Verderflex® Rapide family of simple to operate industrial tube pumps which are perfect for heavy duty applications, where viscous mediums are being pumped. The R8 has a maximum flow rate of 470 l/hrand discharge pressures of up to 2 bar. These industrial peristaltic tube pumps have a compact footprint, deliver high output, offer multi-directional orientation of the pump head and are available with dual pump head as an option. These key features make the Rapide easy to integrate into your working process. The customer saved both cost and time by having high dependability and only one wearing part – the tube. With a simple clamping mechanism enabling tube change, the pumps are easy to maintain onsite, without requiring specialist repairs. There are no seals or valves to replace, nor impellers that can become clogged. Result A very happy customer quoted that the Verderflex Rapide R8 is a “great pump and very reliable”. In addition to the benefits described above, the customer was delighted that the pumps also save money on ink during setup/cleaning between jobs by being reversible. They simply pump any unused ink back into the supply after the print job is finished. For more information contact Verderflex Ltd, Castleford, West Yorkshire. Tel: +44(0) 1924 221020 E-mail: info@verderflex.com Web: www.verderflex.com

STEEL MAKER IMPROVES ROLLER TABLE RELIABILITY WITH AC DRIVES A steel maker is improving the reliability of its roller table by retrofitting four ABB variable-speed drives. The roller table has 80 rollers to transport finished steel billets at Celsa Manufacturing’s plant in Cardiff. Each drive controls four banks of 20 roller motors. Celsa’s existing roller table drives were obsolete and it was getting difficult to source spares for them.As a trial, ABB authorised value provider, APDS, installed an ABB general purpose drive, ACS550. Although the objective was not energy saving, APDS estimate that Celsa will be saving about 30 percent on its energy costs for this drive. All the motors are connected to the drive using scalar control. Some drives do not like the inductance imbalance that goes with trying to control so many motors, but with the ABB drive, it’s simply sized for 20 motors and there is no need for a filter. For more information contact: ABB Limited, Tel: 01925 741 111 E-mail: energy@gb.abb.com Web: www.abb.co.uk/energy

APPLICATIONS

“EASY DECISION” TO UPGRADE TO SPIRAX SARCO’S HEAT EXCHANGER SYSTEMS CONSIDERABLE SAVINGS FOR FLOWPLANT CUTS LEIGHTON HOSPITAL’S WATER THANKS TO INVEND™ HEATING COSTS BY 10-15% The UK’s leading distributor of industrial maintenance, repair and overhaul (MRO) products and services, Brammer, has helped Flowplant save 60 per cent on its consumable spend through industrial vending solution, Invend™. Flowplant manufactures and supplies equipment for a range of industrial applications, such as drain and sewer cleaning, abrasive blasting and descaling and hydrostatic testing. It is essential for them to have sufficient stock of consumables to ensure downtime is minimised. One of the problems was with small value, high volume items, as they are difficult to track and control in terms of stock holding. Storage was another problem area for Flowplant, with items either locked up in cupboards which slowed down access, or handed out items to all employees, leading to a high volume of cash tied up in consumable stock. Additionally, Flowplant’s historic management of low-value consumables consisted of paper ordering and the purchasing department having to constantly liaise with stores, which were not always open when stock was required. Brammer’s Invend™ allowed Flowplant to benefit from an industrial vending machine service without the upfront cost of having to purchase the machine. Brammer installed the Invend™ machine into Flowplant’s factory, giving site managers a complete oversight of what is being used, by who and how often. It can be used on a 24/7 basis. Mark Bastable, Managing Director of Flowplant, said: “We have been delighted with the introduction of Invend™ in our manufacturing facility. We have received fantastic feedback from our operators, who find the ease of use a considerable benefit, as well as the availability of equipment to them during all times of the day.” For further information, visit www.brammer.co.uk/invend

ROTORK CMAS ENABLE SHALE GAS WELL COMPLIANCE WITH EPA EMISSIONS MANDATES

Leighton Hospital has cut its water heating costs by an estimated 10-15% per annum by upgrading its hot water system to two Spirax Sarco EasiHeat™ steam-to-hot-water systems. The installation by Leighton Hospital, a 540bed acute hospital in Crewe, brings the total number of EasiHeats at the site to ten, underlining the hospital’s confidence in the technology’s superior reliability and energy efficiency. The EasiHeat systems will supply almost 90% of the DHW in the main hospital building. “Our aims in installing the latest EasiHeat systems were to achieve a more accurate control of our outgoing water temperature, eliminate wasted energy due to storing large volumes of hot water, and reduce/eliminate scheduled maintenance works regarding annual inspections,” explains Brian Colley, Energy & Environmental Engineer at Leighton Hospital. “We have a lot of experience with plate heat exchange systems, which meant our decision to upgrade to the EasiHeat systems was an easy one to make – we knew they would be perfect for this project.” Spirax Sarco EasiHeat is a ready-to-install system that uses steam in a compact, plate heat exchanger to deliver water on demand at a constant, stable temperature. As the hot water is supplied on-demand, there is no need to store it, avoiding the associated energy losses and significantly reducing the risk of Legionella. “Before we installed the EasiHeat systems, we had to pasteurise the water by keeping it at 80°C for an hour before we could open it up onto the circuit. Then, because it is domestic hot water, we had to cool it down before it could be used, which was a huge waste of energy. Installing the EasiHeat systems means it is no longer necessary to store hot water, which will reduce carbon emissions.” The EasiHeat systems are also expected to reduce maintenance costs at Leighton Hospital. Unlike calorifiers which are pressure vessels and must be stripped down for annual insurance inspections, EasiHeats do not need to meet this requirement, saving substantial maintenance costs. For more information contact Spirax Sarco, Cheltenham, Glos. Tel: 01242 521361 E-mail: UK.Enquiries@spiraxsarco.com Web: www.spiraxsarco.com/uk

Rotork CMA electric control valve actuators have delivered an efficient and reliable process control solution and eliminated venting and greenhouse gas emissions in compliance with new environmental protection legislation at remotely sited shale gas installations in the USA. Traditionally, spring diaphragm actuators powered by the produced gas have been used, but recent EPA (US Government Environmental Protection Agency) mandates now limit this process to lower fugitive emissions caused by bleed gas. A shale gas company in Louisiana was therefore looking for an affordable and efficient low power solution that could be run by solar panels to replace existing actuation equipment and control a variety of fluids at line pressures up to 413 bar (6000 psig). Most shale wells and flow lines are unmanned and located in remote areas that are difficult and expensive to monitor. Skilled technicians must check data and perform manual shutdowns, increasing costs for the time to travel to site, identifying the problem and stopping the flow, which is not cost-effective or practical. Actuators provide an ideal solution to automate valves at the remote wells. The key objective was to provide an efficient and reliable process control actuator which could be retrofitted on installed valves to reduce costs and downtime. Rotork’s local agent Setpoint Integrated Solutions engineered an interface to enable CML-250 actuators to be easily fitted to installed valves and improve the level of control, without venting gas and with the low power demand required for solar powered operation. Designed for quarter-turn, multi-turn and linear valve operation, robust Rotork CMA actuators perform numerous process control valve, choke valve, metering pump and damper applications demanding precise position control and continuous modulation. Single-phase or DC electrical power is all that is required for simplified installation and control valve actuation. Explosion proof certification to international standards is available for hazardous area applications. Recent developments enable the CMA to be specified with increased functionality encompassing local controls, LCD positional display and programmable fail-to-position performance. The success of this solution has enabled the Louisiana customer to standardise on the CMA actuator for future flow control applications. Around the world, increasing numbers of CMA actuators are used for similar duties. For more information contact Rotork plc, Brassmill Lane Bath Tel: (0)1225 733200 E-mail: information@rotork.com Web: www.rotork.com

Retrofit installation of Rotork CML250 electric actuator on a high pressure control valve at a shale gas well in Louisiana

PROCESS INDUSTRY INFORMER September 2015

APPLICATIONS BABCOCK WANSON PROVIDES FLEXIBLE PROCESS HEATING FOR AUTOMOTIVE MANUFACTURER Babcock Wanson’s high efficiency Thermal Fluid Heaters have been installed at Gurit Automotive’s site in Newport, Isle of Wight, as part of a very close control heating and cooling system for its composite part production facility. Gurit has been supplying leading OEMs with carbon fibre based Class-A composite panels since 2007. The company’s strength is its understanding of composite materials, structural design and materials processing which provides the capability to formulate, design, prototype and manufacture fully assembled, primed and coloured exterior body panels. A flexible process heating and cooling solution that can be precisely controlled is vital to the manufacturing process. Gurit selected a Babcock Wanson Thermal Fluid System which is used in their multi mould production facility for composite panel production and hot roller heating for prepreg material production. Keith Netting, Product Development & Industrialisation Manager and Sam Robinson, Plant Engineering & Maintenance Manager at Gurit Composite Components, comment: “The heaters are well constructed and easy to maintain and have performed well. One existing unit on site has run approximately 24/7 360 days with only one failure in eight years. The controls are straight forward without any unnecessary complicated add ons which is refreshing; they are constructed to carry out what’s required and perform very well.” Sam is very pleased with the service provided by Babcock Wanson: “We have experienced excellent service from Babcock Wanson. They are willing to help and advise as required, with several site meetings, until the correct solution for our needs was found.” 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 contact Babcock Wanson on Tel: 020 8953 7111 Email: info@babcock-wanson.co.uk or Web: www.babcock-wanson.co.uk

PROCESS INDUSTRY INFORMER September 2015

ENERGY SAVINGS IN THE CAN FOR BRAMMER AND BALL Expertise in pump management and maintenance from Brammer, the UK’s leading distributor of industrial maintenance, repair and overhaul (MRO) products and services, has delivered £30,000 in energy savings for Ball Packaging Europe, a leading manufacturer of beverage cans. Ball regularly reviews opportunities for reducing energy consumption as part of a commitment to reduce the carbon footprint of its beverage cans by 25 per cent by 2020. Identifying its high pressure can cleaners as an area for improvement, they called in Brammer to conduct an extensive audit. Each of the two production lines at Ball’s Rugby site is supplied with hot water by five immersible pumps. Brammer found that the 10 pumps within the can cleaners were at least 20 years old, providing an opportunity to upgrade to more modern, energy-efficient models. With a run time of 8,400 hours per annum, based on the pumps running 24/7 for 50 weeks of the year, Brammer identified potential energy savings of more than 450,000 KWHh/yr. With a clear opportunity to provide more efficient, cost effective pumps which would reduce consumption and optimise flow, Brammer worked with strategic partner Grundfos pumps to recommend replacements – Grundfos MTRE64 and MTRE45 series pumps – and carry out initial energy monitoring. The new pumps were installed as part of a fully integrated pump, motor and variable speed drive package, and were selected on the basis of the warranty and support available within Brammer’s turnkey solution. Thanks to a significant reduction in energy usage, the associated cost savings have provided Ball Packaging with a return on investment in only 12 months, with projected savings set to rise beyond £400,000 in the next ten years. John Cosgrove, Plant Systems Manager at Ball Packaging Europe, commented: “We were impressed with the thorough up-front audit from Brammer, as well as the comparison testing and custom fabrication the team were able to provide. The installation was quick and caused negligible disruption to our production processes. We are now looking at how we can replicate these results at our other sites.” For further information on Brammer’s MRO products and value-added services, visit www.brammeruk.com

APPLICATIONS ENGINEERING FIRM DELIVERS ON CONTRACTS IN NORTHERN POWERHOUSE CITIES TO CONSOLIDATE UK EXPANSION

ABB TO PROVIDE POWER AND AUTOMATION SOLUTIONS FOR OILFIELDS OFF UAE COAST

Cooling specialist Aqua Cooling has delivered on contracts to supply state-of-the art cooling towers at Manchester MediaCityUK and for Clarke Energy in Liverpool. After extensive design consultation Aqua Cooling, which specialises in providing effective cooling systems designed to meet the specific needs of clients across a wide spectrum of industry sectors, supplied SPX Marley low-rise towers fitted with low-sound fans to meet strict noise and height requirements. Aqua Cooling’s business is built on the expertise of fully-trained and innovative engineers dedicated to providing practical and effective bespoke cooling solutions. Securing these contracts reflects the company’s reputation for highquality, energy-efficient solutions and best-practice customer service.

ABB has received orders from Hyundai Heavy Industries for electrical and telecommunication systems. The order is worth around $100 million, with about half booked in the last quarter of 2014, almost $27 in the first quarter of this year and $20 million in the second quarter. It enables Hyundai Heavy Industries to fulfill its obligations to Abu Dhabi Marine Operating Co. under the contract for EPC Work of Nasr Full Field Development Project (Package 2). The solution provided consists of interconnected power management, powerfrom-shore and telecom systems ensuring the highest levels of efficiency, reliability and safety. The power management system is based on ABB’s System 800xA Extended Automation control system, which integrates the network of transformers and switchgears enabling operators to control the electrical installation in a safe and consistent manner. It includes an intelligent asset management system for predictive maintenance of equipment, reducing operating costs and extending its service life.

For more information on Aqua Cooling contact Tel: +44 (0) 800 808 5580 E-mail: sales2@aquacooling.co.uk or visit Web: www.aquacooling.co.uk

For more information contact ABB Ltd, ABB Group Media Relations, Zurich, Switzerland Tel: +41 43 317 7111 E-mail: media.relations@ch.abb.com

PROCESS INDUSTRY INFORMER September 2015

FEATURE

MAKING THE MOST OF YOUR

IT INFRASTRUCTURE Tony Mannion, Business Unit Leader Industrial IT from SolutionsPT, looks at the pressures faced by manufacturing businesses and the tell-tale signs that they’ve outgrown their infrastructures.

aking the jump from SME to a larger enterprise is exciting, but not without its challenges. Having the right software and technology in place is essential to growing a business, yet many companies – particularly manufacturers – are being constrained by out-dated process and applications. So how can decision makers identify when their IT systems have reached the tipping point? Following the recent financial downturn and subsequent on-going recovery, it is now essential for manufacturers to ensure they maximise their assets and applications to achieve their business goals. As IT has become an increasingly vital service to manufacturers, so too has the requirement for systems not to fail and for performance to remain consistent. In order to stay ahead of the curve, UK manufacturers must utilise the latest innovations in technology. This becomes increasingly important when you consider a recent Government Department for Science report, which highlighted the UK manufacturing industry as one of the sectors that will undergo drastic change in the coming years, as the impact of the Internet of Things becomes more widespread. The Internet of Things is just one of a host of new approaches that will allow manufacturers across the country to gather smarter, ‘realtime’ analytics meaning they can see how and why their factories are performing. However, before manufacturers are in a position to adopt and adapt, they must take a close look at the quality of the IT systems they are currently running. There are many pressure points that manufacturers need to be aware of when it comes to the performance and strength of their IT systems. Ageing assets and legacy replacement are among the costliest hurdles, often requiring replacement to avoid unexpected and unnecessary downtime. Increased competition requires systems which give manufacturers the edge and ability to operate faster and increase productivity. With cyber threats increasing across the globe, security and resilience is now, more than ever, a key aspect of IT systems.

BEWARE – LITTLE THINGS MEAN A LOT…

Identifying these potential issues before they turn into more serious problems is vitally important and there are a number of tell-tale signs that can help manufacturers spot the first signs of an outgrown IT system. For instance, if the cost of maintenance and continued usage of the system become prohibitive, it is time to look at a replacement structure. Similarly, as businesses grow, so too does the amount of data that is generated. If systems are not set up to support this growth then manufacturers could be basing key decision making on false, incomplete or inaccurate data. Accurate data is essential to achieve operational intelligence and drive efficiency. The inability of systems to adapt is a further indication that it is time to reassess IT provisions. This can be identified by businesses spending vast amounts of time and money integrating data from different sources and equally large resources used on system maintenance. The most damaging result of inflexibility can be as the company is growing and expanding into new markets or launching new ranges, the infrastructure and system it is based on is limiting and therefore holding it back. Today’s

PROCESS INDUSTRY INFORMER September 2015

manufacturers need to offer their customers flexibility. Whilst some may want a standard product, others will require variations bespoke to certain markets. Older systems often prevent manufacturers responding flexibly to these requests, leading to lost revenue opportunities. As a company grows, so does its geographical spread. Opening international offices or production sites will only add to the pressure placed on existing systems. These offices, or sites, need to be able to communicate seamlessly. They will all be producing their own data, but to ensure the overall business is operating efficiently, engineers and operatives need access to all the information being produced. If the correct system is in place then data silos are created where potentially valuable data that could drive business decisions is simply wasted. Often the most costly indicator that a manufacturer has outgrown its IT systems is when it becomes over reliant on manual processes – processes that, in an ideal scenario, the system could take on itself. IT is supposed to drive efficiency by making automation processes easy to implement and increase output standardisation. However, if the system is not performing, existing workloads will be added to through the necessity to manually check systems and correct any issues. This said, few companies are able to afford a complete overhaul of their IT systems and infrastructure, so the key to delivering much needed improvement is by managing the existing legacy systems. This can be achieved by carefully protecting and preserving IT investments to ensure that they remain operational and perform to a high standard for as long as possible.

DON’T PANIC, HELP CAN BE AT HAND…

Legacy systems can also be migrated onto new manageable, scalable technology. Legacy IT system migration is the process of transferring data or programs from one computer system, software application or website to another. This may involve physical system migration, when old hardware is no longer capable of meeting the needs of the system or if it has been damaged. It may also take the form of software or databased migration, where files, data, users and many other settings are transferred between systems. Ensuring that the right knowledge and experience exists within organisations can guarantee that IT systems are maximised to work efficiently, delivering the support and services required. However, this does not have to mean employing an entire new workforce of IT specialists. In truth, the skills gap within the IT sector means that more companies are turning to managed services to support their IT systems. This means that a third party can be used to manage and monitor IT systems, allowing manufacturers to benefit from their expertise and knowledge, whilst providing the peace-of-mind that systems are operating as expected and risk and downtime are reduced. Ensuring that factories are secure from cyber threats, operating efficiently and producing to a high quality should be high on any manufacturers list of priorities. What links these separate issues is that they can all be improved by ensuring that IT systems are fit for purpose. Importantly, it is now time for manufacturers to review their plant floor infrastructure and what options are available to them. It comes down to a simple choice – preserve and protect or modernise.

FEATURE

STAYING CYBER SAFE IN INDUSTRY By Jonathan Wilkins of Stafford based European Automation In 2014, the total number of cyber security incidents detected rose to 42.8 million according to PWC’s Global State of Information Security Survey 2015, which you can find at http://goo.gl/ MZR3zg. For those of you that have not done the maths, that is 117,339 attacks per day, every day. And these are just the strikes that were detected and reported.

o comprehend the sheer extent of current threats, antivirus business Kaspersky has created an interactive map. It depicts the number and type of cyber threats in real time. If you are reading this white paper online, I am sure you will agree that it is almost hypnotic. If you are reading offline, I recommend you visit http:/cybermap.kaspersky.com. But the map is also incredibly worrying. The total number of security attacks detected increased by 48 per cent from 2013 to 2014 and there is little evidence to suggest this percentage will decrease in 2015. Despite these figures, it appears that information security programs have actually weakened, due largely to naivety and inadequate investment. In the industrial sector alone, companies reported a 17 per cent increase in detected security incidents in 2014. The resulting financial costs increased by 34%, while research from Barclays suggests that nearly 50% of businesses that suffer a cyber security attack cease trading. This special report analyses the increasing global cyber threat and outlines the value of implementing a business focussed security strategy to ensure the wellbeing of both employees and industrial automated systems.

WHO DONE IT?

The year 2014 featured some of the biggest hacking and cyber security breaches of the decade. It seems nobody was safe, not even the biggest corporate players. eBay, Sony Pictures Entertainment, Apple and Sony Playstation, were all victims of cyber attacks in one form or another. Interestingly, there is one thing most security threats have in common and that is the source. The results of PWC’s survey illustrate that 34.55 per cent of companies asked, reported that the attacks on them last year were estimated to originate from current employees of the company and 30.42 per cent from former employees. These were the two biggest culprits. Statistically, you are far more likely to come under cyber attack because of someone plugging in a corrupted USB stick to your network, than you are to be specifically targeted by a hacker trying to exploit a weakness in an automated system. However, that’s not to say that you shouldn’t prepare for both eventualities. Hackers still ranked highly in the survey - third with 23.89 per cent of companies surveyed pinning their security attacks on them. However, there is another, less prevalent threat that companies should be aware of too. Every business encounters third parties on a daily basis - such as consultants, contractors, suppliers and providers. It is imperative that the information shared

with these parties, on and off site, is restricted to an appropriate level. 18.16 per cent of businesses surveyed responded that they believed their current third party providers were responsible, actively or passively, for their cyber attacks. For example, the US retail giant Target had a considerable breach in 2013 when the personal identifiable information (PII) and credit card details of customers were stolen. The multi-staged hack began with Target’s heating, ventilating and air conditioning supplier, who, it would seem, had access to Target’s network. Credentials were stolen from the US vendor using common malware implemented through an e-mail phishing campaign. This was the hackers’ way in. The moral of the story is that to develop secure systems, companies must implement technical, conceptual and organisational measures to prevent different types of security threats.

WHERE TO START

In a manufacturing context, typical security incidents include infection by malware, unauthorised use, manipulation of data, espionage and denial of service - the latter being an attempt to make a machine or network resource unavailable for its intended users. Defence against these kinds of threats takes more than simply investing in new software or hiring a Chief Information Security Officer (CISO), although these measures are a good start. Changes need to be implemented from the ground up. Before we get ahead of ourselves there are certain steps that should be taken prior to anything else. To evaluate properly the likely threats, system owners must first assess the weak points of that system - including the human element. In an automated environment, this may reveal a scenario in which a property of the whole is considered beneficial from an automation perspective, but detrimental from security one. For example, a remote device that is free to gain access to a programmable logic controller (PLC) without authentication saves time in an automated process. However, from a security perspective this is a definite weak point. It is necessary to identify these weaknesses in order to access risks and take appropriate action. Manufacturers and industrial companies should pay particular attention to three core areas. The first is the weak points that arise due to improper equipment or software implementation. This could be a faulty device or piece of programming. The rise of interconnectivity and the Internet of Things allows everything in a

PROCESS INDUSTRY INFORMER September 2015

factory to communicate using a common protocol, generating a large amount of data. This brings us to the second area companies should focus on: securing the mass data flow so that hackers cannot exploit it. Finally, weak points often arise due to organisational measures, or lack thereof. For example, it is important to ensure that the CISO’s team update operating systems, web browsers and applications whenever necessary. This negates the worry of using a product that has known flaws, which a developer has corrected in a later version. You should implement a corporate policy dedicated to updating software to solve this problem. Overall, it is essential that, during an initial security assessment, the team identify, group and isolate the critical information belonging to the business so that the CISO’s team can properly protect it. This should be the main priority for any company concerned with its cyber security.

NETWORK PROTECTION

One of the most effective means of safeguarding automated production systems is cell protection. This form of defence is especially effective against a number of different threats, including man-in-the-middle attacks, whereby the attacker has the ability to monitor, alter and inject messages in a communications system. Cell protection employs a security integrated component that supervises access to an automated cell. This is often referred to as a doorman, because it plays the same role as its human namesake by deciding who can and who can’t come in. The most common device used for this purpose is an industrial Ethernet communications processor that integrates a firewall and virtual private network (VPN), filtering out attacks and keeping the network connection secure. Cell protection also prevents unauthorised access and control, denial of service attacks and online threats via the office network. However, it is important that risk assessments and security measures don’t focus solely on automated systems. Staff, suppliers and third party providers should also come under scrutiny.

SECURITY VIA EDUCATION

Part of the current problem is that the topic of cyber security isn’t being elevated to a board level discussion in most companies despite the damaging consequences of security breaches including loss of production, reduced product quality and safety threats to both humans and machines. Most governments have created or are in the process of creating, cyber security regulations that impose conditions on the safeguarding and use of PII. Companies that fail to sufficiently protect sensitive information risk financial penalties. Despite this, some companies remain ignorant. Regulations are particularly prevalent across Europe and should serve as an example of what countries that do not yet have legislation should expect in the near future. The US also has mandatory conformance policies when it comes to companies protecting PII. At the beginning of 2104, the US implemented a framework for improving cyber security infrastructure: a set of industry standards and best practices aimed at helping organisations manage cyber security risks. However, these measures have been heavily criticised for not going far enough, especially in light of the recent high profile Sony Pictures Entertainment hacking scandal allegedly involving North Korea. To help educate businesses in the ways of information security, the UK Government has allocated £860 million until 2016 to establish a National Cyber Security Programme. Part of this agenda is to ensure the UK is one of the most secure places to do business online. This comes after it was revealed that 81 per cent of large corporations and 60 per cent of small businesses in the UK reported a cyber breach in 2014.

Under the programme, the Government has developed a cyber essentials scheme to give companies a clear goal to aim for. This will allow businesses to protect themselves against the most common cyber security threats but also advertise that they meet this standard. For more information about the scheme, go to www.gov.uk/government/publications/cyber-essentials-scheme-overview. In addition, a ‘Ten steps to cyber security booklet’ is available for anyone seeking advice on current risks and methods of prevention. The literature outlines important elements when creating a business-focussed security strategy, such as risk management regimes, secure configuration, network security, user privileges, education and awareness, incident management, malware prevention, monitoring and home or mobile access. The security booklet can be downloaded by going to www.gov.uk/government/publications/cyber-riskmanagement-a-board-level-responsibility. Businesses that want to find out more about how to increase their security levels can also access a useful guideline document from the industry standards agency PROFIUBUS & PROFINET International (PI). The Security Guideline for PROFINET was originally developed in 2006 and later revised at the end of 2013. It specifies ideas and concepts regarding how and which security measures should be implemented. It also contains a list of commonly used security acronyms and offers a series of proven best practices, such as the cell protection concept mentioned earlier. PROFINET’s guide can be downloaded by going to http://goo.gl/yT7rKW. The information is out there for companies seeking advice regarding cyber security. However, from the statistics provided by PWC’s survey, it would appear that industrial product companies are already leading the way.

INDUSTRY

On the whole, cyber threats are increasing and yet information security budgets seemed to decrease in 2014. The industrial products market is the exception because it has created budgets to protect itself. According to the PWC security survey, this sector, more than all other surveyed - power and utilities, healthcare, retail and consumer, technology and financial services - appears to understand rising security risks. Moreover, it’s investing accordingly. Information security budgets for industrial products companies have soared more than 150 per cent in the past two years. In 2014, information security spending represented 6.9 per cent of PWC survey respondents’ total IT budget, the highest of any sector surveyed. However, in 2014, security incidents in the sector also increased six fold. So perhaps even a 150% increase is not enough. The result of this investment has been notable improvements in security processes and technologies, as well as training initiatives. However, there is still generous room for improvement.

STAY SAFE

Megatrends such as Industry 4.0, the Internet of Things and big data have driven industrial automation to a completely new level, creating more efficient and sophisticated production lines. Industry is integrating its manufacturing lines with IT layers and the traditional industrial automation pyramid is collapsing due to the need for faster, cheaper and more effective production. However, there is a price for these gains: with greater openness, interconnectivity and dependency comes greater vulnerability. There is a definite need for more training when it comes to cyber security, both at the top and bottom of the manufacturing ladder. Too often businesses slip into common pitfalls - believing they are either untouchable or not a target. If the majority of cyber attacks in 2014 were committed by current employees of the affected company, how many of these do you think were undertaken knowingly? Or were they the result of an individual not fully understanding that his or her actions could lead to security breaches? Understanding that you don’t have to be a desirable target for hackers and that cyber threats can be the result of non-malicious, poor judgement from one employee is key to understanding the risks. Even if management wholeheartedly implements a dedicated cyber security downwards, all it takes is one malware-infected device plugged into the network to cause disruption. We cannot prevent accidents, but it is possible to manage them by instilling knowledge in employees and putting in place reliable monitoring devices and procedures for when an attack occurs. Security training shouldn’t be limited to a one off seminar for the staff and an initial systems upgrade. Patch maintenance and updates need to be carried out as and when vulnerabilities are revealed or new software is released. Senior management need to implement vigorous maintenance and monitoring policies. Security is a constant and evolving concern, not something that can be solved with one quick fix. Risk assessments need to be undertaken for suppliers, providers and contractors and restrictions on information should be put in place. Again, this can’t simply be an initial appraisal. Unified procedures should be written up and followed when dealing with any third party that requires a certain level of information from a business. With financial investment and appropriate attention paid to cyber security infrastructure and procedures, a business will be ready should a malicious external attack take place. Otherwise, a company does not just face loss of production and financial penalties; there is also loss of reputation and potential danger to both machines and humans to consider.

NEWS

SEPTEMBER 2015

SAD NEWS…. On September 7th is was announced that the Flowserve plant was in serious trouble and there are a considerable number of job losses, rumoured to be as many as 180 of the current workforce of 220 . At the time of the announcement, there were no precise details given other than to say that the business was being re-aligned. The company management did say that the difficult universal trading conditions were to be blamed. Acting General Manager at Flowserve Peter Bechus said “It’s a difficult decision to make but a lot of thought was put into this before making the proposals” “ We understand that a lot of people are affected but the business decision was made and we are moving forward”

MOVING UPWARDS...

Membership that is – it’s always good to welcome new members and we have two to announce. First, The Pump Company, who offer a complete range of centrifugal and positive displacement pumps and market pumps for the Process Industry providing solid answers to fluid questions. Secondly, Flowtechnik Ltd, who are a joint venture company between UK Flow Ltd (the UK distribution arm of the E-Holdings group of companies) and Flowtechnik (formerly the process flow metering division of Hydrotechnik UK Ltd). They manufacture and supply flow meters, instrumentation, process sensors, specialist pumps, magnetic couplings and high quality hydraulic components from quality brands.

HOW THINGS CHANGE! 1

GOLF DAY Another successful event was held at Goodwood this year with 56 spirited golfers enjoying a Texas Scramble. Unfortunately, the weather was not with us this year and waterproofs were required for a good part of the day. Nevertheless, everyone agreed the course was excellent as was the service and facilities provided by Goodwood. The day ended with a fantastic meal and presentation of trophies which Jon Bennett of Calpeda hands over the were awarded as follows: trophy to Gary Cox of Flowserve 1st Place – Flowserve

MARKET SURVEILLANCE DEVELOPMENTS Notwithstanding BPMA efforts in the past 18 months to deal with the issue of non ErP Directive compliant Circulators appearing on the UK market it appears the matter is still a major issue. Accordingly BPMA met with the Better Regulation Delivery Office (BRDO) in the summer in an attempt to put further pressure on the National Measurement Regulatory Office (NMRO—the UK Market Surveillance authority in regard to the Energy Related Products Directive –ErP) to take appropriate action. And indeed the NMRO responded and as a consequence BPMA and several CEO`s of affected BPMA members will meet with the NMRO in September to consider courses of action to tackle this ongoing issue of illegal products appearing on the UK market.

2nd Place – ITT Goulds 3rd Place – Grundfos

Longest Drive went to Ray Andrews of Grundfos Nearest the Pin awarded to Paul Pearce of Flowserve Next year’s event will take place at The Vale Resort in Glamorgan on Thursday 19 May 2016 and if you would like to enter a team please contact Jeanne Page at j.page@bpma.org.uk for a booking form.

NEW EUROPUMP HANDBOOK

BUYERS GUIDE 2015/16 edition of the BPMA Annual report Directory and Buyers Guide now available! Contains full guide to pump types, applications and matrix for specifying. Also contains information on BPMA activities, useful articles, UK pump market data and details of products and services offered by our members

Assessing the Energy Efficiency of Pumps and Pump Request your copy now by emailing j.page@bpma. Units – new Europump Handbook - A guide to org.uk understanding and calculating the new EU energy efficiency standards for pumps and pump units. Assessing the Energy Efficiency of Pumps and Pump Units, developed in cooperation with Europump, is the first book available providing the background, methodology, and assessment tools for understanding and calculating energy efficiency for pumps and extended products (pumps+motors+drives). Responding to new EU requirements for pump efficiency, and US DOE exploratory work in setting pump energy efficiency guidelines, this book provides explanation, derivation, and illustration of PA and EPA methods for assessing energy efficiency. It surveys legislation related to pump energy efficiencies, provides background on pump and motor efficiencies, and describes the concept of Energy Efficiency Index (EEI) for circulators and single and multi-pump systems As a Trade Association, BPMA receive KEY FEATURES via their website both pump enquiries • The first book to cover Europump-sponsored research on and project tenders from the UK and energy efficiency in pumps, including coverage of new EU abroad which we are then able to pass guidelines implemented in January 2015 on to our members. • Discusses Product Approach (PA) and Extended Product Approach (EPA) to assessing energy efficiency These enquiries are sent by email • Derives and explains the Minimum Efficiency Index (MEI) circular to all members headed up ‘Pump Enquiry’ or ‘Project To order a copy of the book, please go to: Tender Opportunity’ with the request that the contact details http://store.elsevier.com provided are used to get in touch direct with the enquirer if Europump members receive a 30% discount they are able to assist.

Project Tender Service

Finding a solution

TRAINING

Lecture training - Final dates for 2015 Module 001 Part 1 – 23 November – Pumping Fundamentals Module 001 Part 2 – 24 November – Pump Selection Module 001 Part is divided into two sessions, the first session covers pump performance, construction and selection whilst the second session covers pumping systems and pump operation Module 001 Part 2 covers the basic principles of selecting the best pump to suit a given duty. Visit www.bpma.org.uk/training to download a full explanatory

It is appreciated that not all enquiries will be relevant to you, but always take a moment to read the details—don’t miss an opportunity! BPMA provide this service to all members completely free of charge.

Visit www.bpma.org.uk ‘I

have had three calls this morning already from companies and can now finally proceed with this project—Phillips Consulting SA’

‘An excellent response!

Many thanks—Costain’

THE ENERGY SAVINGS OPPORTUNITY SCHEME (ESOS) & PUMP SYSTEM AUDITS The Energy Savings Opportunity Scheme (ESOS) Regulations 2014 came into force on 17 July 2014 and are a mandatory energy assessment and energy saving identification scheme for large undertakings (and their corporate groups). The scheme applies throughout the UK. ESOS Energy Audits have the potential to increase businesses profitability and competitiveness by identifying cost-effective savings which, if implemented, will improve energy efficiency. The scheme is estimated to lead to £1.6bn net benefits to the UK, with the majority of these being directly felt by businesses as a result of energy savings. ESOS is the UK Government’s approach to transposition of Article 8(4) of the EU Energy Efficiency Directive, which requires all large (non-SME) enterprises to undertake energy audits by 5 December 2015 and every 4 years thereafter. The scheme’s regulations are published on the government’s legislation website http://www.legislation.gov.uk/uksi/2014/1643/contents/made More information about the Energy Savings Opportunity Scheme can be found on the ESOS webpage https://www.gov.uk/energy-savings-opportunity-schemeesos Guidance has also been published to help potential participants in the scheme understand their obligations and on page 43 of the full ESOS guidance document you will see that the ISO/14414-Pump System Energy Assessment standard is referenced as an auditing methodology that can be accepted by “Lead Assessors” approved by the Environment Agency. Accordingly it is hoped BPMA CPSA accredited persons (who are trained according to the IS0 14414 standard) will be recommended by Lead Assessors to undertake the pumping system elements of company energy audits. And bear in mind: • Pumps are the largest consumers of global motive power • Pumping System improvements can deliver up to 40% reduction in energy costs - and therefore improve user bottom line P&L account performance • The fact that BPMA’s CPSA scheme has been designed to help by equipping people with the skills to conduct a Pumping System Audit in accordance with ISO/14414 So when considering auditing your pumping systems, remember the BPMA Certified Pump System Auditor Scheme (http://www.bpma-cpsa.co.uk) has established BPMA as THE body to train and certify personnel who undertake “Pumping System Assessments” as referenced in UK Government Energy Strategy documents BPMA are now offering the opportunity to attend a four day residential course culminating in certification and eventual personal ID “Certified Pump System Auditor” status following approved audits. Course Dates: 9-12 November 2015 Course Venue: Rezidor Park Inn, West Bromwich, West Midlands (1 min from J1, M5) Course fees: £1,500 + VAT (BPMA Members), £1,750 (nonmembers) Fee includes 3 nights (b&b) accommodation Contact j.page@bpma.org.uk for registration form or telephone 0121 601 6691 for more information

The path to a greener future... Efficiency l Strength l Reliability Since January 2015, EU MEPS have stipulated that any new motors on the market ranging from 7.5 kW to 375 kW power output have to meet the IE3 efficiency standard or IE2 efficiency standard if used with an inverter drive. WEG believe that all products should be energy efficient so we offer a complete range of W22 IE2, IE3 and IE4 low voltage motors. Our inverter drives will work with new and existing motors to help you reduce energy consumption. We have adopted the energy efficiency standard for our hazardous area motors although they do not yet fall within the scope of the regulations so our W22X motors are available to IE2, IE3 and IE4 efficiency rating.

To take your first steps on the path to a greener future visit www.weg.net LV

Watt Drive high performance gearboxes are built to withstand the toughest industrial applications meeting the demands for operation across different industries. Individually, our gearboxes, drives and motors are amongst the most energy efficient available. Together they give you unbeatable levels of reliability and performance

WEG LAUNCHES COMPACT HYDROELECTRIC GENERATORS WITH SHORTER LEAD TIMES WEG, a global leading manufacturer of drive technology, has launched two new series of efficient, high quality and compact hydroelectric generators - GH11 and SH11 - with up to 70% more power density than previous models. As a result, engineers can benefit from a low weight and space-saving solution for easier installation. The new generators are also available with shorter lead times thus helping hydroelectric power stations to reduce downtimes and increase productivity. With rated capacity from 500 to 18,000 kVA., the GH11 and SH11 8-pole to 36-pole hydroelectric generators are available with frame sizes from IEC 630 to IEC 1800 and output voltages from 400 V to 13.8 kV at 50 or 60 Hz. The hydroelectric generators provide excellent reliable performance. The GH11 series is designed for standard applications with relatively small and simple turbines, while the robust SH11 series is designed to meet more demanding specifications for turbines and complex hydroelectric power stations. The SH11 generators have a modified mechanical and electrical design that allows them to be operated with higher inertial forces and relatively large axial and radial loads despite their compact construction. They can also withstand adverse conditions such as high continuous speeds or load shedding. WEG’s generators are easy to install and commission in existing plants because the design is based on a standard technology platform. WEG has standardised the production of the new WEG3793 The GH11 series of hydroelectric generators offer generators and key components are provided in the preliminary design stage. As a result, cost-effective and smart solutions for common hydroelectric the manufacturing process is therefore similar to series production and end users can benefit applications without forcing users to sacrifice efficiency or quality from shorter delivery times. The generators are highly versatile and can be easily adapted to individual application specifications. “WEG is committed to helping its customers increase efficiencies throughout its process, and this includes reducing downtime. By delivering products to customers as fast as possible means they can get their process up and running quickly, therefore maximising productivity and profitability,” says Marek Lukaszczyk, European & Middle East Marketing Manager at WEG. Both the GH11 and SH11 can be installed either horizontally or vertically and are available in versions for brushless excitation (with or without an auxiliary exciter) or static excitation with brushes.

For further information contact WEG Electric Motors (UK) Ltd. Tel: 01527 513800 E-mail: info-uk@weg.net or visit Web: www.weg.net/uk.

Highly efficient water-supply unit (non self-priming) ready for connection with 2 to 4 vertically arranged Helix EXCEL stainless steel high-pressure centrifugal pumps switched in parallel; each pump is equipped with an integrated air-cooled, high-efficiency frequency converter and an EC motor.

You’ve got enough on your plate. You can trust Wilo.

You can trust Wilo.

Fully automatic water supply and pressure boosting in residential, commercial and public buildings, hotels, hospitals, department stores and for industrial systems Pumping of drinking water, process water, and cooling water into building management systems For more information visit www.wilo.co.uk or call 01283 523000

Pioneering for You 4

REDUCE COSTS WITH A SUNDYNE HMD KONTRO SEALLESS SUMP PUMP Sundyne HMD Kontro has extended its range of vertical inline sealless pumps with the development of a sump pump variant. The new GSPVS, which meets the requirements of API 685 (as applicable to this style of pump) and is fully ATEX compliant, has been designed for use in tank farms for tank fuel transfer, as well as in oil and gas refineries, chemical and petrochemical processing plants. The vertically mounted GSPVS pump provides all of the benefits of a magnetic drive pump in a compact package, using fewer parts with no seal systems for reduced cost operation. Composed of modules which can be joined to reach a total assembly length up to five metres / sixteen feet, the GSPVS is mounted on a base available to ANSI B16.5 or to customer specific requirements, including lifting points as standard. The modular construction uses a flexible jaw coupling to join drive shafts and to absorb misalignment, decreasing vibration and increasing life expectancy. Greased for life ball bearings are used along the column, removing the need for lubricating or cooling the intermediate sleeve bearings using system fluid. The use of labyrinth bearing seals and a suction strainer avoids external contamination to maximise seal and lubrication life. Sundyne HMD Kontro has more than twenty-five yearsâ&#x20AC;&#x2122; experience in API applications and over a sixty-five year heritage in magnetic drive technology. It was the first pump manufacturer to develop a sealless pump. With stricter demands for the safety and welfare of both personnel and the environment being imposed, sealless pumps are playing an increasingly important role. Sundyne HMD Kontro is continuously developing and extending its range, as improved magnet drive technology enables ever more efficient and powerful pumps to be built, widening the application scope of this versatile pump format.

A copy of the new GSPVS brochure can be downloaded from the Sundyne HMD Kontro website at www.hmdkontro.com.

ACT NOW TO BEAT EU CHANGES TO WASTEWATER TREATMENT REGULATIONS - In the wake of changes to EU wastewater treatment legislation, the right preparation and early investment in accurate chemical metering makes commercial sense - Both municipal and industrial wastewater processors must take heed - Better chemical metering is an important step in that process

by Andrew Ashton, UK Sales Manager, Watson-Marlow Fluid Technology Group Over the past few months, signals have been emanating from Brussels that hint at tighter wastewater treatment regulations. For instance, not only has Carlos Moedas, EU Commissioner for Research, Science and Innovation, recently been calling for better treatment systems for wastewater, but former Environment Minister, Janez Potocnik, has backed a Friends of the Earth report lobbying for improvements on water reporting and pollution.

PUNITIVE MEASURES

Time is of the essence regarding this increasingly urgent matter, as a number of recent actions indicate. Since March of this year, the EU Commission has taken France to court over non-compliance with legislation on urban wastewater treatment, and asked Poland to bring its national laws on groundwater protection into line with the Groundwater Directive. Put simply, recent EU documents on water policy contain key recommendations that encourage action on industrial plants and pollution. History shows that such recommendations and encouragements are often precursors to law.

UNDERCURRENT OF CHANGE

Clearly, there is an undercurrent of change with regard to wastewater and its associated treatment, for both municipal and industrial processes. As with all change, the trick is to make improvements ahead of the game, which means that water companies, the treatment chain and industrial water users, need to start thinking about correct and thorough preparation, as well as investment in the right technology. Better treatment of wastewater, through improved chemical metering technologies, is among the primary ways to help. Better chemical metering is important for many reasons. For example, to help reduce operational expenditure, higher concentrations of chemicals are being used by plants to help reduce transportation, handling and storage costs. This increases the demands on metering pumps for higher accuracy, higher viscosities and greater chemical compatibility. As a result, the inherent precision and performance attributes of the latest peristaltic chemical metering pumps are proving increasingly popular.

COMPATIBLE TECHNOLOGY

Beyond precision, an increase in chemical concentration requires the pump fluid contact materials to have stronger chemical resistance. Although this can prove problematic to many pump types, in peristaltic metering pumps, nothing but the tube touches the fluid, eliminating the risk of the pump contaminating the fluid, or the fluid contaminating the pump. This also makes this pump type ideal for high concentration or aggressive chemicals. The absence of ancillaries, such as back-pressure valves, pulsation dampeners, degassing valves, foot valves, strainers and float switches, all of which are typically required to support a diaphragm pump installation, is another major benefit. As a result, peristaltic metering pumps, which instead feature a single piece pumphead, offer simpler configuration, reduced spares inventory and lower total cost of ownership (TCO).

MAINTAINING EXCELLENCE

Maintenance remains a key driver in the water treatment market. With the recent recession and economic conditions that remain challenging, many plants have seen budgets squeezed. As a consequence, there has been reduced spend on infrastructure and operations, which has led to poorly maintained facilities without adequately trained staff to repair them. This makes switching to peristaltic metering pumps – which unlike gear pump, piston or diaphragm pumps commonly used for chemical metering, feature no expensive seals, valves, diaphragms or rotors to leak, clog or corrode – a shrewd business move. For example, a 520DuN/REM peristaltic pump from WMFTG has met the immediate needs of three chemical dosing schemes implemented recently at

various Severn Trent Water facilities. Deployed as part of a temporary dosing rig constructed by engineering group, Costain, the three schemes to date have seen the peristaltic pump used for ferrous chloride and ferric sulphate dosing. The feedback has been very positive: “In my mind there are so many things that can go wrong with a metering pump,” says Paul Pearson, Process Commissioning Engineer at Costain. Only the tubing requires replacement, which is quick and inexpensive, and provided this is done at the recommended intervals, there won’t be any problems. We’ve certainly had no issues so far.”,” he concludes. Peristaltic metering pumps score well against other pumps types in a number of performance areas. For instance, while a typical diaphragm metering pump a flow range of 100:1, this is expanded to 875,000:1 with a peristaltic pump.

TRANSPORTATION AND ACCURACY

The accuracy of a peristaltic pump is 0.5% in comparison with the 5% accuracy of a typical solenoid pump. Chemicals are not cheap, hence accuracy can be enormously beneficial in terms of saving costs’. For example the Togliatti, Russia plant of steel wheel manufacturer, Mefro Wheels, has opted to use our latest Qdos 30 metering pumps at the facility’s water treatment unit. As well as featuring patented ReNu pumphead technology, which is fully contained for safe, tool-free maintenance, the pump’s metering accuracy clearly caught the eye of Mefro engineers. “When compared with some manufacturers of metering pumps, including diaphragm types, we were surprised by the high accuracy characteristics declared in the brochure,” says a Mefro spokesman. “However, following operational measurements, these characteristics were substantiated completely.” Consider this; to reduce the cost of transporting chemicals, more and more companies are using higher concentrations. For example, calcium hydroxide in suspension is normally offered at 18%; but to be competitive on transportation, this is being increased to 45% in the UK. Higher concentrations require greater accuracy to ensure that chemicals are not over- or under-metered.

MORE ADDED VALUE

Boosting the added value offer, peristaltic pumps do not require pumped fluid to be continually present, which means the pumps can run dry without costly downtime or repairs. Furthermore, the recovery of the tube as part of its operating principle creates a powerful self-priming action that allows the pumps to move liquids containing entrapped air. Peristaltic metering pumps also offer reversible action, so if a blockage should occur it can be cleared at the flick of a switch.

the use of modern pumphead technology on peristaltic models ensures safe containment.

FLOCCULATION

Many plants use diaphragm pumps to perform flocculation, The use of common clarifying agents such as ferric chloride can lead to clogging - an unwanted effect that increases both maintenance and process downtime. Moreover, environmental conditions such as temperature, affect fluid viscosity and consequently diaphragm pump performance. In fact, most diaphragm pumps struggle to pump viscosities of 2500 cP or more. Typically, flow must be reduced to 25% and the system designed sufficiently to achieve accurate performance. Conversely, the latest peristaltic pumps deliver accurate metering even with fluctuating viscosity, while their powerful suction capability eliminates the need for a day tank or specialist piping schemes.

HIGHER FLOW OR HIGHER VISCOSITY?

For applications where extremely high flows or product viscosity are present, robust hose pumps can provide the solution. Market leading hose pumps deploy heavy duty bearings within the pump rotor, eliminating overhung load. In addition, high torque gearing aligns directly to the pump housing and is protected by a buffer zone. Among the key features of hose pumps are: suitability for high viscosity and/or high flow applications; suction lift capability to 9 metres; dry running and selfpriming; simple design; no slippage (allowing true positive displacement for accurate and repeatable metering); no ancillary equipment; and full reversing capability to blow out suction and drain lines safely. Convenience food manufacturer, Greencore Group Plc is an excellent example of a business that has achieved significant savings in downtime and repair costs on the water treatment plant Greencore thanks to the installation of a Bredel 50 high pressure hose pump. At this Yorkshire site, our technology is used for dosing a magnesium hydroxide solution [Mg(OH)2] that helps correct fluctuations in pH levels caused by food effluent, resulting from frequent wash-downs. Switching from a ‘budget’ dosing pump to the this model means there are no longer any abrasion issues leading to downtime or repair, thus reducing costs. According to Greencore Group, the pump “paid for itself extremely quickly”

PRE-EMPT CHANGE – AND START SAVING NOW

In general, smarter water management and pumping technologies represent the optimum strategy for treatment facilities moving forward. This is because water is on course to be scarcer than oil by 2030, with demand outstripping water supply by 40%. Close to half the world’s population will be living in water stressed areas. And yet wastewater reuse stands at just 2.4% of all water withdrawals globally. Public attitudes to wastewater reuse will need to change, with greater levels of chemical metering becoming a necessity.

With the tides of change clearly beginning to shift in regard to wastewater regulations, organisations and companies should grasp the chance to improve performance. In the first instance, getting ahead of potentially tighter legislation can provide a certain level of futureproofing. Secondly, it can save money when competitor organisations are later rushing to install the systems required to catch up. In short, there’s no sense in waiting; embedding the best wastewater treatment systems not only begins to save money immediately, it pre-empts changes and places businesses in a better position to win new contracts.

APPLIED SOLUTIONS

Among common water treatment applications is disinfection using chemicals such as sodium hypochlorite, which is known to create gas locking and crystallisation in diaphragm pumps. When metering disinfectant, flow rates and pressure changes can fluctuate, impacting metering accuracy. Diaphragm pumps are often set to ‘over-dose’ to ensure water quality is maintained as they are frequently not accurate below 30% of their peak flow. For sodium hypochlorite this “over-dosing” usually results in excessive levels chlorine which need to be subsequently removed, thus increasing the quantity of dechlorination chemicals required. In contrast, class-leading peristaltic pumps deliver predictable, accurate metering at variable pressure, even in fluctuating process conditions. Gas locking and crystallisation issues are also eliminated. A related industrial water treatment process is pH adjustment, as water pH influences the effectiveness of disinfection. Furthermore, accurate pH control is critical to meet water standards and ensure process continuity. However, metering alkalis such as calcium hydroxide, or lime slurry, creates issues with mechanical damage to the pumps due to the abrasive nature of the chemical, while metering acids carries safety implications and can corrode pipework and equipment. Conversely, peristaltic pumps minimise pH ‘overshoot’. In addition, suspended solids are handled with no risk of clogging.

REAGENT DOSING

High accuracy to optimise yields is a prerequisite in applications such as reagent dosing. Here, peristaltic metering pumps deliver linear and accurate metering across the flow range, improving the efficiency of flotation cells and increasing mineral yields. Reagents such as sulphuric acid are hazardous and can damage pumps, but

UK FLOWTECHNIK’S REVOLUTIONARY NEW PROGRESSIVE CAVITY PUMP Accurately dispense fluids and pastes containing up to 60% fillers.UK Flowtechnik Ltd, sole agent for the UK for the Beinlich Pump, synonymous with Gear Pumps for many years has recently launched a new small-scale progressive cavity pump, the VISCO.pump®. This innovative pump has been designed specifically to enable the precise dosing of fluids and pastes proportional to speed. The VISCO.pump® can be used in many areas of industry and its pumping principle allows for precise dispensing of beads and dots as required, normally as part of an automated process. The pump is well-suited to applications such as; adhering to magnets in motors and loudspeakers, for LED strips, glob topping, dam-and-fill processes, underfilling, for sealing housings, greasing motor shafts, applying cooling paste on chips or for dispensing PU. The newly developed pump is able to accurately dispense liquids and pastes with up to 60% filler content. The dosing quantity can be set to be absolutely linear, with a dosing accuracy and repeatability of ± 1% or less. With such a linear volumetric efficiency and high predictability on delivery, this makes the pump almost “Plug&Go” when regarding the control theory, making handling and using the pump considerably easier than other pump designs and also reduces the cost of installation and commissioning. The VISCO.pump® can be retro-fitted into existing systems if required. Richard Price, UK Flowtechnik’s Managing Director, said, “The size of the VISCO. pump®, combined with its meticulous precision in continuous dosing of fluids and pastes, sets it apart from other pumping technologies currently available and we’re delighted that we now have this innovative solution which delivers continuous dosing across a broad range of applications with exceptionally high accuracy and repeatability. “It is generating considerable interest across all the major advanced engineering sectors, from aerospace and automotive, through to electronics, medical and pharmaceuticals.” “We are constantly faced with new challenges using existing pump technologies. At times gear pump technology is not the best choice for dosing and dispensing of fluids, particularly those containing materials that are shear-sensitive or containing solids. The new technology is based on the volumetric principle of an endless or infinite piston where the core components; rotor and stator form a perfectly sealed metering chamber. The eccentric movement of the rotor allows for a low-shear motion of the medium from one chamber to the next chamber without damage to the media.”

KSB PUMPS HELP AERATE ANGLIAN WATER

Pumps are big energy consumers that currently account for 10% of global electricity and many are needlessly inefficient. Today by focussing on changing to high efficiency pumps that incorporate advanced motor technology, an average pump’s energy consumption can be reduced by up to 60%. Efficiencies are a function of good pump design and not purely a standalone benefit so it is important to understand the true value of pump efficiency. This means that to achieve the highest overall efficiency the complete installation needs to be examined in terms of the entire system, as opposed to just viewing the pump in isolation and being able to deliver real energy savings with a short return on investment, of less than 2 years is now reality. By thinking beyond the pump and taking the entire pumping system into account it is possible to optimise the way pumps, drives, controls & protection, measurement and communication units work together as part of one system. A manufacturer like Grundfos, can incorporate specific demands with our application expertise, take these requirements, and translate them into state-of-theart pump intelligence - for any application. This approach that is both integral as well as encompassing the integrity of the entire system and is called Grundfos iSOLUTIONS. The need to optimise and control speed is something that will continue to gain in importance within areas such as building services, industry and wastewater applications and therefore the ability for systems to become increasingly synchronised, will also continuous to play a more significant role.

KSB have supplied two new Amerex KRT pumps with specially fabricated Duckfoot for Jet Aeration tank at Anglian Water’s Southend. The need for energy savings, improved carbon footprint and lower whole-life costs is becoming an important driver for innovation in Anglian. As a result KSB Amarex KRT duty standby pumps were installed in their Jet Aeration tank at the Southend site to replace existing pumps. KSB Amarex KRT is a vertical, single-stage submersible motor pump in close-coupled design. It is available with various impeller designs and can handle all types of abrasive and aggressive waste water in water and waste water engineering. The Jet Aeration tank was commissioned and built at the Southend site during the mid 1990’s by Anglian Water and serves two functions: Transfer of atmospheric oxygen into the liquid and the agitation of the tank contents. The Jet Aerator consists of three components: The KSB Amarex KRT pump which provides recirculated and pressurized liquid to the jets, the air blower which provides oxygen to the submerged jet at the necessary pressure; and the jet assembly itself. A twin guide rail system was supplied for installation using a specially designed and fabricated straight-pattern duckfoot by KSB Ltd. Two submersible KSB Amarex KRT pumps were installed at the outlet base of the jet aeration tank, with suction level at the pump at 0.5m, discharging to a 400mm GRP pipe down the centre of the 32m long x 12m wide tank. The KSB Amarex KRT pumps are rated at 370 l/s delivering against a static head of 5.18m and friction head of 0.91m, giving the total developed system head of 6.1m. A 200mm air pipe is mounted above the water pipe and the air/ MLSS flow is Jet Aerated through 32 nozzles. Efficient aeration is all about maximising the contact of oxygen from air with the wastewater. At the heart of the process in the Southend Jet Aeration tank are the KSB pumps. Liquid is discharged through the inner jet nozzle as a high velocity jet stream, and spreads slightly as it travels through the outer air/liquid nozzle. Within the air/liquid nozzle, the spreading liquid jet stream traps air prior to discharging into the basin. The high velocity air/ liquid cuts through the static basin liquid until the momentum dissipates creating a ‘’plume’’ of air bubbles which rises to the surface. Due to the turbulence caused by the large difference in velocity between the jet and basin liquid, the bubbles formed are quite small and create a powerful air-lift effect. Mixing is therefore caused by the liquid jet action, and by the flow of liquid/bubbles in the plume rise area. As air flow to each nozzle increases, more air will escape the plume and rise directly over the jet as larger bubbles. In order for the jet to operate properly, air must reach the nozzle properly. This means that an equal amount of air must reach each nozzle, and the jets must all be at the same elevation. Project Manager Alison Taylor of WRNI stated; ‘This Project has been delivered in an integrated collaborative approach with KSB working alongside AW Operations and the @one Alliance to meet the demands of the site in a timely, efficient and effective manner’.

For more information or a Literature request contact Grundfos ltd, Tel: 01525 850000 E-mail: grundfosuk@grundfos.com Web:www.grundfos.co.uk

For more information contact KSB Ltd, Loughborough, Leicestershire. Tel: 01509 231872 E-mail: Sales@ksb.com Web: www.ksb.co.uk

GRUNDFOS iSOLUTIONS - PUMPS AND SYSTEM IN HARMONY

NEW CONFIGURABLE BY DESIGN COMPONENT SEAL RANGE LAUNCHED BY AESSEAL® AESSEAL® has launched a completely reengineered modular component seal range that aims to raise. the industry standard and allow configurable component seals to be built to order. With 10,000 product lines available from stock and over 44,000 product permutations configurable, it offers customers the greatest possible product availability, quality assurance, and service. The new range, in development for almost 4 years, incorporates unique patented features which help to improve pump reliability. These features include; improved seal face cooling through directed barrier fluid flow systems, hydraulically balanced seal face technology and “plug in” designs to improve performance and reliability. Incorporating a build to order philosophy the new range offers a larger selection of product variants, and standard product lines can be easily adapted to suit the customer’s requirements. By manufacturing the majority of the parts, and having full control of the supply chain AESSEAL® can offer a portfolio of seals suitable for the Food and Beverage industry. These seals are manufactured in accordance with Good Manufacturing Practice (GMP), assuring compliance with EC2023/2006, and allowing customers to be confident that they are sealing their equipment with seals that meet EU, FSA and FDA requirements. The new product range is further supported by the AESSEAL® Seal Selection Application enabling an equivalent AESSEAL® component seal to easily be selected knowing just the pump type, competitor seal reference, or dimensional information. Project Manager Tom Broadbent stated; “It has been a huge undertaking that not many companies would take on, but we now have the same modular build to order business model in our Component Seal Range portion of our business as our cartridge seals, allowing us to have complete control of the design, manufacture and supply of component seals so that we can provide our customers the exceptional service they expect from AESSEAL”. For more information contact AESSEAL Plc, Rotherham, South Yorkshire. Tel: +44 (0) 1709 369966 E-mail: enquiries@aesseal.com Web:www.aesseal.com

SPP PUMPS DELIVERS INCREASED EFFICIENCY & EASE OF MAINTENANCE TO NORTHUMBRIAN WATER SPP Pumps, a leading manufacturer and global supplier of centrifugal pumps and systems, has recently completed a major refurbishment project for Northumbrian Water, in association with consultants Amec and the appointed contractor BAM Nuttall. After almost 40 years of continuous service the pumps at Northumbrian Water’s Great Lumley Raw Water Pumping Station had reached the end of their useful life. Pumping water from the River Wear along a two kilometre pipeline to Great Lumley Water Treatment Works, maintenance had become ever more frequent and in order to ensure the site was fit for future generations, replacement was essential. Working closely with consultants Amec and supporting the appointed contractor BAM Nuttall, SPP Pumps used its expertise and engineering excellence to provide a solution that delivered maximum efficiency, performance, operability and total cost of ownership. Four SPP LLC GT20A 4 stage dry well mounted vertical turbine pumps were specified and installed to provide a true whole-life cost solution, with SPP’s unique dry well pump suction connector ensuring that vital installation dimensions and a water-tight solution were delivered. A critical factor in the installation was the need to maintain water delivery throughout the refurbishment process, just one of the challenges associated with the project which also demanded the resolution of several key points namely: o Low net positive suction head available (NPSHa) o Severely limited space o Three fixed connection points with no flexibility- suction bend, discharge pipe and motor room floor o No discharge thrust block to restrain momentary back thrust and pump movement on start-up and shutdown Stuart Wallis was SPP’s Sales Manager (Water). He explains how the company’s depth of engineering knowledge and innovation enabled the delivery of the perfect solution: “The SPP Water Business Unit worked closely with our engineering team to develop an innovative adaptor, we then mounted and assembled the suction connector onto the clients duckfoot bend. This complex installation was completed to programme and, when commissioned, the suction adaptor met all the challenges, performed as designed and together with the rest of the installation represents the very best in engineering solutions.” For Northumbrian Water, Hedley Young, Project Manager - Investment Delivery - commented: “We have gained a solution that gives Great Lumley Water Pumping Station a more secure supply of water, more efficient and easy to maintain pumps and a cost-effective whole life installation to continue delivering the best customer service.”

For more information contact SPP Pumps, Reading, Berkshire. Tel: 0118 932 3123, E-mail: enquiries@spppumps.com Web: www.spppumps.com

THE EXTENDED RANGE OF MAGNETA ERP COMPLIANT CIRCULATORS FROM

SMEDEGAARD MAGNETA

ErP compliant circulators represent the latest innovation in pumping technology from Smedegaard. Chris Barrett Managing Director of Smedegaard Pumps Limited says ‘When it comes to maintenance and refurbishment a major problem can be encountered when the pump purchased is substantially larger in physical size when compared to unit in situ. No such problem exists for the installing engineers who choose Magneta. Not only is Magneta extremely compact when compared to competitor models, it is also designed with superior advanced technology in a user friendly package benefiting the installer and consumer. The simplicity for the customer is further enhanced as all models are supplied as standard with full BMS capability and can be programmed by the use of ones finger.’ MAGNETA ADDITIONAL BENEFITS: ENERGY EFFICIENT

• Future-proofed optimised efficiencies, exceeding future energy efficiency regulations. • Magneta models are single phase IP44 Advanced Technology – Simple to use with no gimmicks • Commissioning is straightforward with the press & turn dial. • Integrated display and symbols indicating the operating mode. • Dual pump operation with auto changeover (integrated interface). • Integrated protective and manual functions.

COST-EFFICIENT

• High-efficiency technology combined with speed control • Advanced Eco Mode offer maximum savings. • Fully integrated communication interfaces that save on both investment and commissioning costs.

VERSATILE

• Magneta covers a broad application range spanning from heating to cooling with fluid temperatures from -10°C to +110°C. • Comprehensive product range with standard pipe connections.

SAVE UP TO 50% OF ENERGY COSTS 10% of global electricity is consumed by pumps – did you know that? Not only that, but as most are needlessly inefficient, they offer huge potential for a wide range of organisations to save up to 50% pump energy costs. Grundfos Pumps have been at the forefront of energy optimised pump development for years, they take real pride in their achievements and their approach to sustainability. Today this leading edge approach has taken yet another step forward with the introduction of a specialist Energy Pack that combines a plethora of useful information that can help you to save money. Finding out what energy savings you could make is now even easier as Grundfos can provide a range of diagnostic tools such as an Energy Check or Pump Audit that will establish the current pump system performance. Not only that, but these tools also provide various post-analysis reports that include details regarding the potential savings and payback periods as well as various pump options you could opt for. So if your priority is cost reduction, CO2 savings, ROI, water usage reduction or simply receiving advice on your current installations, Grundfos have the tools, expertise and integrity to help you to achieve your ambitions. Find out more by visiting www.grundfos.co.uk and see how you can use your energy more wisely. For more information or a Literature request contact Grundfos ltd, Tel: 01525 850000 E-mail: grundfosuk@grundfos.com Web:www.grundfos.co.uk

ITT RELEASES I-ALERT®2, BREAKTHROUGH EQUIPMENT MONITOR WITH BLUETOOTH® SMART CAPABILITY We are excited to officially launch today the i-ALERT®2, a BluetoothSmartenabled machine health monitor that allows customers to identify potential problems before they become costly failures. It tracks vibration, temperature and run-time hours and wirelessly syncs the data with a smartphone or tablet through the iALERT2 mobile app. The i-ALERT2 combines the latest in Bluetooth low-energy and sensor technologies commonly used in the newest consumer health and fitness trackers and smart watches such as the Apple Watch and Fitbit®. The i-ALERT2 is the first to successfully integrate these technologies into an industrial package. It is engineered and rated for use in a wide range of industrial environments. It is chemical resistant, rated for extreme temperatures (-40 to 84°C, -40 to 183°F) and is rated to operate in environments with explosive gases, dust and fibers. “The breakthrough development of i-ALERT2 is industry-changing. It further solidifies ITT’s continued commitment to providing customers with the most innovative monitoring and maintenance programs,” said Aris Chicles, president of ITT’s Industrial Process business. “ITT’s i-ALERT2 delivers sophisticated technology so economically that it extends the practical reach of in-plant monitoring systems to all types of machines, enabling rapid connection of industrial machines to the Industrial Internet of Things,” said Dan Kernan, Global Product Director, Aftermarket Solutions, ITT’s Industrial Process business. With 24/7 monitoring, a wireless range of up to 100 feet (30 meters) and the ability to scan multiple i-ALERT2 devices at once with a mobile device, customers will be able to quickly and safely inspect multiple pieces of equipment and be alerted of potential problems before they become critical failures. “Customers will be able to spend less time collecting data and more time solving problems,” Kernan added. Through the i-ALERT2 mobile app, customers can now view real-time and historical data, diagnostic information and machine records. This provides them with the data necessary to make informed decisions. ITT’s i-ALERT®2 is available three ways: · Retrofitted to any rotating equipment in the field, · Included with an equipment repair or upgrade through ITT PRO Services, or · Added to newly purchased ITT pump equipment. The i-ALERT2 will be available globally to major industrial markets. Shipments will start in early July and the iOS mobile app will also be available for download then on the App Store on iTunes with an Android version to follow. For more information on ITT’s i-ALERT2 visit www.i-alert.com or follow the @ITTPROServices Twitter handle.

For further information relating to the BPMA please contact British Pump Manufacturers Association, National Metalforming Centre, 47 Birmingham Road, West Bromwich B70 6PY, UK Tel: 0121 601 6350 Fax: 0121 601 6373 E-mail: enquiry@bpma.org.uk or visit our website: www.bpma.org.uk The BPMA takes no responsability for the statements, claims or opinions expressed in this Newsletter

FEATURE

HOW EFFICIENT ARE YOUR MOTORS REALLY? Around the world, legislation relating to electric motor efficiency is tightening in an attempt to reduce carbon emissions and damage to the environment. However, far less attention is paid to some of the practicalities. Here, Lucie Hodkova of Exico looks at how best to determine the efficiency of an installed motor.

otors are the greatest consumers of electricity in the world, with about 70% of all power generated being used by them. Since the Rio Earth Summit a generation ago, there has been a continuous effort to improve motor efficiency, with much effort being put into drafting efficiency standards and new testing methods for newly manufactured motors, which get gradually tighter over the years. However, this approach misses the point that there is a huge number of motors already in use around the world and their efficiency does not come under anything like so much scrutiny. So, a review of the motors in your place of work may well lead to the identification of significant improvements to your energy efficiency, carbon footprint and – perhaps most importantly – saving on your utilities bill. If you use machine tools, automated manufacturing systems, conveyors, or other ‘technical’ equipment, each of these is likely to use a number of motors. If you have air-conditioned offices, there will be motors driving pumps and fans. Medical equipment, displays, test stands, lifts, escalators, extractor fans in kitchens and laboratories are all motor-driven and, typically, their efficiency may never have been checked! All motors should have their efficiency checked and it may be best to start with those motors that are used a lot; if a motor runs constantly or for long periods, any inefficiency will have a compounding effect over time. Other motors that would be worth investigating early include those that are more than 7–10 years old, that have been repaired or rewound, that were originally installed for one purpose but have since been switched to a different duty, or those that appear to be oversized for their role. In essence, a motor’s efficiency is the ratio between the electrical power input to the motor and the mechanical power it outputs. Both types of power are measured in kilowatts or horsepower, so are directly comparable. The Energy-related Products (ErP) Directive however changed the testing method of how the efficiency has been calculated. This means that the IE efficiencies for a particular motor may be declared lower than it was under EFF efficiency rating scheme. All motors have a rated load, but most are designed so that they run over a range of loads. Typically, the load will be 50% to 110% rated load and generally, motors are at their most efficient at 70% to 80% load. The dropoff in efficiency can be very significant outside of this small optimum window, particularly in smaller motors. Fortunately, there are several quick and easy ways to check that a motor is optimally loaded. The simplest is probably to feel its temperature (be careful, it could be very hot). If it is unusually warm it is probably overloaded. The next step is to check the nameplate values on the motor and compare these with the calculated load. This will require a little technical knowledge and some interpretation. It is important to note that the stated values for the motor are

only true at the rated motor voltage, so the supply voltage must be checked too. Further, the total load on the motor may be the sum of several separate loads including the driven load and mechanical losses in the transmission system. At this point power factor may need to be considered. Power factor is the ratio between the theoretical or calculated power being supplied and the actual power delivered to the motor. Again using a multimeter, the power in the mains near the motor can be measured. If a power factor correction unit is present, the theoretical and actual values will be very similar giving a small power factor ratio. Larger power factor ratios must be incorporated into relevant calculations. The next step is to calculate the power output. A simple practical method to do this is to compare the rated and actual output speeds of the motor. The rated speed is calculated from the theoretical speed of a motor and is related to the frequency of the supply and the number of poles in the motor. The actual speed can be measured using a tachometer, strobe light, calculated from production rates etc. There are other methods for calculating motor efficiency; these may include special devices, computer models or complex analytical processes. In practical terms, the best answer may be to bring in an expert, who will probably be able to check ten motors in the time it would take you to do one! There is no absolute answer to the question ‘What is acceptable efficiency for an installed motor?” In each case you have to compare the current efficiency to the potential improved efficiency and work out the energy/cost implications over the duty cycle and remaining life of the installed motor. Once you have determined the efficiency of each motor you have to decide whether to accept it, rebuild it, or replace it. As a general rule, smaller motors are better replaced than repaired; it’s a cheaper option and automatically ensures that the latest efficiency standards are being met. With larger motors, the repair/replace decision is harder and unique to each situation.

OF:

HOWEVER, WE CAN DEFINE A RULEOF-THUMB STRATEGY ALONG THE LINES

· Motors that are significantly oversized or inefficient should be replaced with properly sized ones that meet current efficiency standards fairly urgently. · Motors that are moderately oversized or somewhat inefficient should be replaced when appropriate. · Motors that are properly sized but older should be replaced with modern high efficiency units when appropriate. · Sometimes, fitting a variable-speed drive to an existing motor will pay significant efficiency dividends. · Check the duty cycle of each motor: if there is a lot of idling time, consider PLC control to switch it off instead. · Some motors are deliberately oversized so that they have a bit of extra power in reserve to overcome stiction, blockages, icing, etc. A properly sized motor and variable-speed drive will provide the same effect far more efficiently. · And finally, developing a motor management strategy may be best done with the help of your expert.

PROCESS INDUSTRY INFORMER September 2015

FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves

PFA LINED GEAR PUMPS SUIT AGGRESSIVE OR HIGH PURITY LIQUIDS When pumping applications involve aggressive liquids such as inorganic acids, bases and salts, or those that are regarded as high purity where contact with metallic components must be avoided, the Liquiflo Polygard Series pump are the ideal choice. These PFA lined magnet drive gear pumps are perfect for accurate and reliable pumping of challenging liquids such as Hydrochloric Acid, Ferric Chloride, Sulphuric Acid, Hydrofluoric Acid, Sodium Hypochlorite, Nitric Acid, Sodium Hydroxide and Chromic Acid. Available through MICHAEL SMITH ENGINEERS these pumps feature nonmetallic wetted parts and offer the important characteristics of zero leakage and therefore safer pumping. They are available in seven sizes in both DIN and ANSI flanged connections and provide flows up to 47 lit/min at differential pressures to 7 bar and they can operate at temperatures to 90ºC. Among the advantages of PFA lined stainless steel housings for these types of pump is that they do not suffer from wicking problems associated with fibre reinforced housings while the effects of heat entrapment and corresponding thermal expansion issues are minimised, as are the effects of fluid absorption. The stainless steel housings also increase the strength and durability required for process pump applications. In addition to their corrosive resistance Liquiflo PFA lined pumps provide smooth, pulseless flows so they are easy to monitor and control, also their accurate output (within +/- 2%), means wastage is eliminated. They are also designed for easy servicing so downtime for routine maintenance is minimal. Further details are available from Michael Smith Engineers Ltd, Woking, Surrey. Tel: 0800 316 7891 E-mail: Info@michael-smith-engineers.co.uk Web: www.michael-smith-engineers.co.uk

BELLOWS SEAL VALVE IDEAL FOR CHALLENGING APPLICATIONS Liquids handling specialists PUMP ENGINEERING offer the extensive range of Badger Meter control valves which enable the precise control of liquids and gases in the most challenging applications and demanding environments. A good example of this is their range of valves available in a bellows seal design, such as their Type 808 bellows sealed globe valve. This is an ideal choice for critical, zero-fugitive emission, high-purity or high-vacuum applications where the potential for hazardous emissions has to be eliminated. The bellows forms a flexible static seal that is leak-free, as long as the integrity of the bellows remains intact. However, should the valve fail, a set of back-up packing allows the valve to continue to operate safely until repairs can be made. The valve is available in sizes ¼”, ½”, ¾” and 1” and standard features include interchangeable trim sets, bellows packing, PTFE CV ring back-up packing and PTFE bellows gasket. The trim characteristics available are; linear, equal percentage, quick-open, or double taper. A range of accessories to enable the valve to suit specific application requirements includes positioners, filter regulators, gauges, I/P limit switches and solenoid valves. Badger Type 808 Bellows Valves can be widely used in industrial applications including research and process plants on liquids, gases or steam. For more information contact Pump Engineering Ltd, Tel: 01903 730900 E-mail: badger@pumpeng.co.uk Web: www.badgermeteruk.com

PROCESS INDUSTRY INFORMER September 2015

FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves REDUCING ENERGY & WATER COSTS IN HYGIENIC CLEANING The food and drink manufacturing industries are large users of power and water and their associated costs impact on production and finished product costs. It is, therefore, in manufacturers’ interests to employ technologies that can reduce these costs, as well as comply with UK government energy saving initiatives. However, it is not always that easy, making it necessary for management to identify application areas where costs can be reduced. One major government initiative on energy is ESOS (Energy Savings Opportunity Scheme), this being a mandatory energy assessment scheme for larger companies with turnovers in excess of Euros 50 million and a balance sheet total of Euros 40 million/or employ over 250 people. ESOS was established by the government to implement Article 8 (4-6) of the EU Energy Efficiency Directive (2012/27/EU), with the ESOS Regulations of 2014 giving effect to the scheme. Administered by the Environment Agency, organisations that qualify for ESOS must carry out ESOS assessments every four years, with the first assessments having to be carried out and notified to the Environment Agency by the 5th December 2015. With plant hygiene being a priority for food and drinks manufacturers, expenditure on cleaning systems and water is always going to be a major concern. However, it is one area where savings can be made and will make a positive contribution to an energy assessment report. Many food and drink processing plants operate multiple sanitation wash-down systems that are sized to run at full demand at all times, with the water being re-circulated until it is required and the demand is increased. This is very uneconomic both in terms of energy consumed and water used. However, an energy efficient wash-down system has been developed by Cat Pumps that is suitable for food and drink production plants of all sizes. NEW SOLUTION Cat Pumps’ Wash-Saver pump package has been developed for centralised hygiene and sanitation cleaning systems and only uses water when it is required. The Wash-Saver is a fixed, multiple gun pressure wash down system utilising Cat Pumps’ high pressure plunger pumps in combination with a sophisticated variable speed controlled motor arrangement and control panel. As the pump remains fully primed and pressurised even when in idle mode, water is delivered at the required pressure and flow as soon as any wash-down gun is activated. This removes the need for the water to be continuously re-circulated, resulting in significantly lower energy costs and water usage. The energy savings achieved can be used as part of the ESOS assessment carried out by companies to demonstrate ESOS compliance. HOW IT WORKS Water consumption demand is managed by the Wash-Saver control panel, designed specifically to match demand with supply. The Wash-Saver uses a feedback signal from a sensor to a variable speed drive (VSD) to control the pump speed. The pump, drive motor, accessories and VSD panel come fully assembled, tested and pre-configured to match customers’ individual requirements. Furthermore, the system can be provided with an optional pre-piped water header tank, with installation into an existing centralised high-pressure pipe system being a simple procedure. The control panel can be readily incorporated into a factory automation system or linked into a local area network. As each additional gun is opened, the pump speed ramps up rapidly in response to the increased demand, and then gently slows down when no longer required. As a result, each operator will not notice any drop-off in cleaning performance when coworkers activate adjacent guns. When left in idle mode for longer periods of time, the control stops the pump completely, yet the system still responds instantly when any wash-down gun is activated. Built-in protection against dry-running should there be any disruption to the water supply, as well as automatic detection of both minor and major pipework leaks, come as standard. TYPICAL INDUSTRY ENERGY SAVING Illustrating how energy savings can be made, Cat Pumps has evidence that shows the value of energy savings that have been achieved when running its Wash-Saver system under the same operating conditions and for the same length of time as pitot tube pump wash-down pumps in a food processing plant. Running 50 wash-down guns at pressures of 50 bar and 16l/ min at an energy cost of 0.114p, the energy costs for the WashSaver were £13,497.43 and £31,693.82 for the standard pitot tube pump system, realising a saving of £18,000. SUMMARY Most large food processing and production sites have a centralised hygiene or sanitation cleaning system, many of which feature one or more high pressure pumps feeding a distributed array of wash-down guns and lances. Using high pressure water demonstrates several advantages over chemicalbased cleaning, not least of which are the effective removal of deposits and simpler wastewater disposal. The additional advantages of using a wash-down system using a high pressure triplex plunger pump is that the pump does not suffer the problems of lime-scale build up, which is common on pitot type rotary pumps, and they can be serviced in-situ thereby reducing maintenance time and costs. For more information contact Cat Pumps (UK) Limited, Tel: 01252 622031 E- Mail: sales@catpumps.co.uk Web: www.catpumps.co.uk

PROCESS INDUSTRY INFORMER September 2015

FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves PUMP OPTIMIZATION – HERE’S HOW YOU SAVE ENERGY IN YOUR PROCESS Here’s a surprising fact: pumps account for some 10% of global energy consumption – and as much as 50% of consumption in some processes. However, here is some good news – nearly everyone can make substantial savings by optimizing pump selection.Pump optimization is highly relevant in today’s competitive business climate and with the right pumps, you can reduce total cost of ownership, raise system performance and enhance your plant’s environmental profile. The payback time for required modifications? – Often less than a year. It is time for action! SAVING PUMP ENERGY, HOW? The principles of efficient pump operation apply to both new and existing systems. Because systems change over time and even minor changes impact efficiency, it is important to evaluate and modify systems continuously. By auditing existing systems, it is possible to adjust pump operation and restore efficiency. • Change your pump so it operates at the Best efficiency point (BEP) • Add a variable frequency drive, which will reduce energy costs • Change the diameter of the pump impeller • Change of pipe layout OPTIMIZE TO ECONOMIZE So how do you save the energy used on pumping in your process? – choose the right pump and optimize it! For that you need knowledge and support and Industrial Trading Solutions can offer that. We are industry experts at guiding you to choose the right pump for your dairy applications. For more information visit Web: www.industrialtradingsolutions.com or call on Tel: 01675 465 191

PROCESS INDUSTRY INFORMER September 2015

PROCESS MEASUREMENT

& INSTRUMENTATION

BRONKHORST SPECIALISES IN LOW FLOW FOR OIL & GAS RESEARCH

The Serious Pipe* *No side splitting comedy guaranteed High-volume manufacture means high-quality pipework that’s reliable, flexible and easy-to-maintain but costs less than custom-built sheetmetal ductwork.

Jacob (UK) Ltd T: +44 (0) 1694 722841 E: sales@jacob-uk.com W: Jacob-uk.com

The unique capability for Bronkhorst to accurately measure and control low to ultra-low flows has increasingly been called upon for research & development within the Oil & Gas industry with even the largest of global multi-nationals becoming reliant upon their expertise and experience. Clearly the precise measuring/controlling capability is important but perhaps more so is the in-depth knowledge and collaborative approach to process improvement and cost reduction. Despite a vast product range Bronkhorst have found that specialized solutions are more commonly required within this industry sector. One such solution is the capability to offer the world smallest flow range meter/controller using Coriolis technology in combination with dedicated pump technology to provide research establishments the flexibility to test and develop at laboratory scale whilst maintaining the pressures and conditions required by the Oil & Gas Industry. This same technology can then be up-scaled for field-test and ultimately production requirements. Currently, researchers are either manually dosing or using such devices as syringe-drivers to deliver the smallest of quantities of liquid into vials, vessels or reaction chambers. Both methods are tried and tested and, with years of application, are known to work adequately. However, as the need for greater precision, higher repeatability and greater reproducibility has developed so the need for finer control of the flow or dose has followed. The answer is simple - Bronkhorst not only has the ability to measure the tiniest of flows but also to directly control the addition or dosing of the additive by using a proportional control valve, an electro-shut off valve or by directly controlling a suitably specified pump. The researcher therefore receives a complete solution, fully integrated and tested, ready to “plug and play”. The total solution not only gives the user the confidence that the actual flow rate required is being delivered but also provides instantaneous readout, data logging and diagnostics. Further advantages include the ability for continuous flow mapping without, for example, the need to change out a syringe once it has run empty. This improves the integrity of data, ensures longer run times and, with the programmable software, can automate the process for un-manned experimentation. Over-dosing is reduced, the need to re-run experiments is reduced whilst cost- and time-efficiency are improved. A clear application where Bronkhorst has been successful is the dosing of performance chemicals, both within R&D and within Production. Solutions can be supplied from component level through to simple-to-use systems with the emphasis firmly based on quality, service and support. Components include the ATEX Zone 1 Coriolis Meter and Controller for gases and liquids with a flow rate capability as low as 50 milligrams per hour. More complex solutions include the Dosing Cube with programmable dosing rates, master/slave functionality and process diagnostic tooling. The use of Coriolis technology has additional benefits as the determination of density further aids process optimization. Recent shifts within the industry have further strengthened the need for a critical review of both project costings and mid- to long-term returns and the specific expertise of Bronkhorst within low to ultra-low flow applications has, as a result, seen particular focus. The capability to measure, and control, the smallest flows of both gas and liquid offers a great many benefits – no revenue streams are ever left un-measured, not one drop of additive is ever wasted and auto-calibration of analytical equipment can be refined to truly exceptional levels... A further development within Bronkhorst R&D is a multi-parameter module for the measurement of properties in gases. The module uses a combination of Coriolis, pressure and thermal technologies to derive real-time continuous measurement of viscosity and heat capacity to bring new advantages for Formation Analysis and Core Sampling Techniques. The technical specification is equally impressive, to mention but a few; accuracy is +/-0.2% of Reading, the instrument is certified to ATEX Zones 1 and 2, on-board PID control is standard, as is over-run protection and a self-learning function, the turn-down ratio is 2000:1, flow rates down to 50 milligrams per hour are easily achieved and the physical size (“the smallest Coriolis instrument inthe world”) is perfect for multiple injection points within confined spaces.

For more information contact Bronkhorst UK Ltd, Tel: 01223 833222 E-mail: sales@bronkhorst.co.uk Web: www.bronkhorst.co.uk/

PROCESS INDUSTRY INFORMER September 2015

FEATURE

A PRACTICAL GUIDE TO IMPROVING TEMPERATURE MEASUREMENT ACCURACY By Gary Prentice, National Sales Manager Moore Industries-International, Inc. For many temperature applications, getting a high level of accuracy is vital. This new white paper highlights how plant and site engineers can ensure the most accurate temperature measurement for critical applications. It details steps that can also help end users improve the stability of their measurements and reduce calibration costs. “A Practical Guide to Improving Temperature Measurement Accuracy” shows how to select the best sensor for a particular application and ways to improve the accuracy of the sensor you choose. In particular, it details the reasons why 4-wire RTD sensors are almost always the best choice for high-accuracy temperature applications. Using 4-wire RTD sensors eliminates the errors caused by a copper lead wire. The paper also explains the relationship between classes of sensors (such as Standard and Premium Grade thermocouples and Class A RTDs) and their error rates. Along with learning how to select sensors, the paper also covers how to reduce errors caused by plant noise, using bath calibration to minimize RTD measurement errors and the relationship between remote I/O and temperature accuracy. TEMPERATURE MEASUREMENTS CAN BE CATEGORIZED INTO THREE GROUPS:

1) Those which do not require accuracy. You simply need to know if the temperature is stable or going up or going down. 2) Those which do require accuracy. Strategies in this paper will help with those measurements. 3) Those where there is uncertainty about the accuracy requirement. If the measurements in this category are on a Preventive Maintenance schedule for calibration or verification you may want to take steps to improve accuracy. The same steps we take to achieve higher accuracy also result in reduced drift and that would have a positive impact on your maintenance frequency. Improving accuracy and reducing measurement drift are often related and can have measureable results. This paper shows how to: • Select the best sensor for the application • Reduce errors caused by external environment • Reduce errors caused by lead wires • Reduce measurement errors

SENSORS AND ACCURACY

There are times when the temperature sensor is selected based on convenience, what is on the shelf or the “plant standard.” It is not uncommon to see a Type J or K thermocouple measuring a temperature that should be measured with a Platinum RTD. ASTM and IEC temperature standards provide us with sensor measurement uncertainty. If we pick a sample temperature of 500°F (260°C), the uncertainty of a standard grade J or K thermocouple is ±4°F (±2.2°C) while a Class A 100Ω Pt RTD has an uncertainty of ±1.2°F (±0.67°C).

Many process engineers and technicians prefer RTDs. Selecting the best sensor for the application greatly affects the accuracy of the measurement and an RTD is the most accurate sensor to use when the process temperature is within its measuring range. But you will need to use less accurate thermocouples when you need to measure temperatures

PROCESS INDUSTRY INFORMER September 2015

that are hotter than the RTD’s upper measuring limits. In these instances you will want to take specific steps with thermocouples to improve the accuracy of the measurement results. You can improve sensor accuracy by using thermocouples constructed with Special Tolerance (also called Premium Grade) wire. The reduced error is achieved by using wire with higher purity alloys. At 500°F (260°C), the uncertainty of a Special Tolerance thermocouple is about ±2.0°F (1.1°C). Sensor selection is very important to measurement accuracy. As stated above, a Class A Pt RTD uncertainty is about ±1.2°F (±0.67°C) at the same operating temperature. To simplify the process of choosing a sensor, you can operate from the assumption that changing from a Standard Grade thermocouple to a Premium Grade thermocouple cuts the error rate in half; changing from a Premium Grade thermocouple to a Class A RTD cuts the error in half again.

THE ROLE OF THERMOCOUPLE EXTENSION WIRE IN MEASUREMENT ACCURACY

Thermocouples wired back to a PLC or DCS must use thermocouple extension wire. Unfortunately the extension wire Figure 1. Moore Industries TCM is yet another source of measurement Remote IO (top) and Moore error. Using standard grade J or K Industries TDZ3 Transmitter extension wire also adds another ±4°F (bottom) (±2.2°C) error. You can cut the error rate by using premium grade extension wire, which has half the error rate of standard extension wire, just as with premium thermocouples. (These error figures are only true when the wire is new and “pure.”) Over time the error gets worse as the wire gets contaminated from the atmosphere

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in your plant and the wire is exposed to temperatures greater than or lower than the wire tolerances. There are many instances where contamination causes even more “drift” than the original uncertainty of new thermocouple wire. If the uncertainty caused by thermocouples was a fixed offset, we could simply calibrate it out and be done with it. But when the error is in the form of drift that changes over time, calibration becomes a Preventive Maintenance program that few want to take on. Most plants prefer to avoid that extra labor whenever possible. How do you solve these problems? Start by determining how much error is caused by the thermocouple extension wire. Most people overlook this option until Plant Operations declares there is a problem or a catastrophic measurement failure occurs. We all know thermocouples fail, but it is easy to forget that thermocouple extension wire also fails. When it does, it has to be replaced. If you replace the extension wire with new extension wire, you perpetuate the same problems by reintroducing the error and drift it causes. You may have to live with thermocouples, but you don’t have to live with thermocouple extension wire – you can replace it with other solutions. Two options for replacing thermocouple extension wire are temperature transmitters and remote I/O hardware. (Figure 1) Both use copper wire to transport their signals back to the control system. Unlike thermocouple extension wire, you can expect the copper to last the life of the plant. Modern I/O products have performance characteristics similar to transmitters and can save a lot of money. You still need short sections of extension wire when you use these transmitters or I/O products. Use special grade thermocouple wire instead of standard extension wire in these cases to further minimize the error.

error of about ±4.7°F (±2.6°C). If you are trying to achieve a ±1°F (.55°C) measurement accuracy, this corrosion is standing between you and success. You can spend your life calibrating this error out or eliminate the error totally with a 4-wire RTD. Remember the voltage measurement is high impedance so, for all practical purposes, there is no current flow thru R2 and R3 and no voltage drop (Figure 3). The voltage is only measured across the RTD. R1 and R4 are never measured, thus they cannot create a differential resistance and an error. When using 4-wire RTDs, for all practical purposes, there is no error caused by the lead wire. 4-wire RTDs can have a lead wire of any length and the leads can undergo constant resistance change and still cause no measurement error. It is still important to ensure your total resistance does not exceed the drive capacity of your constant current source. Typically modern day temperature transmitters offer enough current drive to support RTD circuits that have up to 3-4K ohms of total resistance. With lead wire error eliminated you are able to focus on the sensor and measuring device to further reduce error. The only reasonable objection to using the 4-Wire RTD is that the existing legacy input card only accepts 3-wire RTDs. This is old technology and should be considered for replacement.

COMPENSATING FOR RTD LEAD WIRE INACCURACIES

Copper wire is used for RTD lead wires. If you are familiar with 3-wire RTDs you know one lead is called the compensating lead. Between copper and a compensating lead you might believe that RTD lead wire does not contribute to the measurement error. Unfortunately, this is not true. Copper wire can cause significant error in an RTD measurement because RTDs are resistors and copper wire is resistance. There are many contaminants in a typical process plant that cause corrosion and this corrosion changes the resistance of the copper lead wires. This resistance change in the lead wire can cause error. To eliminate lead wire error the solution is to use 4-wire RTDs. Here is why: When a third lead wire is added to the RTD, the measurement is made with today’s electronics by taking two voltage measurements (as shown, V1 and V2). The important thing to remember is that these are high impedance voltage measurements. For all practical purposes, there is no current flow through that third lead; thus R2 never enters into the equation. (Figure 2)

Figure 3.: 4-wire RTD diagram There is another option to consider if you are not able to use 4-wire RTDs: switch from 100Ω Pt RTDs to 1000Ω Pt RTDs. As stated earlier in this paper, 1Ω of resistance imbalance in the current carrying legs of a 100Ω Pt element produces about ±4.7°F (±2.6°C) error. If you change to a 1000Ω sensor that same 1Ω of imbalance will have onetenth of the effect. The 1Ω of imbalance error drops to about ±0.47°F (±0.26°C). While the use of the 1000Ω 3-wire RTD is a big improvement over the use of a 100Ω 3-wire RTD, it is not a panacea. When the lead wire resistance imbalance changes, that causes the measurement accuracy to change. That means you still need a calibration program to temporarily eliminate the error. The 4-wire RTD is still the single best solution because it removes all lead wire error and eliminates the need to calibrate due to the inevitable corrosion.

PLANT NOISE

Figure 2.: 3-wire RTD diagram Constant Current Source R1 R2 V1 Red = High Impedance 100 Ω Pt RTD R4 V2 V1 gives the value of the lead wire resistance R1. V2 gives the value of the RTD + R4 lead resistance. Subtract V1 from V2 and as long as the lead resistances R1 = R4, only the value of the RTD remains. This is an accurate measurement. Realize that too many things work against making R1 and R4 identical when accuracy is your primary concern. Wire gauge intolerance and work hardening varies the resistance. Even if no human error takes place during installation, corrosion constantly works against the measurement and is the main reason R1 never equals R4. So what happens if the lead’s resistances are not equal? If the resistance imbalance is as little as 1 ohm, a 100Ω Pt RTD has an

VFDs, motors and radios create “normal” levels of EMI and RFI which can cause errors on temperature measurements. Thermocouple and RTD signals are very low level mV signals. It does not take much noise to cause significant distortion of the measurements. If you are wiring these low level signals back to the control system please use best practices to keep noise off these signal wires by using drain wires, proper grounding and physical separation. A better solution is to convert the low level signals to high level signals as close to the temperature sensor as possible. The same amount of noise will affect high signals less than low level signals. Signals like 4-20mA, HART or RS-485 survive most typical levels of noise.

THE TEMPERATURE MEASUREMENT DEVICE AND REMOTE I/O

When you finally get to the actual temperature measurement device your ability to make significant improvements to accuracy has passed. Modern temperature transmitters and temperature I/O systems from major instrument companies have similar performance specifications. If you are trying to differentiate the finer points you might compare these specifications: • The greater the input resolution the measuring circuit can detect, the smaller the changes in the sensor’s temperature can be detected • Long term drift spec is a measure of the transmitter’s stability • RTD Excitation current should be low to minimize the self-heating error

PROCESS INDUSTRY INFORMER September 2015

• Seek the highest Input Impedance possible so that the measuring device does not draw current • Advanced diagnostics help to predict failures If you are pursuing the very highest accuracy, you have to deal with the final “as built” error in the RTD. The transmitter can be used to calibrate out that final offset error and match you to the ideal curve. Such a process delivers a typical transmitter and sensor combined accuracy of less than 0.05% of span. Putting a temperature transmitter or remote I/O near your sensor digitizes your temperature measurement. You create two more errors if you then send that signal back to the control or data acquisition system using 4-20mA: 1. D/A error occurs when creating the 4-20mA 2. At the control system, an A/D error occurs when turning the signal back to digital Using the HART digital signal is one way to avoid the conversion errors. MODBUS Serial or MODBUS over Ethernet is another option to keep the measured value digital. In summary, using transmitters and remote I/O helps: • Eliminate errors caused by thermocouple extension wire • Avoid errors caused by noise • Keeps the signal digital and avoids the analog conversion errors If you are direct wiring temperature sensors back to the DCS or PLC, it likely means that you did not want to pay for temperature transmitters for each of those data acquisition points. If you use modern remote I/O instrumentation instead, you will actually save money on instrumentation and wiring. It has the same accuracy, ambient temperature specifications and sometimes similar hazardous area certifications as you would find on temperature transmitters at a fraction of the cost. The remote I/O digitizes all the temperatures and can deliver them as 32-bit floats to the DCS or PLC MODBUS port using your choice of physical layers. Remote I/O also eliminates thermocouple extension wire and all the associated drift, errors and replacement costs.

PRACTICAL STEPS TO IMPROVE YOUR MEASUREMENTS In conclusion, here are a few practical steps you can take to improve your temperature measurement accuracy. Remember that these steps also improve the stability of your measurement which minimizes your calibration expenses. • 4-wire RTDs eliminate the errors caused by the copper lead wire • Use premium grade thermocouples and premium grade extension wire if the temperature to be measured requires the use of thermocouples • Be sure to use noise protection installation techniques whenever you have long extension wire runs • Mount transmitters or remote I/O as close to the sensors as possible in order to get rid of long thermocouple extension wire runs which are an error source, have a finite life, and are expensive to replace • Get rid of the final RTD offset error by bath calibrating • Buy the highest accuracy and highest stability transmitter or I/O you can afford • Once you have spent all that money to get your signal digital, keep it digital so there are no more errors introduced

PROCESS INDUSTRY INFORMER September 2015

FEATURE

TAKING A LIFE CYCLE APPROACH TO

INSTRUMENTATION Considering the total life cycle of your instruments will help you decide when to maintain and when to replace. Wayne Deeks, Instrumentation Service Account Manager for ABB Measurement & Analytics Service, explains what’s involved in maintaining instrumentation through its operational life and what to do when it’s time to upgrade.

time comes in the life of every measurement instrument when it becomes obsolete. Whilst it may be working perfectly, doing the job it is supposed to do accurately and well, the lack of any technical support or spare parts will mean it is nearing the end of its practical working life. But what is obsolescence? How is it defined and who says when an instrument has reached that status? What can be done to mitigate it and can it in fact be planned for? Like many other items of equipment, instruments go through four phases in their lives. At each phase, particular levels of support are offered by the manufacturer. These four phases are Active, Classic, Limited and Obsolete. The Active phase is the sales and manufacturing phase. At the end of this phase, volume manufacture ceases and the product moves into the Classic phase. Complete life cycle support is guaranteed throughout these two phases. The Limited phase is where this product support is gradually ramped down, ending in the Obsolete phase when no product support is offered for the instrument. Most instrument vendors keep to the same scheme, with roughly equivalent durations for each phase. On average, an instrument can have a lifespan of 10 -15 years as long as it continues to be supported and it is not unknown for users to still be using obsolete equipment that is 20 or more years old. The danger of using instruments in the obsolete phase is that there is little or no possibility of replacing worn parts. This can lead to more inaccuracies in reading, resulting in a possible degradation in product quality. Inaccuracies in flow measurement of such commodities as gas or water could reduce a utility’s profits, while large offsets in critical instruments could have serious consequences for safety or result in non-compliance with regulatory requirements. Also, a consistently inaccurate instrument could erode confidence in its ability to provide a reliable measurement, leading to staff ignoring its reading. This could prove particularly problematic in applications such as measuring the purity of water driving turbine blades, for example. Inaccurate instrumentation readings could lead to a build-up of mineral deposits on the turbine blades, causing significant pitting and other damage. In these cases, the instruments are monitoring, not controlling, and users need to be fully aware that if an electrical fault occurs they will have to replace the instrument.

GET THE DETAILS RIGHT TO PROLONG LIFE

The useful life of an instrument can be extended by ensuring routine maintenance, servicing and calibration is conducted according to the manufacturer’s recommendations. Another factor is having the right instrument that has been properly sized and specified for the application and which is able to handle operating conditions such as ambient temperature and vibration. A user should also have contingencies for when the instrument does breakdown, including having an arrangement in place to call out the manufacturer or its agents to repair a failed instrument. The response time can vary among manufacturers, who often offer different levels of response depending on the criticality of the unit. This can range from five days, down to three days or to 24 hours. Identifying the effects that breakdowns can have and identifying high risk instruments is essential in choosing the desired response time. For super-critical applications that must be back on line to comply with regulations or to avoid serious losses in revenue, a 24 hour response may be vital. An example was an ABB customer that was losing £20 to £30,000 for every 3-4 hours the instrument was down. Another is one of the UK’s main airports, which

employs instrumentation to measure the run-off of cleaning chemicals used on the runway. The airport needs a 90 percent up time for the instrument and every four hours off line counts as a full day, meaning 24 hour response is essential. Power stations also need this type of fast response as they must adhere to strict emission levels laid down by the Environment Agency. Tempting though it may be to specify a fast repair response from the vendor, this must be balanced against the criticality of the application, the losses incurred on failure and the increased cost of the rapid reaction. Having access to spares and keeping a stock of consumables is also a factor. It was once common for instrumentation users to keep one unit in use and another on standby, though pressure on costs has made this practice less common than it once was. Similarly, fewer users now keep an extensive spares stock, preferring their instrumentation suppliers to hold bonded spares on their behalf.Instigating a lifecycle plan means instrumentation users can plan upgrades and repairs effectively.

MANAGE THE LIFE CYCLE FOR BEST RESULTS

Understanding which phase your instruments are in and which course of action to take to maximise their life is the aim of a Life Cycle Assessment or LCA. With ABB, the life cycle assessment begins with a life cycle audit. This highlights the condition of the equipment, its revision status and necessary maintenance needs for its operating environment. This helps formulate the best maintenance programme and identifies the appropriate migration points. The life cycle audit has a number of features. The process begins with a site survey of installed instrumentation and analyser equipment, followed by an evaluation of the life cycle status of ABB and third party equipment. The condition of the products is evaluated and their installation to ISO guidelines is confirmed. The final stage is a comprehensive inventory and life cycle report, including recommendations. The life cycle audit offers a number of benefits. One of the main ones is that it provides knowledge of the equipment condition and revision status to aid maintenance planning and costing. It also helps set out a life cycle management plan to prolong equipment life and avoid premature failure, while also assisting with the development of life cycle planning and budgeting. Once the exact condition of the equipment is known, the next stage is a life cycle management service to provide effective maintenance, migration and obsolescence planning as part of an integrated programme. Essentially, the life cycle management plan implements recommendations from the life cycle audit and develops preventative maintenance schedules for installed devices based upon criticality. It also implements appropriate predictive maintenance technologies, as well putting in place any support functions needed. Its central benefit is that it enhances the condition and reliability of instruments and extends operating life. It makes the correct resources and parts available to implement upgrades, while providing lower cost of ownership and minimal disruption.

SUMMARY

Taking a rational approach to instrument servicing and replacement such as taking a whole life approach, is the only sure way to get cost-effective, extended use from valuable plant assets and in turn ensure that quality, safety, compliance, production time and revenue is maximised.

PROCESS INDUSTRY INFORMER September 2015

PROCESS MEASUREMENT & INSTRUMENTATION FLEXIM PRESENTS THE NEW FLUXUS® F/G 721

NEW – SUPERFAST THERMAPEN® 4 THERMOMETER

FLEXIM presents new generation of clamp-on ultrasonic flowmeters: the FLUXUS® F/G 721. With its new hardware design and improved, powerful digital signal, it sets standards in terms of accuracy, reliability and versatility. FLUXUS® F/G721 offers non-intrusive flow measurement of virtually any kind of liquid or gas, from the smallest tubing to the largest penstock, independent of the pressure inside the pipe and over a very large temperature range. Higly sophisticated signal filters and substantially improved measurement algorithms together with the proven transducer technology and sturdy mountings make the FLUXUS® F/G721 a state-of-the-art measuring solution even for the most challenging applications, such as flow measurment of liquids with gaseous of solid entrainments or even of wet gas. The meter adapts itself automatically to the respective measurement conditions and compensates for perturbations. Extremely fast measurement cycles allow for precise real time monitoring of highly dynamic processes. FLEXIM calibrates transmitters and transducers independently from each other, therefore ensuring highest accuracy in the field, regardless of the actual configuration of the measuring system. Explosion proof versions for operation in hazard areas (ATEX, IECEX Zone 2, FM Class I, Div. 2, EAC TR TS, Inmetro) are available. The FLUXUS® F/G721 comes with all common communication protocols. HART, Modbus, Foundation Fieldbus, Profibus PA and BACnet allow bidirectional field communication, parameterisation and online diagnostics. Further special configurations guarantee optimal customisation to the individual application. The FLUXUS® F/G721 is also one step ahead in terms of user guidance and diagnostics. It can easily be parameterised via USB. Its ethernet connectivity provides additional bidirectional communication capabilities.

The SuperFast Thermapen is the UK’s number one selling food thermometer measuring temperature over the range of -49.9 to 299.9 °C. Used by hundreds of thousands of people worldwide, it offers a combination of speed, accuracy and convenience of use. Electronic Temperature Instruments Ltd, the UK manufacturers of the Thermapen thermometer have now made it even better …. Advanced technology makes the new Thermapen 4 even more intuitive than previous models. The patented 360° self-rotating display automatically turns so the user can read the thermometer in any position — in either hand, left or right. The Thermapen 4 knows when it’s dark and turns on the backlight for you, making it easy to read in poorly lit areas or complete darkness. Alternatively, just touch the sensor window with your finger and the display lights up. The Thermapen 4 is powered by a single AAA battery with a life expectancy of 3000 hours in normal use. Both low battery and open circuit (broken probe) are displayed, when applicable. The motion-sensing sleep mode automatically turns the Thermapen 4 on or off when the user picks it up or puts it down, maximising battery life. Close the probe when you’re finished and the Thermapen 4 turns off for storage. The plastic casing is washable and includes ‘Biomaster’ additive that reduces bacterial growth. The ergonomic rubber seal minimises the risk of the ingress of water, dust or food. The true temperature of a product can be tested in just three seconds. Each Thermapen 4 is supplied with a traceable certificate of calibration. Competitively priced, at £50 each exclusive of VAT and available in ten vibrant colours direct from www.etiltd.com

For more information contact Flexim GmbH, Berlin, Germany Tel: +49 30 936676 915 E-mail: ofoth@flexim.com Web: www.flexim.com

For more information contact Electronic Temperature Instruments Ltd Tel: 01903 202151 E-mail: sales@etiltd.com Web: www.etiltd.com

THE FUTURE OF GAS FLOW CONTROL

Visit: www.bronkhorst.com/prestige

Bronkhorst (UK) Ltd - T 01223 833222 - I www.bronkhorst.co.uk - E sales@bronkhorst.co.uk

PROCESS INDUSTRY INFORMER September 2015

FEATURE

CARBON BRUSHES A NEW LEASE OF LIFE

Jon O’Brien, Application Engineer at Morgan Advanced Materials, discusses the evolution of carbon brushes and the maintenance techniques that can extend the life span, improved motor performance and reliability of these essential components, as well as providing guidance on the material choices available.

HAT IS A CARBON BRUSH?

Although they may differ in size, shape and technical composition, carbon brushes used in DC motors and generators all fulfil the same basic function – to transfer electrical current from a moving device to a stationary point and vice versa, within a circuit. The main function of the brush is to conduct current without interruption, meaning the point at which the brush transfers current from its surface to the moving collector is critical. During operation, a film – or patina - is automatically formed on the surface of the collector, and this is critical in conducting current and reducing friction. Carbon brushes were first patented in 1885 by Scottish inventor Professor George Forbes. They proved a more effective conductor than the earlier brushes which were made of strands of copper and frequently left deep scratches and grooves in the collector, resulting in the need for regular resurfacing. Additionally, the hard metal brushes would themselves often wear away, releasing debris which could short circuit the collector by becoming wedged in moving parts. Gauze brushes, an early alternative to copper, provided improved surface contact and reduced segment wear, but were much more expensive than their copper counterparts. The use of carbon brushes minimises sparking and arc damage at the point of contact, while the low friction characteristics and lubrication properties of carbon minimise damage to the collector (commutator or slip ring) surface, reducing the amount of wear debris that can collect within the machine. Carbon brushes are also more versatile than copper alone, as they can be adjusted for individual applications by altering the ratio of carbon to metal powder – brushes with a high metal content perform best with low voltage and high current, while a higher carbon content results in a brush ideal for high voltage and low current density. Despite the benefits of carbon brushes over their copper predecessors, friction between the brush and collector is inevitable and eventually causes wear to the surface of both. As carbon is the softer of the two, it will wear faster, and is therefore designed to be easily replaced. The life of the brush can also be affected by factors including the holder design and alignment; temperature and humidity variations; contamination by debris or lubricants; vibration; or changes in current, speed or pressure. Effective inspection and maintenance are therefore critical in avoiding both unnecessary downtime and premature replacement.

GENERAL MAINTENANCE POINTS

Routine condition-based maintenance begins with a visual inspection of the carbon brush and associated components. Brushes, holders, collectors and connections should all be regularly checked for general condition, cleanliness and contamination from excessive dust or grease. When inspecting collectors, the patina (an oxidised film which forms on the surface) should be closely monitored as this will reduce frictional wear and so improve the life of the brush, as well as minimising the wear on the collector. Brushes fitted to a freshlyturned collector are liable to wear faster than brushes running on an established patina as the patina takes a while to fully form, and this should also be taken into account during inspection. The alignment of brush holders should be measured to ensure there has been no slippage or shifting which could hasten wear and damage, while brushes themselves should be thoroughly checked from terminal to contact surface – with particular attention paid to contact faces where a smooth, well-polished surface is indicative of good performance.

INFLUENCING FACTORS

Damage to carbon brushes can occur due to mechanical, electrical or environmental factors, and inspection schedules can be designed around common faults in these areas. Mechanical problems which must be identified

quickly include poorly mounted or aligned holders; worn springs; eccentricities in wear patterns on the collector; and incorrect pressure. Contamination, temperature and humidity are among the environmental factors which may cause premature damage or quicken wear, and the causes of any ambient changes should be identified and rectified to prevent further damage. Poor commutation, leading to sparking, as well as a lack of a fully formed patina, are electrical factors which can lead to wear of both the brush and commutator.

VITAL CHECKS

If a brush is found to be wearing prematurely, maintenance engineers should work through a list of vital checks which will uncover the causes of shortened brush life and inform the corrective strategy. The following should be ascertained: - Current density - Collector run-out - Surface speed - Collector temperature - Humidity - Brush pressure - Amount of sparking - Duty cycle - Level of vibration during operation - Appearance of the patina/ collector film - Brush set-up in terms of whether it is correctly aligned - Spacing of brush holder - The presence of any contaminants nearby Discovering if any of these factors is beyond acceptable limits, combined with the brush life history taken from maintenance records, should lead engineers to diagnose and rectify problems, whether they are mechanical, environmental or electrical.

MECHANICAL CAUSES AND SOLUTIONS

As previously discussed, mechanical issues can cause problems such as ill-fitting brushes in the holder. If the fit is too tight, it will cause sticking which in turn will lift off the collector, breaking the current path. Too loose a fit allows movement of the brush in the holder which in turn will cause intermittent breaking of the current flow. When fitting new brushes, it is advised to bed the brushes into the shape of the collector as illustrated in Figure 1. To ensure the brushes are fitted correctly, check that brushes are free to move easily in their boxes after bedding in and cleaning. Brushes and holders manufactured to either IEC 136 or DIN 4300 tolerances should always be selected.

BRUSH HOLDER ALIGNMENT

Carbon brushes are fitted into holders which are designed to keep them in the correct position and allow the brush to run on the surface of the collector to transfer the maximum current and so deliver optimum performance. There are two main types of holders; one in which the brush is rigidly attached to a swivel arm, and the other in which the brush is free to slide in a supporting box. Slide type holders are generally

Fig. 1

PROCESS INDUSTRY INFORMER September 2015

classified according to the angle at which the brush meets the collector as per Figure 2.

brush surface of the brush (Figure 6). If the brush is overloaded, it is advisable to check the brush material and ensure use of a brush with the optimum current density for the application. Low load – often evidenced on variable load motors seen in steel mills by streaking on the commutator - can potentially be overcome by selecting a brush grade suitable for a broad spectrum of loads including light load running.

Fig. 5

Fig. 6 To ensure the brush is at the optimum distance from the collector – and so prevent brush movement issues or the brush holder arcing current to the collector - the holder should be positioned approximately 2.5mm from the collector. If distance falls below 2mm or exceeds 3 mm, the window holder needs to be reset as shown in Figure 3.

ENVIRONMENTAL ISSUES AND PROPOSED SOLUTIONS

Interruption to the formation of the patina can be caused not only by mechanical and electrical issues but environmental issues such as; ambient temperature, humidity, contamination, vibration and maintenance standards – all of which can have an impact on the film formation. For the film or patina to form correctly, optimum conditions are required. Moisture is essential, with humidity levels of less than 4.6 mg/L (1.5 grains/ft3) potentially disrupting this process. Cooling air is often supplied from outside and is generally forced directly onto the collector, but problems can arise if the air is too hot or too cold. Furthermore, at low load, the collector may never achieve normal operating temperature – which will also impact on the film formation and ultimately on the brush performance.

Fig. 7

SPRINGS AND SPRING PRESSURE

The final area that can cause mechanical and also electrical issues, is that of spring pressure. To prevent inequalities the spring pressures should be the same across all the brushes in the motor or generator. Such inequalities - where some brushes are optimally configured while others are at too low or high a spring pressure – are likely to result in rapid mechanical or electrical wear, and may also cause selective action across the whole system. Due to the radial travel of the brush through the holder as it wears, it is advantageous to use constant force (CF) springs. Figure 4 shows the force in these springs is constant over a wide range of spring extensions. As the spring travels down the brush holder, the force remainconstant until it has reached 0.8 times the diameter of the coil. To optimise performance, a rubber tufnol top with a locating radius should be fitted to allow best possible location of spring with damping to reduce any potential vibration issues.

Fig. 4

COMMON ELECTRICAL ISSUES AND SOLUTIONS

Poor commutation, leading to sparking, as well as a lack of a fully formed patina, are electrical factors which can lead to wear of both the brush and commutator. This is frequently evidenced by ghost marked surfaces on the brush (Figure 5), which could indicate issues such as an incorrect neutral point or interpole problems. The neutral point should be checked with a neutral meter before any further issues are investigated. Overload, low load or varying load can also cause damage to the brushes, holders or collector. Overload current will be shown by burnt flexes or a pitted

PROCESS INDUSTRY INFORMER September 2015

GRADES OF BRUSH MATERIAL

The brush/ holder/ collector system plays a key role in optimising motor uptime. Ensuring continuous, even current flow is paramount and correct brush grade selection is vital to that process. Various grades are available depending on the specific application requirements. Entity in a steel mill motor, for example, a combination of issues may be present such as contamination, high temperatures, varying current loadings with periods of light load running and vibration caused from other equipment in the area. For this application, an electrographitic grade, able to cover a spectrum of current densities, coupled with a CF spring and rubber Tufnol top design to counter vibration, is a recommended solution. As well as electrographites, the most commonly used brush grades are metal graphites, natural graphites, resin-bonded products, metal impregnated products, and hard carbon/ carbon graphite products. Electrographite, used for both commutation and collection, consists of carbon which has been partially transformed into graphite by heating the material to temperatures between 2200°C and 2800°C. Electrographite is suitable for a range of applications including DC drives and AC rings, with current densities normally in the range 4 to 16A/cm2 and surface speeds up to 50m/sec. Metal graphite products are mainly used for collection, except in low voltage applications. Specifiers typically choose between copper, which is best at current densities 12 to 30A/cm2 and surface speeds up to 30m/sec, and silver which is suitable for the same speed range but for low voltage applications with good signal integrity, and varied current densities from just above zero to 30A/cm2. Natural graphite products are also suitable for collection applications, particularly Turbine Alternator (TA) exciters with steel sliprings, current densities up to 12A/ cm2 and surface speeds up to 80m/sec. For commutation applications, resin bonded products are ideal for applications where there is high contact drop (poor commutation) or in low current/ temperature applications with current densities up to 8A/cm2 and surface speeds up to 30m/ sec. At higher current densities up to 30A/cm2 and surface speeds up to 40m/ sec, metal impregnated products are the best choice. The final option is hard carbon/ carbon graphite, which is suitable for current densities up to 10A/cm2 and surface speeds up to 30m/sec in older applications or where commutation is difficult for any reason.

PROCESS MEASUREMENT

& INSTRUMENTATION

TEST & MEASUREMENT

HBM OVERCOMES NEW CHALLENGES FOR ANDROID APP NOW AVAILABLE FOR MEASUREMENT TECHNOLOGY! SENSOREX SAM-1™ SMART AQUA METER SAM-1 transforms Android smartphones or tablets into portable pH, ORP or Conductivity meters Sensorex’s SAM-1™ Smart Aqua Meter is now globally compatible with Android devices. Already popular with Apple iPhone and iPad users for laboratory and field monitoring, the SAM-1 measures and records pH, ORP, Conductivity and temperature values. With the release of the Android app, Android smartphone and tablet users (Android version 4.0 and newer) can now use this powerful, portable water quality meter for accurate analytical measurements in environmental, educational, and industrial applications. The SAM-1 Smart Aqua Meter transforms smartphones or tablets into convenient and powerful pH, ORP, or Conductivity/TDS meters with integral temperature measurement. It plugs into the headphone jack of virtually any smartphone or tablet, and easily connects to Sensorex smart analytical sensors. The free SAM-1 App instantly recognizes the smart sensor and provides an easy-touse interface for taking measurements and managing data. Readings can be tagged with GPS location and user comments. Stored data can be securely transmitted via email and opens in Excel for analysis and reporting, eliminating data transcription errors. The SAM-1 can be used in the lab, field or plant for applications ranging from environmental monitoring, aquaculture, and horticulture; to municipal water sampling and wastewater compliance testing; to product quality control. As an educational tool, the SAM-1 provides hands-on experience. The language-aware SAM-1 App operates in the set phone language. Languages supported by the app include: English, French, German, Japanese, Italian, Russian, Spanish and Simplified Chinese. The free SAM-1 App can be downloaded from the Google Play App Store for Android devices, and the Apple App Store for Apple devices. To learn more about the SAM-1 Smart Aqua Meter and the company’s full range of analytical sensing products, visit Sensorex at: www.SmartAquaMeter.com or www.Sensorex.com, E-mail sales@sensorex.com or phone +1 714-895-4344.

CUSTOMISE YOUR FORCE MEASUREMENT REQUIREMENTS WITH HBM HBM – a market leader in the field of test and measurement – has consolidated its leading position in force measurement technology by combining the series production of strain gauge sensors with its customised line, to match specific applications. Designed to meet unique requirements, this new development means that all components are available in one place, which enables high quality customised sensors to be developed with no restrictions of quantity. Featuring swift manufacturing, adaption’s during the development of strain gauges and calibration measurements are made directly in house, negating the need to involve third parties, which means that development cycles are therefore significantly reduced. As this approach also applies to piezoelectric sensors from the PACEline series, HBM is able to offer custom designed sensors produced in series – both strain gauge based or piezoelectric. With 65 years of experience firmly under its belt, HBM, which placed its first sensor on the market in 1958, has all the required key technologies in-house to develop sensors, strain gauges, wiring and calibration, which can be offered for the force range of 10 N to 5 MN. For more information contact HBM on Tel:+44 (0) 208 515 6000 or visit Web: www.hbm.com

Now available from HBM – a market leader in the field of test and measurement – is the new range of M Series Strain Gauges (SGs), specifically developed to meet the demanding requirements of measuring strain in fibre composites. New materials offering high strength, such as fibre composites, pose a major challenge for Strain Gauges used in measurement purposes, particularly when pushing components to their mechanical limit of performance. An example of this would be when a Strain Gauge, subjected to alternating loads at increased load levels, is weakened and fails earlier than the component under the test. In response to this problem, HBM has added the latest M Series of Strain Gauges to its existing range. The new range of Strain Gauges from HBM has been specifically developed for high resistance to alternating loads, at increased strain levels and high temperatures - up to 300°C - and is available with various geometries, measuring grid lengths and temperature response matching. Suitable for applications in aviation, automotive and power supply industries, the demand for specialist Strain Gauges is continually increasing. HBM’s extensive range allows for an exceptionally wide range of differing strain measurement applications, from experimental stress analysis, durability testing through to transducer manufacturing. Additionally, HBM provides all the necessary accessories and components and also supports its customers with training and contract installation. For more information contact HBM UK Ltd, Tel: +44 (0) 208 515 6000 E-mail: info@hbm.com or visit Web: www.hbm.com

NEW PERCEPTION 6.60 DESIGNED FOR FAST & RELIABLE DATA PROCESSING Perception 6.60, from the HBM Test and Measurement range, has now been upgraded to make adjustments for individual user requirements. The new version will offer complete flexibility to users due to a function that allows the main user to adapt the software according to the needs of other users. It also has a patented StatStream technology that can process 100GB within 10 seconds. The ‘User Definer Mode’ will enable the ‘Definer’ to create and change workbenches with respective restrictions, define the functions a user may use or see, as well as protect all settings with a password. Pereption 6.60 also provides an enhanced eDrive application for taking measurements on electric inverters and drive systems. It has improved cycle detection for subsequent computations, visualisation of cycle detection in the live screen for verification, integrated online help including enhanced connection diagrams and new live and time-based computations. In addition it also features new computations in the ‘Formulas’, visualisations of torque and rotational speed as live curves, software-based sign reversal of measured rotational speed, angle measurement of the encoders used, and new RPC command for making entries to the ‘Information’ sheet. Designed for fast and reliable processing of large quantities of data, Perception is ideal for use with the data acquisition devices of the Genesis HighSpeed family. To further make Perception 6.60 user friendly, it can be installed in eight different languages. For more information contact HBM on Tel: +44 (0) 208 515 6000 E-mail: info@hbm.com or visit Web: www.hbm.com

PROCESS INDUSTRY INFORMER September 2015

COMPRESSED AIR NEW BOGE GUIDE EXPLAINS HOW TO KEEP COMPRESSED AIR SUPPLY CLEAN & PURE BOGE Compressors has released a new guide that explains how to ensure compressed air supply is kept clean, pure and free of contaminants. With so many potential contaminants placing the purity of compressed air and quality of manufactured products at risk, this new guide is an essential tool for compressed air system operators. The free guide outlines in depth the variety of threats that impact on compressed air systems. These threats include airborne particles such as dust and pollen, water vapour, which naturally occurs in air, and compressor oil that is emitted as an oil vapour. It also discusses the consequences of ignoring or failing to deal with potential contaminants, such as the contamination of end products. This creates health risks and can result in reduced productivity and profitability when product batches must be discarded and is especially true in the highly regulated and competitive food and beverage industry. The guide also explains how to prevent the problem of compressed air contamination, providing a variety of options for breaking down and removing contaminants. This includes: building a defence system by utilising effective filtration systems, which can be installed at the compressor intake stage or downstream for further protection; and removing moisture to combat excess water vapour using adsorption technology. For more information contact: BOGE Compressors Ltd. E-mail: m.heeley@boge.com Tel: +44 (0) 1484-719921 Web: www.boge.co.uk

GAS DETECTION EQUIPMENT CROWCON LAUNCHES NEXT-GENERATION “INTELLIGENT” FIXED-POINT GAS DETECTOR Key Facts: XgardIQ has been developed to: • Minimise the time operators must spend in hazardous areas where they may be exposed to gas hazards • Enhance site safety using Crowcon’s unique ‘+ve Safety” feature • Enable simple installation and commissioning

HEALTH & SAFETY TEREX OFFERS LATCHWAYS’ FALL PROTECTION SYSTEMS • Solutions for safe working at height • Helping employers to meet health and safety obligations • Synergy with Demag material handling product range Terex Material Handling is a registered specifier, supplier and installer of Latchways’ comprehensive range of fall protection and working at height products. The company is offering the safety systems alongside its extensive range of Demag lifting equipment for new crane installations, retrofits and refurbishments. Terex Material Handling will also supply and fit the fall protection systems to the cranes of other original equipment manufacturers. Latchways manufactures a comprehensive range of safety equipment, including the innovative ManSafe® fall protection system for working at height. ManSafe® affords operators unfettered movement and continuous, hands free security whilst working at height. The operator’s safety harness is secured to the ManSafe® line via a high integrity lanyard and a ‘transfastener’ mobile anchor point, providing comfort and mobility for the operator. Technicians from Terex Material Handling’s Demag Services’ Department have undergone extensive product familiarisation and training on Latchways’ products and are fully qualified to specify and install fall protection systems. Demag technicians are also well placed to provide instruction on the safe operation of the ManSafe® system to end users. Terex Material Handling’s Services Director, Gordon Baird, stated: “Latchways’ fall protection products are a good fit with our lifting equipment. We are now well placed to act as a single source for customers seeking material handling products and services, together with associated working at height safety systems.” For more information contact Terex MHPS (UK) Ltd, Tel: 01295 676100 E-mail enquiries to: bnb-service@terex.com Web: www.demagcranes.co.uk

ENCLOSURES EPLAN’S PRO PANEL CUTS WIRING TIME BY 75%

Crowcon Detection Instruments Ltd – a leading manufacturer of specialist gas detection equipment – announce the next generation of intelligent gas detectors and transmitters: XgardIQ. XgardIQ is an intelligent and versatile gas detector and transmitter compatible with Crowcon’s full range of sensor technologies. XgardIQ is available fitted with a variety of flammable, toxic or oxygen gas sensors or may be installed with a remote sensor housing up to 15 metres from the transmitter. Providing analogue 4-20mA and RS-485 Modbus signals as standard, XgardIQ is optionally available with Alarm and Fault relays and HART communications. This comprehensive set of output interfaces ensures compatibility with virtually any control system from gas detection panels, to PLC’s, DCS’s and SCADA systems. HART communications enables diagnostic checking and maintenance using industry-standard communications tools remotely or locally in the hazardous area. The HART feature also enables XgardIQ to be logged and monitored automatically on asset management systems. Crowcon’s unique “+ve Safety” feature confirms the detector is operating safely using a bright blue LED and screen messages. XgardIQ automatically alerts operators to any irregular events that may affect product integrity such as the ambient temperature or gas concentration exceeding sensor limits.

The Pro Panel engineering software from EPLAN enables companies to achieve savings of up to 75% on wiring time, 50% time savings on layout and mounting and up to 50% increase in overall productivity. With EPLAN Pro Panel, engineers can design and construct three-dimensional control cabinets and switchgear systems easily and without expensive errors and rework. The software features include 3D mounting layout, wiring and design, modification and adjustment of copper busbars. Designed with flexibility in mind, Pro Panel allows the user to choose their preferred approach whether it is based on equipment lists, connection lists, or circuit diagrams. All necessary components can be easily entered and positioned on the 3D layout, thanks to the innovative eTouch technology. The virtual 3D model of the control cabinet switchgear system helps designers make best use of the valuable control panel space available. Integrated planning aids such as collision testing, adherence to manufacturer installation guidelines, minimum clearances and bending radii, allow quick and optimum positioning and installation. As an added benefit, error detection and other aspects of consistent quality control are predefined at the development stage, considerably reducing rework efforts and thus speeding time to market. For correct wiring of control systems, EPLAN’s new software utilises 3D mounting layout and schematic. Based on a combination of the exact position of the component in the mounting layout and the connection information from the schematic, the control cabinet can be wired virtually.

For more information contact: Crowcon Detection Instruments, Tel: +44 1235 557700 Email: fiona.macrae@crowcon.com Web: www.crowcon.com

For more information contact EPLAN UK, Tel: 01709 704 100 E-mail: info@eplan.co.uk Web: www.eplan.co.uk

PROCESS INDUSTRY INFORMER September 2015

FEATURE

FOOD GRADE THERMAL FLUID ESSENTIALS With thanks from Global Heat Transfer.

It is reported that there are around 4000 companies operating high temperature thermal fluid systems in the UK and Ireland alone. Roughly one in five of these systems is used in the manufacture of food products. However, the current framework of self-governance and external audits means there is a potential for companies to use thermal fluids not suitable for incidental contact with food. In this industry report, Global Heat Transfer analyses the benefits of using food grade thermal fluid and establishes why some food and beverage manufacturers opt not to.

OOD GRADE – AN INDUSTRY ‘MUST’

Heat transfer refers to the transfer of thermal energy. In this process, heat transfer fluids (HTFs) act as a heat carrier between a heater and a heat consumer. This is the basic requirement of a wide range of industrial processes and the principle behind indirect heat transfer plants. Indeed, a recent report estimated that the value of the market in 2011 was $1,684 million and by 2017 this will increase to $2,557 million. A food manufacturer should source food grade HTFs that are suitable for use in food processing. Food grade fluids carry a HT-1 certificate issued by governing bodies such as NSF International and the US Food and Drug Association (FDA). Any manufacturer that wants to sell into the US food market must abide by the correct standards. In the case of the NSF, the components of a thermal fluid are compared against the NSF’s registration guidelines for proprietary substances and nonfood compounds. Based on a toxicological analysis, a HTF can then be registered as HT-1. The supply of food grade HTFs is highly regulated in Europe and companies must comply with REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals) and CLP (Classification, Labelling and Packaging) regulations, which refer to the classification, labelling and packaging of substances and mixtures. Failure to use FG oil in a food application can result in the loss of the manufacturer’s top tier accreditation if the EFSIS (the European Food Safety Inspection Service, part of SAI Global Insurance Ltd.) learns that an inappropriate product is being used. Furthermore, food grade thermal fluid is a requirement for manufacturers that want to supply to the top supermarkets and fast food chains in the UK, in compliance with the British Retail Consortium’s (BRC) global standards. Members of the BRC include Tesco, Sainsbury’s, Asda, Morrisons, Waitrose, Aldi, McDonalds, KFC, Burger King and many more retail giants. Thus, compliance with the standards outlined by the BRC is a must for companies wanting to reach these distributors. A list of recommended food grade HTFs

is also commonly reviewed by insurers and food retailers. With all these compliance and control standards in place, the lack of commercial awareness is surprising. At Global Heat Transfer, we still meet food manufacturers who are keen to sell to the European and US markets, but are not entirely aware of what mandatory requirements exist for HTFs. Unfortunately, on an international scale, there are still ways to get around the current regulatory framework and use HTFs that are not suitable should they come into contact with food products. For example, one such justification is that a company can choose to dispose of all products that come into contact with the fluid. The real problem is that food manufacturers are central to all the external audits and controls mentioned previously, but there is no one mechanism to ensure that food grade HTFs are used in the processing of food. Hazard analysis and critical control point (HACCP) is an internal Food Standards Agency document used to define the acceptable contamination limits for a food. But instead of using a non-toxic food grade fluid, some manufacturers may choose to dispose of all food that comes into contact with an HTF. Lastly, an insurer could stipulate the use of a food grade HTF, but confirmation that a food grade HTF is used would be based on a paper-based audit only. Insurers also assess the frequency that an HTF is sampled and chemically analysed to ensure the flash point temperature of the HTF is being managed as stipulated. However, at no point would the insurer request the HTF to be sampled and chemically analysed to validate documentation. On a final note, some companies still do not fully appreciate the costs they can incur if things do go wrong with their heat transfer system or if entire batches of products need to be discarded. Better awareness of the complexities of thermal fluid would be beneficial for food and beverage manufacturers, suppliers and the general public. Recalls of food and beverage products due to contamination concerns have risen significantly over the last decade and the associated costs can be

PROCESS INDUSTRY INFORMER September 2015

crippling. Not to mention the inevitable dent the incident will leave in the company’s reputation.

FOOD GRADE VS. NON-FOOD GRADE FLUIDS

Food grade thermal fluids are highly refined mineral oils designed specifically to be used in the processing of food. They are non-toxic, non-irritating and have no odour to ensure consumer safety in the event of a leak or spillage. As you can imagine, this is an essential health and safety measure in the food processing industry. Food grade fluids consist of a complex combination of hydrocarbons obtained from the intensive treatment of a petroleum fraction with sulphuric acid and oleum, by hydrogenation or via a combination of hydrogenation and acid treatment. A food grade HTF consists of saturated hydrocarbons with carbon numbers predominantly in the range C15 to C50. A recent test carried out by Global Heat Transfer illustrated that, on average, carbon residue for food grade fluid was lower than non-food grade. 1,223 fluid samples were examined - 280 food grade943 non-food grade. These were taken from 97 customers (24 food grade HTF and 73 mineral HTF) with multiple HTF system lines based at multiple locations in the UK and Ireland. All identified systems were sampled whilst performing under normal operating conditions. A 500 ml sample of the HTF was withdrawn from the system using a custom designed sampling device. The sampling method ensured a true and representative sample of the HTF was obtained. The first aspect of this analysis showed that carbon level was 0.10 and 0.23 of the percentage weight for food grade and non-food grade respectively. This reflects a percentage difference of 118 per cent (- 0.12/0.10 * 100). Total acid number (TAN) levels were also lower for food grade HTF (0.13 versus 0.18 - food grade versus non-food grade HTF). The data clearly showed mean and maximum values for carbon residue and TAN were higher for non-food grade HTF than for the food grade one. Individual data was then explored and linear analysis showed there was a strong positive relationship between carbon residue and TAN for both types of HTF. The analysis demonstrates the non-fouling nature of a food grade HTF, making it more sustainable and less costly in the long-run. HTFs suitable for use in food processing are commonly referred to as ‘nonfouling’, which means when they thermally degrade, they produce small carbon particles that are suspended in the liquid. Moreover, the carbon formations are less sticky and this reduces the extent of adhesion to the internal surfaces of a heat transfer system. It is important to remember that all HTFs undergo thermal degradation over time. At high operating temperatures, the bonds that exist between hydrocarbon chains will start to break and form shorter (commonly referred to as ‘light-ends’) and longer chained hydrocarbons (‘heavy-ends’). Both of these products have consequences for the safety of a HTF system and for HTF sampling. The build-up of light-end components is a potential fire risk because they decrease the ignition temperature of the HTF. The accumulation of heavy-ends results in the formation of sticky carbon deposits or sludge and can be monitored by analysing the carbon residue in a system. The same is true for oxidation of a HTF: this leads to the formation of carbon sludge and acids. Sludge or soft carbon will lead to a carbon coat forming on the internal surfaces of the HTF system and with time this will harden. The insulating effect of carbon means that the HTF system is less efficient: heat transfer rates are reduced resulting in longer heat-up time and lower production rates. Also, the hard carbon deposits work to form hot spots and have the potential to cause heater tubes and electrical elements in the HTF system to burn-out. The salient point is that routine heat transfer fluid analysis is the only accurate way of assessing the condition of HTFs and predicting when the system needs topping up or flushing. Ideally, all plants using heat transfer fluids should create a robust lifecycle maintenance plan that contains regular sample analysis and careful flashpoint management and thermal fluid condition maintenance. Safety can be further enhanced in food and beverage manufacturing by using non-fouling food grade HTFs that have a lower tendency to result in carbon residue than non-food grade HTFs. This will implicitly mean a reduction in maintenance and production costs and should eliminate the unwelcome prospect of discarded product batches.

CONCLUSION

Global Heat Transfer’s analysis of both food grade and non-food grade fluids revealed the former was less fouling to systems, had a lower carbon residue and lower TAN levels. This means higher safety levels, as well as lower maintenance and operational costs in the long run. Despite these obvious advantages, some food processing facilities still don’t use food grade transfer fluids. We believe food and beverage manufacturers require a higher level of awareness when it comes to the regulatory, environmental and maintenance benefits of using food grade heat transfer fluids in food and beverage applications. We believe awareness is the key to make food and beverage manufacturing more cost-effective in the long run, while ensuring companies don’t make any unnecessary sacrifices when it comes to product quality and process safety.

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IONIX ADVANCED TECHNOLOGIES LIMITED FLUKE INTRODUCES EIGHT NEW INFRARED CLOSES £2M FUNDING ROUND CAMERAS WITH UP TO 2.5 TIMES THE Ionix Advanced Technologies Limited, a company specialising in high performance piezoelectric materials and devices, is pleased to announce that it has closed a RESOLUTION TO QUICKLY ASSESS £2m funding round with backing from IP Group plc, ParkWalk and private sources. The funds will accelerate the commercialisation of a range of devices based EQUIPMENT HEALTH on its novel high-temperature piezoelectric materials, for applications in areas Fluke has introduced eight new Fluke® TiS Performance Series Infrared Cameras, with improved resolution to help industrial and maintenance professionals analyse equipment health more quickly and accurately. Fluke TiS models deliver up to 2.5 times more pixels and a 70% improvement in distance-to-spot than the Fluke Ti1xx series cameras, for better image quality to enhance identification of potential equipment problems in industrial and electrical maintenance and process industries. The new models feature large 3.5 inch screens to help pinpoint issues while still in the field and offer one touch image access, which eliminates the need to scroll through a menu to view images. Eight models are available, five fixed focus and three manual focus, with resolution up to 260 x 195 pixels. The rugged infrared cameras upload images to the Fluke Connect Cloud via a wireless connection to securely store and manage images and potentially reduce administrative time back in the office. Reports can be created and emailed from the jobsite via Fluke Connect®, eliminating the need to return to the office to process reports. For more information contact Fluke (U.K.) Ltd, Norwich, Norfolk Tel: 0207 942 0700. E-mail: industrial@uk.fluke.nl

PROCESS ENGINEERING MANAGER ROLE POSITION: Permanent We require a Process Engineering Manager with approx 15 to 20 years experience to work on various UK projects, working in the Chemical, Petrochemicals and Pharmaceuticals sectors. The role comprises managing a small team of principal process engineers (approx 5 to 10) whilst participating in the delivery of process engineering solutions for various projects.

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such as condition monitoring, and flow measurement in extreme environments. Ionix’s devices have the potential to offer significant productivity gains, as well as cost and energy savings, by facilitating more efficient, safe and reliable process and inspection operations in extreme environments, where existing technology is unable to operate effectively. Ionix is initially targeting applications where high temperature operation, up to 420 degrees C, provides a capability not offered by conventional piezoelectric devices. Initial target markets for these high temperature devices include: industrial plant process, energy and nuclear power, refining, aerospace, and oil and gas, and represents a total market potential in excess of £500m per annum. Dr David Astles commented: “Ionix exists because of the need for the industrial world to better monitor plant condition and performance in extreme environments. The company has developed a range of promising materials and associated devices which fit with this challenge, and offer exciting opportunities in a range of applications. Our technology looks ideally placed to play a part in the drive to increase continuous condition monitoring, and we are gaining good traction in this area. I look forward to working closely with our talented Ionix team and our partners and clients as we move into the next stage of commercial development. We are looking for the right partners to realise our full potential.” For more information contact Ionix Advanced Technologies Ltd. E-mail: david.astles@ionix.at Tel: +44 (0)1484 505859 Web: www.ionixadvancedtechnologies. co.uk

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