Process Industry Informer March/April 2015

www.processindustryinformer.com

MAR/APR 2015 Volume 11 No. 2

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THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

10 FEATURED ARTICLES INCLUDING FOOD INDUSTRY AT ROBOTICS TIPPING POINT page 14 PUMP CAVITATION & HOW TO AVOID IT page 30

UNDER PRESSURE

SENSORS IN THE SPOTLIGHT page 33 THE HYBRID HEAT EXCHANGER page 49

+ 21 Product Sections

PUSH THE ENERGY EFFICIENCY BUTTON

Page 36

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

CONTENTS. 4-7 News & Events 9-15 Applications 15 Seals 15 Air Compressors 18-19 Test & Measurement 19 Inspection & Vision Systems 23-24 Health & Safety 24 Dust & Fume Control 24 Network & Communications 32, 34 & 35 Process Measurement & Instrumentation 39-41 Fluids & Liquids Handling (incl. Pumps & Valves) 42 Drives & Motors 42 Spectral Sensors 43 Wastewater & Effluent Treatment

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FOOD INDUSTRY AT ROBOTICS TIPPING POINT

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

46 Data Acquisition 46 Calibration 46 Maintenance 46 Particle Sizing 48 Process Control 48 Heat Transfer & Energy 48 Busbar Systems 50 Rotary Blowers 50 Battery Pack Design 50 Enclosures 51 Products & Suppliers Directory

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Pump Industry AWARDS

25 Show Preview

36

44

30

PUMP CAVITATION & HOW TO AVOID IT

47

ELIMINATING DATA LOSS FROM REMOTE FACILITIES

33

UNDER PRESSURE SENSORS IN THE SPOTLIGHT

49

THE HYBRID HEAT EXCHANGER

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THE GREAT FOOD MANUFACTURING INDUSTRY DAM BURST

ONLY THE COMBINATION OF FUNCTIONAL SAFETY & CYBERSECURITY ENSURES THE OVERALL SAFETY...

Printed By Bishops Printers Ltd Advertisement & Editorial Offices Process Industry Informer, Passfield Business Centre, Lynchborough Road, Passfield, Liphook, Hants, GU30 7SB Tel: 01428 751188 Fax: 01428 751199 Email: info@piimag.com Web: www.piimag.com Subscriptions UK £25 | EIRE £35 Overseas prices on application © Process Industry Informer

ENERGY EFFICIENCY’S AUTOMATION LENS

SELECTING THE RIGHT GREASE FOR ROLLING BEARINGS TO MAXIMISE PROCESS UPTIME

DIVING DEEP INTO PROCESS SAFETY

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Mar/Apr 2015

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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Copy supplied over length will be cut to the amount paid for. Units and abbreviations will be standardised in accordance with house style.

No part of this publication may be reproduced or transmitted by any means without the prior written consent of the publishers.

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NEWS & EVENTS BRAMMER EXTENDS RANGE WITH LATEST PRODUCT CATALOGUE Brammer, the UK’s leading distributor of industrial maintenance, repair and overhaul (MRO) products and services, has launched its latest Industrial Supplies Catalogue for 2015/16 with extensive additions to its product range.

Customers will now have easy access to the extensive product ranges Brammer has to offer, as well as outlining value added services, including Invend™, Insite™ and managed inventory services as well as energy savings, and workshop services. The new hardback catalogue contains over 60,000 individual products, of which over 7,700 are brand new to Brammer customers.

With more than 90 branches nationwide offering same day or next day delivery, customers can be assured of a timely solution to their MRO requirements which can help them maximise performance and minimise downtime.

The catalogue is divided into five sections of high quality maintenance repair and overall products for easy reference: Bearings & Seals; Mechanical Power Transmission; Electrical Power Transmission; Fluid Power; and General Maintenance. Within each section, Brammer offers thousands of products from market-leading brands including 3M, Siemens, SKF and Stanley. In addition, Brammer customers have access to two exclusive specialist brands – Q-Safe and Roebuck – through the new catalogue. More than 100 pages of products from industrial quality hand tools supplier, Roebuck are included.

For more information or to request your free catalogue visit www.brammeruk.com or emailmarketing.uk@brammer.biz

WAGO APPOINTS NEW MD FOR UK AND IRELAND WAGO Limited has announced the appointment of a new Managing Director.

Tony Hoyle, formerly Measurement Products General Manager (UK and Ireland) at ABB Ltd., will have overall responsibility for the company’s activities in the UK and Ireland.

He succeeds Gordon Smith who has announced his retirement after overseeing the company’s strong growth since its formation in 1992. Gordon will however, work with Tony in a joint management capacity until the middle of 2015.

In addition to his time at ABB, Tony has held senior management, sales and marketing posts at some of the world’s leading technology providers including Danfoss, Siemens and Telemecaniqe. He has considerable experience in a number of key sectors including water treatment, processing and factory automation.

Commenting on his new role, he said “WAGO was a leading innovator in interconnection technology when it was formed almost 70 years ago.

Its focus is, of course, considerably broader now. Our mission is to offer a comprehensive range of truly innovative automation technology solutions for industrial and building services customers throughout the UK and Ireland.

“I look forward to working with WAGO and building on the considerable success which Gordon and his team have achieved” For more information contact WAGO Ltd, Rugby, Warwickshire.

Tel: 01788 568008 Email: ukmarketing@wago.com Web: www.wago.com

BENEFIT FROM IMPROVED EFFICIENCIES IN PROCESS APPLICATIONS WITH HBM TRAINING Following on from a successful series of training and workshops, HBM – a market leader in the field of test and measurement – has announced the dates for its next training course, which will take place on the 21-22nd May 2015.

Suitable for all personnel working in a field where fast weighing and high accuracy is demanded, ‘Fundamentals of dynamic weighing and strain gauge load cells’ is a two day seminar designed to improve efficiencies in your process application.

Providing practical and theoretical advice, the seminar begins by introducing the fundamentals of strain gauge (SG) sensors. Leading on, the seminar explains how to find and set the optimal parameters for HBM digital load cells and digital transducer electronics in check weighing and dosing applications; the use of HBM panel software to set and change the parameters of digital load cells or transducer electronics; and what the relevant parameters are for weighing transducers in dynamic applications and how to compare them.

The seminar also looks at how the demand for higher weighing accuracy determines the minimum measuring time of checkweigher, dosing or filling applications and why the measuring time determines the maximum through put rate of checkweighers / dosing applications and what the maximum measuring time required for a certain through put rate is.

Participants on the course will also learn how to shorten the required measuring time for check weighing and dosing applications by electronic filtering and how the mechanical construction of your weighing scale affects the measuring time. Located at the Woodland Grange Conference Centre, Warwickshire and presented by Dr. Henrik Brutlach, this HBM seminar is aimed specifically at technical orientated users, technicians and engineers from the field of mechanical engineering or similar, especially users of strain gauge based load cells in dynamic weighing processes. All seminar materials required for the course are included.

‘Fundamentals of dynamic weighing and strain gauge load cells’ provides the calibre of training expected from HBM, a quality producer of transducers and measuring electronics for more than 60 years.

To register or for further information on this training course, contact HBM on Tel.: +44 (0) 20 8515 6000 Email:info@uk.hbm.co.uk / Web: www.hbm.com/en/menu/seminars/seminar-calendar/

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PROCESS INDUSTRY INFORMER March - April 2015

NEWS & EVENTS COMPANY NAME CHANGE REFLECTS THE SIGNIFICANT PRODUCT PORTFOLIO EXPANSION FOR WORLD-LEADING POSITIVE DISPLACEMENT PUMP MANUFACTURER Watson-Marlow Pumps Group announced today that it has changed its name to Watson-Marlow Fluid Technology Group to better reflect the evolution of the company from its roots as a manufacturer of peristaltic pumps and tubing, to its current position as a world leader in fluid path technology.

Watson-Marlow Fluid Technology Group, which has a global network of operations including seven factories and 28 direct sales offices, is part of the Spirax-Sarco Engineering Group plc and is headquartered in Falmouth, UK. The company now encompasses seven distinct brands which, combined, deliver a complete suite of fluid technology solutions to the biopharmaceutical , chemical process, food and beverage, mining and environmental market sectors. The name change follows the recent acquisition of BioPure, which signaled the company’s strategic move to offer a wider range of solutions to the biotechnology and pharmaceutical markets.

Reflection of Today’s Portfolio Commenting on the name change, Watson-Marlow Fluid Technology Group’s President, Jay Whalen, said: “Our new name unifies our growing portfolio of fluid path technologies, it is an expression of what we deliver today, and a reflection of the growing portfolio of businesses and opportunities that sit within our group. Our sector market focus, combined with the recent acquisition of BioPure gave us the opportunity to rethink the way we present ourselves to the market. We can no longer simply be defined as a pump or tubing company: we now offer customers a much more holistic offering”.

Growth Strategy The company name change is part of a five-pronged growth strategy, which includes targeted investment in selective product development and market sector diversification. This is highlighted by the additions of MasoSine (sinusoidal pumps for the food and beverage sector), Flexicon (filling and vial capping systems used in the aseptic filling sector), BioPure (single-use tubing connection systems as used in the biopharmaceutical sector) and non-pump transfer tubing development.

Mr Whalen concludes: “This re-presentation of our company cements our position as a business that never stands still and is committed to embracing change and innovation. This is what our customers deserve and expect from a business such ours. I am delighted we can demonstrate this ‘evolution’ in such a positive and sustainable way”.

For more information contact Watson-Marlow Fluid Technology, Falmouth , Cornwall Tel: 01326 370370 E-mail: info@wmftg.com Web: www.wmftg.co.uk

PROCESS INDUSTRY INFORMER March - April 2015

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NEWS & EVENTS DEMAG V-TYPE CRANE WINS iF DESIGN AWARD • • •

Innovative crane girder design convinces the judging panel Internationally acknowledged award Sophisticated design makes the crane more precise, lighter and more durable

The Demag V-type crane has won the internationally renowned iF (International Forum) Design Award for its outstanding design. The award recognises the innovative construction of the V-type crane girder, which is based on bionic principles. In a similar way to bone structure, the design only uses material where it is necessary. Depending on requirements, the new girder design can be adapted with millimetre accuracy to the height of existing or planned buildings.

This versatility facilitates simple implementation in existing production bays and greater freedom for planning new buildings.

The distinguished judging panel, comprising members from 20 countries, recognised the crane in the Industry/Skilled Trades’ category. “The award demonstrates that our new Demag V-type crane design truly represents a revolution in the market and that industrial cranes can also achieve new levels of design excellence”, explains Andreas Hambrock, Head of the Universal Cranes business line at Terex Material Handling. “At the same time, the optimised crane girder design makes it more precise, lighter and more durable than other universal cranes.”

Exhibition in Hamburg As an award winner, the Demag V-type crane will be shown at the iF design exhibition in Hamburg’s HafenCity from 28 February to 7 June 2015. The award ceremony was held in Munich on 27 February. iF International Forum Design GmbH has been recognising excellent design and outstanding design achievements with its iF Design Award for more than 60 years. Candidates have to meet strict criteria in order to win the renowned award. 2015 saw a total of some 5,000 submissions from 53 countries.

For more information contact Terex MHPS (UK) Ltd, Banbury, Oxfordshire Tel: 01295 676100 Fax: 01295 271408 Email: bnb-help@terex.com Web: www.demagcranes.co.uk

LIFTVRAC - ON-SITE TRIALS FROM GENESIS

HBM COURSE TEACHES FUNDAMENTALS OF STRAIN GAUGE INSTALLATION ON PLASTICS / FIBRE REINFORCED COMPOSITES HBM – a market leader in the field of test and measurement – has announced the dates for its ‘Fundamentals of strain gauge installation on plastics / fibre reinforced composites’ training course, which takes place on the 18th – 20th May 2015.

This three day seminar provides both practical and theoretical advice and covers a variety of topics, beginning with an introduction to the fundamentals of strain gauges (SGs), which looks at the fundamental relations between strain, mechanical stress and electrical resistance and the characteristics of SG installations on plastics.

The course also includes other essential training on strain gauge installation with both hot and cold curing adhesive; connections of strain gauges for measurements; installations of SGs in composites and plastic casts; installation planning; calibration of measurement chains; and determination of strains with unknown principal direction.

Suitable for all personnel who would like to learn how to install strain gauges on plastic and fibre reinforced composites, no prior knowledge is required to participate in the course.

Located at the Woodland Grange Conference Centre, Warwickshire and presented by Dr. Henrik Brutlach, the course will enable attendees to distinguish the differences between strain gauge installations on fibre reinforced plastics from standard installations, through a mix of sound knowledge and practical guidance.

HBM has been a leader in Strain Gauges for over 60 years. Its 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 for the installation of Strain Gauges, for maximum convenience.

To register or for further information on this training course, contact HBM on Tel.: +44 (0) 20 8515 6000 or via Email: info@uk.hbm.co.uk or visit the Website: www.hbm.com/en/menu/seminars/seminar-calendar/

Liftvrac, the inventors of the amazing conveying systems of the same name, shown at PPMA in October, has appointed Genesis Process Solutions as their agents for the UK and Ireland.

Phil Cameron is the Sales Director of Genesis Process Solutions: “We started to talk to Liftvrac some months before PPMA and convinced them that taking exhibition space was a good way of introducing the system to the UK markets. The level of good quality response was excellent with the number of companies requesting on-site trials well into double figures. We have now taken delivery of a Model S Liftvrac and already conducted on-site trials with some companies” To state that the Liftvrac conveying system is revolutionary is something of an understatement. It is more efficient, more economic and easier to clean than any other short-range mechanical or pneumatic system currently available for handling powdered, fluid, fragile or sticky products.

The key component is a polyurethane belt which forms a tube around the product and carries it the entire length of the elevation. The flat belt is formed into a tube just after the product inlet and this tube then carries the material up to the top of the Liftvrac, where the belt opens flat again. The belt always wants to become flat naturally so doesn’t squeeze the product. Once the speed and belt load is set up the product holds itself in position so there is no stress on the product itself. A lip system effectively seals the tube and holds the product in place until it’s discharged at the end of the line. The seal is so effective that any powdered product, for example, can be conveyed without any risk of leakage into the surrounding environment.

But it isn’t just powders that Liftvrac can handle. Fish, cheese, pasta, meat, plastics and a huge range of other products can be conveyed without any fear of blockages or clogging thanks to a scraper located at the discharge end of the belt.

With a small motor, ranging from 0.5 – 1.5kW the Liftvrac system is extremely energy efficient and can handle product at rates up to18m3/h. The entire system can be dismantled, cleaned and reassembled in around twenty minutes – ideal if different products are going to be conveyed.

Liftvrac is available in two models, C and S which refer to their shapes. C has been designed for tight enclosed spaces where the product needs to be conveyed to a mezzanine while the S model is better where there is more space and the product needs elevating to a mezzanine or overhead production line.

Typical installations including the conveying of finished goods to a multi-head weigher, feeding raw ingredients to a mixer or even transferring from one area to another, the beauty of the Liftvrac is how versatile the unit is.

To discuss an on-site trial or a free site survey please contact Phil Cameron on 01270 766300 or E-mail: phil@genesisps.co.uk

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PROCESS INDUSTRY INFORMER March - April 2015

NEWS & EVENTS ABB OPENS DEVELOPMENT SUITE TO PROVE NEXEN CONTROL SYSTEMS A support facility that allows prooftesting of all change software prior to delivery offshore, is opened by Nexen Petroleum UK Ltd and housed on its behalf at ABB’s Altens, Aberdeen premises.

The Nexen Integrated Control and Safety System (ICSS) Development Suite is a full-scale replica of Nexen’s offshore control network for its Buzzard field. It allows ABB to perform configuration management and comprehensive testing of all software changes prior to installation on site. The facility helps prepare for planned offshore visits and improves the level of operational support provided from base, to facilitate technical troubleshooting and maintenance.

The Development Suite contains a representation of all offshore controllers for Process Control System (PCS) as well as Safety Instrumented System (SIS) controllers for Fire and Gas System (FGS)/ Process Shut Down (PSD). A suite of servers replicate the offshore 800xA aspect and connectivity network. The suite houses ABB’s Extended Operator Workstation (EOW).

For more information contact ABB Ltd, Aberdeen.

Tel: 01224 592 123 E-mail: Arlene.hutchinson@gb.abb.com Web: www.abb.com/service

PROCESS INDUSTRY INFORMER March - April 2015

ASL JOINS TELEFÓNICA’S m2m GLOBAL PARTNER PROGRAMME Programme focuses on “key players in the M2M value chain” M2M communications provider ASL has joined Telefónica’s m2m Global Partner Programme.

In creating the programme, Telefónica wished to partner with “the key players in the M2M value chain”. As a Master Certified Device Partner, ASL provides end-to-end solutions to final users while benefitting from a tight business and technological integration with the telecoms giant. M2M communications technology can be used to improve efficiency in many applications, from utilities, oil and gas, agriculture and manufacturing, to health and care management, transport, logistics, infrastructure, retail and vending.

The programme allows ASL to offer five main advantages to its customers: • Pricing centre – customers can access the latest version of Telefónica’s global price list and discover which operators and prices are available in each zone and for each type of service. Customers can also create simulation scenarios, configure the most appropriate plan and then pass it to ASL using the deal management tool.

• Coverage map – the partner portal offers a complete coverage map that allows customers to gauge the quality of coverage in their intended area of deployment.

• Online ordering – customers ordering their SIM via the dedicated online tool can be confident that all of the required configuration aspects are correct and that proper service activation will take place.

• Service management – As M2M services become increasingly dynamic, customers need to adapt to new requirements regarding rate plans, communications plans and APN configuration. By automating these tasks, Telefónica promises to shorten provisioning time and reduce human errors.

For more information contact ASL, Pitsford, Northampton Tel: 01604 883880 Email: ann.sharrocks@aslholdings.co.uk Web: www.aslh.co.uk

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This year’s Pump Industry Awards Gala Dinner organised by Touchwave Media and in association with The British Pump Manufacturers Association and sponsored by some of the leading brands in the pump sector was held for the second year running at the Chesford Grange Hotel in Kenilworth on Thursday 19th March.

Attended by over 200 pump industry professional who enjoyed the usual “friendly competitive” evening as they anxiously awaited the results, which when announced were met with joyous celebration.

As always there was the raffle in aid of the BPMA’s chosen charity WaterAid which raised just under £2000.

The evening entertainment was provided by Alfie Moore, policeman turned professional comedian who recounted numerous tales from his life at the front-line of the police force and as was compèred by the charming BBC News anchor Babita Sharma.

Folllowing on from the awards programme it was time for the traditional adjournment to the various bars where celebrations and commiseration took place in the usual manner, not to mention that a great deal of networking.

For further information about the Pump Industry Awards, & to view the photo gallery of this year’s event please visit the website at www.pumpindustryawards. com. If you are interested in sponsoring, nominating and/or attending the 2016 event please contact Andrew Castle at andrew@touchwavemedia.co.uk.

MEET THE WINNERS

The awards focus on key areas of manufacture and supply, including innovation and achievement, energy saving, engineering excellence, customer care and employee motivation. On the night, six companies and two individuals were awarded, and a fantastic night was had by all!

TECHNICAL INNOVATION – PRODUCTS SPONSORED BY: KSB WINNER: THE GRUNDFOS GO REMOTE The Grundfos GO is the most comprehensive platform for mobile pump control available to the market today. It provides simple, handheld support acting as an intuitive assistant and saves time on everything from commissioning, data collection, reporting through to sizing and replacement for a wide range of pumps and applications. The Grundfos GO is always online and ready to use wherever and whenever it is needed.

TECHNICAL INNOVATION – PROJECTS SPONSORED BY: PROCESS INDUSTRY INFORMER WINNER: IMPROVING PERFORMANCE OF MINERA COLLAHUASI’S WATER PUMPING SYSTEM, NEPTUNO PUMPS Collahuasi Mining Co., located in Chile at 4.500 meters above sea level, has one of the most aggressive waters in the world, reaching 50.000 (mg/l) of chloride concentration. Neptuno Pumps performed a complete redesign of its pumps through a complete CFD/ FEA analysis together with a full material upgrade, incorporating superior alloys and advanced engineered thermoplastics which improved pump operational availability in a 600%, reaching 18.000 hours of continuous operation, allowing savings of US$650,000 per year.

ENVIRONMENTAL CONTRIBUTION OF THE YEAR SPONSORED BY: SPP PUMPS WINNER: PUMP AS TURBINE IN PLACE OF PRESSURE REDUCING VALVE, KSB LTD & KIER KSB’s ‘Pump as Turbine’ was introduced

by Kier & KSB into South West Water’s Supply Network, to act in place of a Pressure Reducing Valve, thus capturing energy that would otherwise be wasted and converting it to electricity that can be fed into the grid. This environmentally friendly pump project has enabled South West Water to continue to work towards meeting their target for renewable power generation (30GWh by 2015).

MANUFACTURER OF THE YEAR SPONSORED BY: AESSEAL WINNER: CLYDEUNION PUMPS - AN SPX BRAND An SPX brand, ClydeUnion Pumps Glasgow, is one of the world’s leading pump companies - a market leading centre of excellence in providing original equipment pumping technologies and full system solutions. Approaching 150 years Pumping Heritage, including Weir Pumps, we focus on delivering engineering excellence and customer satisfaction.

With dedicated Aftermarket and Field Service, we provide full product life cycle solutions supporting Service, Repair, Overhaul and Spare Parts, Customer Training, RCA studies, Upgrades and Re-rates.

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DISTRIBUTOR OF THE YEAR SPONSORED BY: WEG ELECTRIC MOTORS WINNER: DRILLING & PUMPING SUPPLIES (DPS) DPS designs, supplies and installs pumping equipment throughout the whole of Ireland. As a leading supplier, DPS’s successful track record in customer satisfaction stems from efficient pump selections and advice that often exceeds customer expectations. Excellent communication between the dedicated engineering and service functions ensures seamless delivery from supplier to customer. DPS’s vision is to be the leader in design, supply, and installation throughout Ireland.

SUPPLIER OF THE YEAR SPONSORED BY: TOMLINSON HALL & CO WINNER: WEG ELECTRIC MOTORS UK Preparing for the 2015 change in legislation has been an ongoing process for WEG, IE3 motors were launched for general sale in 2009 with IE4 made readily available in 2013. A programme of training and education has continued throughout 2014 with customers and distributors invited to conferences bringing them together with industry experts to discuss the impact of these changes in legislation.

Moving forward, WEG continues to develop products that exceed the European efficiency standards whilst growing stock holding throughout Europe to meet demands.

ENGINEER OF THE YEAR SPONSORED BY: WORLD PUMPS WINNER: EMMA LAMBERT, CLYDEUNION PUMPS - AN SPX BRAND As Lead Engineer / Team Leader on the Statoil project Mariner, Emma has excelled and exceeded all expectations combining technical excellence and innovation with her notable project & people management skills to deliver three new design pump packages, valuing approximately $20 million, including the world’s largest cast NORSOK (ASTM A995 6A) injection pump. Emma has also created a dynamic, highly motivated team culture perfectly aligned to SPX core values: integrity, accountability and innovation.

LIFETIME ACHIEVEMENT AWARD SPONSORED BY: BPMA WINNER: BOB WENT As an active member of BPMA’s Council and Technical Committees until his retirement in December, he has been involved in many key decisions and contributed, technically, to many international standards and guides that are available today. His hard work, support and technical competence have been greatly appreciated within the BPMA over the last 11 years and his contributions will now be sadly missed.

PROCESS INDUSTRY INFORMER March - April 2015

APPLICATIONS PUMPING YEAST IN WINERIES WITH A PERISTALTIC PUMP The process of fermentation Winemaking or vinification starts with the selection of grapes. After harvesting the grapes, they are taken to a winery for fermentation. Red grapes are made from the pulp fermented along with the skin, which gives it the real colour.

Whereas white wine is made by fermenting the juice extracted from the grapes.

Traditionally the grapes were collected in oak vessels for fermentation.

Nowadays, many wineries adopt a more modern approach of fermenting in Stainless Steel containers open at the top.

During this stage yeast may be added to catalyse the fermentation process. This usually takes one to two weeks during which the yeast converts sugar in the grapes into alcohol. The alcoholic fermentation takes place in the favourable conditions created by pumping over the mixture and pigeages (traditional stomping of grapes), along with the addition of yeast.

At the end of the process, yeast is removed to avoid spoiling of flavor and to leave the wine with a clear, crisp appearance.

Verderflex hose pumps in the filter press The process to remove yeast is usually performed by introducing diatomaceous (kieselguhr) earth into the fermented wine. The fine particles of diatomaceous earth attract the yeast cells to form clumps, which remain in a suspension referred to as yeast slurry. The yeast slurry is then pumped through a filter press with a Verderflex peristaltic pump, before the wine is finally stored or bottled.

A German company manufactures chamber filter press system mounted on a skid with a Verderflex VF25 industrial hose pump as part of a standard filter press system.

From the yeast slurry storage vessel, the slurry is fed into the peristaltic pump through a 32-mm suction line made from flexible Verderflex hose to reduce pulsation. The peristaltic Verderflex pump is fitted with DIN 11851, type SC stainless steel sanitary connections of 32 mm, with reducing inserts to suit the 25mm tubing. The drive of the pump is a 1.1 kW gear reducer giving a pump speed of 48 rpm, delivering 800 l/hr of product to the filter press.

On the discharge side of the filter press pump, a 32mm flexible hose is used to feed the filter press. It is important to eliminate the pulsation on the discharge side of the peristaltic pump, so in addition to the flexible hose, an air dome is installed. The air dome has a volume of approximately 20 liters, allowing it to absorb pulsation, but also to act as a pressurized storage tank for the filter.

The chamber filters are evenly filled with wine/yeast slurry mixture, to a pressure of 10 bar. This pressure is maintained and not exceeded, for effective operation. To achieve this a pressure sensor is installed on top of the air dome and is set to stop the Verderflex pump running when 10 bar pressure is registered. At least one pressing shoe of the pump is always positioned to be fully compressing the hose, acting as a valve, thus maintaining the pressure in the air dome and chamber filter.

As the wine slowly flows through the filter the pressure inside the air dome reduces, until the sensor registers a pressure of 7 bar, at which point it is set to start the Verderflex pump again. The industrial hose pump continues to stop and start in this cycle, maintaining an even pressure between 7 and 10 bar until the filter is completely filled with the yeast solids. At the end of a batch, when the yeast slurry feed vessel is empty, the peristaltic Verderflex pump can run dry without damage.

Or, if the filter is blocked in the middle of a batch, the hose pump can then be reversed to empty the filter and air dome of yeast slurry, leaving the filter dry, so the yeast cake can be removed. Some of the reasons why Verderflex hose pumps are popular in wineries.In these wineries in Germany the duty cycle is for approximately 500 running hours per unit per year. After each season, the hose inside the pump is replaced with a new one.

The advantages and benefits of the Verderflex hose pumps: • Self priming, yeast product can be taken from the storage vessel, even if this is below the filter unit • Metering capability, constant flow to the filter at increasing pressures • No moving part in the liquid stream, only the hose in contact with the wine • Reduced maintenance, only the hose as wearing part • Dry running, at the end of each batch the pump runs dry without problems • Non return valves are not required as the pressing shoe close the hose completely.

For more information please contact Verderflex, Verder Ltd, Castleford, West Yorkshire.

Tel: +44(0) 1924 221020 E-mail: info@verderflex.com Web: www.verderflex/com

PROCESS INDUSTRY INFORMER March - April 2015

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APPLICATIONS PHARMACEUTICAL MANUFACTURER INSTALLS BABCOCK WANSON STEAM GENERATORS Babcock Wanson has supplied two 2000kg/h VPX Rapid Steam Generators to Martindale Pharma, a market leader in the manufacture and supply of specialty pharmaceuticals and services for healthcare professionals worldwide.

These have been installed at Martindale Pharma’s principle site of manufacture in Romford.

Steam is produced for a wide variety of uses across the site, including the manufacturing production processes, production of Water for Injection (WFI) and a Pure Steam Generator (PSG), as well as heating for the company’s Air Handling Systems. The new VPX units have replaced four smaller generators that were unable to meet Martindale Pharma’s growth and subsequent capacity requirements.

VPX vertical coil Steam Generators feature three full gas passes plus an inbuilt combustion air pre heater to give high operating efficiency. To maintain the Steam Generators’ efficiency and maximise their working life, Martindale Pharma has signed up to Babcock Wanson’s Water Treatment Service operated in conjunction with water treatment specialist Deep Water Blue.

Mark McLean, Engineering Team Leader at Martindale Pharma says, “the service from Deep Water Blue has so far been really good and the internet based reporting system is a fantastic tool for daily feedback on the water conditions, with instant advice on what to do to rectify any reading starting to drift out of specification.”

Babcock Wanson also provides a five year corrosion warranty on the steam generator coil.

For more information contact Babcock Wanson Tel.: 020 8953 7111 Email: info@babcock-wanson.co.uk Web: www.babcock-wanson.co.uk

ONDEO INDUSTRIAL SOLUTIONS FAST-TRACKS LATEST FIRE MAIN PROJECT FOR INEOS Ondeo Industrial Solutions, part of Degrémont Industry, has successfully completed its second fire main cross link project this year at INEOS’ chemical manufacturing plant in Grangemouth, Scotland. The industrial water management company’s Site Services team completed the project with a perfect safety record, to budget and five weeks ahead of schedule.

The project required the excavation by hand of a 45 metre fire main section adjacent to high voltage cables, followed by the construction and installation of the remaining 300 metres of 500mm HPPE fire main at INEOS’ Grangemouthbased mature oil refinery complex. INEOS is a leading global manufacturer of petrochemicals, speciality chemicals and oil products that are used by businesses in a variety of markets, including packaging and foods, fuels and lubricants, construction, automotive and transport, and many more.

The fire main, which is the sixth large diameter water project to be installed at Grangemouth by the Site Services team, was designed by the Ondeo Industrial Solutions Engineering & Projects department at Grangemouth. Following planning and an incident free installation process, the fire main was successfully tested and commissioned five weeks ahead of schedule.

For more information contact Ondeo Industrial Solutions, Tel : 0191 491 4274 Email : Sophie.ONEILL@ondeo-is.com Web: www.degremont-industry.com

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HYDRA-CELL® PUMPS IN OXYGEN SCAVENGING Following site trials pumping aggressive oxygen scavenging chemicals, Occidental Petroleum in Oman has approved Hydra-Cell pumps, from Wanner International, for use in one of their most demanding applications.

Dissolved oxygen in injection water can cause destructive oxygen corrosion to metal pipes and process equipment. By-products of this corrosion form sludges that cause plugging and blockages. This oxygen is generally removed through the introduction of oxygen scavenging chemicals into the high-pressure stream.

Oxygen scavenging chemicals such as sodium and ammonium bisulfites are renown for damaging pumps. Occidental Petroleum had trialled several types of pumps and all were found wanting, the majority springing leaks through dynamic seals in a matter of days or weeks. A Hydra-Cell P200 with mechanical speed control has however solved the problem. The seal-less design of this multi-diaphragm pump removed the leakage problem completely, reducing downtime and eliminating seal maintenance at a stroke.

OXY engineers were also impressed by the Hydra-Cell’s small footprint, its ability to handle particulates without damage and its ability to run dry indefinitely. The Hydra-Cell P200 pump has successfully completed the rigorous trial period and is now officially approved by Occidental Petroleum for this application.

For more information contact Wanner International, Fleet, Hants.

Tel +44 (0)1252 816847 Email: NHerrington@wannerint.com Web: www.hydra-cell.eu

RILEY SURFACE WORLD ANNOUNCES SITE CLEARANCE OF ROBOTIC POLISHING EQUIPMENT FROM GLOBAL HEALTHCARE PRODUCTS MANUFACTURER IN IRELAND Riley Surface World is Europe’s leading reseller of new and used surface technology plant and machinery. The company will be exhibiting in the Surface Technology hall of the Hannover Fair in Germany, April 13 – 17, 2015, hall 3, stand E02.

Riley is handling the site clearance of a large quantity of Intec and Bula robotic polishing cells with ABB robots from a global manufacturer of healthcare products based in Limerick, Ireland. These are accompanied by automatic and manual polishing and belt grinding machinery and other ancillaries.

The robotic polishing cells are designed for deburring and polishing of precision profiled objects and moulded parts. They can deal with the most difficult shapes, contours and materials, including steel, non-ferrous metals, wood, plastic etc.

The twin wheel variable speed polishing cells have the robots and polishing machines anchored on a stable frame and surrounded by a cabin. This provides for maximum operator safety and workplace cleanliness with built-in dust extraction and sound dampening.

There are eight polishing cells in total, together with a number of stand-alone Ciclope, Loeser and Wheelabrator Walther Trowal grinding stations, a wax coating unit and other ancillary machinery.

For more information contact Riley Industries Ltd, Aldridge, West Midlands Tel: +44 (0) 1922 45 8000 E-mail: info@rileysurfaceworld.co.uk Web: www.rileysurfaceworld.co.uk

PROCESS INDUSTRY INFORMER March - April 2015

APPLICATIONS MEETING THE CHALLENGES OF PUMPING LATEX There are certain liquids, which, due to their composition, their characteristics, or how they react to process conditions (and in some situations, a combination of all three) will present challenges to achieving efficient, trouble-free pumping. Emulsions are an example of a ‘difficult’ liquid and users should be aware of the potential problems that can occur if the ‘wrong’ type of pump is specified. The basic definition of emulsions, ‘a mixture of two or more liquids that are normally unblendable’ hints at the difficulties that exist in producing and handling them. There are many types of emulsions which exist naturally or have been successfully developed, ranging from milk to cutting fluids and also latex.

A recent example of the importance of understanding the challenges of pumping latex and specifying the most suitable type of pump for them is at Bituchem Building Products where, to enhance both the quality and consistency of their products, they have a process whereby they pump latex into their bitumen lines with the latex metered in proportion to the bitumen flow. It was important to understand the potential pitfalls and to specify the most suitable type of pump from the beginning.

Bituchem approached pump specialists MICHAEL SMITH ENGINEERS with the details of their application and design of their process. Following discussions they specified and purchased a Wanner Hydra-Cell, sealless, positive displacement high-pressure diaphragm pump, Model G25. The pump, which featured a stainless steel wet end and operates between 70 and 650 rpm, was installed around a year ago and has worked well on the latex pumping application ever since.

Commenting on how the Hydra-Cell pump has operated on their application, John Shirley, engineering manager at Bituchem said, “We were aware of the problems involved when pumping latex and thanks to Michael Smith Engineer’s understanding of our requirements and recommending the most suitable type and model of pump, it is working perfectly”.

He continued, “We have not had any issues from day one, the pump saves us time as we now add the latex as part of the overall process”.

For more information contact Michael Smith Engineers Ltd, Woking, Surrey.

Tel: 0800 316 789 E-mail: info@michael-smith-engineers.co.uk Web:ww w.michael-smith-engineers.co.uk

DIGITAL DATA RECORDER FROM ABB SAVES PAPERWORK FOR AIRCRAFT SEALS MANUFACTURER The installation of an ABB SM500F digital data recorder has helped a manufacturer of seals for the aircraft industry eliminate the need to produce vast volumes of paper charts.

Adpol in Worthing, West Sussex, makes a wide range of silicone seals and gaskets for various applications, including aerospace. As the company is accredited to ISO 9001, manufacturing processes need to be documented and fully traceable.

Further requirements are imposed by the AS9100 quality management system for the aerospace industry, which demands that records are kept for the lifetime of each aircraft where the seals are used, which can be as long as 30 years.

Using the SM500F, Adpol records batch processes in the curing oven, where finished products are heated to eliminate volatile organic compounds from the material and ensure the seals achieve the correct rigidity.

Director Gary White at Adpol says; “switching from a paper-based to a paperless data recording device will make it much easier for us to find specific records if we should ever need to find them.”

For more information, E-mail moreinstrumentation@gb.abb.com or Tel.: 0870 600 6122.

PROCESS INDUSTRY INFORMER March - April 2015

ONDEO INDUSTRIAL SOLUTIONS OPTIMISES GREEN ENERGY AT PLANT OF NATION’S FAVOURITE ALE Ondeo Industrial Solutions has optimised the effluent treatment plant at one of the world’s leading beer producers. Maximum performance has been achieved to reduce natural gas consumption and significantly boost energy generation on site.

Ondeo conducted an in-depth review of the site facilities and identified problematic design flaws in the original anaerobic digestion system that resulted in large scale waste of green energy. Following the review, Ondeo redesigned the biogas production system to rectify faults in the original design.

This has enabled the biogas to be used in a combined heat and power (CHP) engine to cost-effectively generate electricity for the site.

The system now generates enough electricity per day to supply 350 homes for a whole year and is producing more energy per day than the effluent treatment plant consumes, meaning it is currently self-sufficient from green energy.

“Similarly to many other food & beverage manufacturing facilities, this site wasn’t optimising its biogas production, and as a result was losing out on significant energy generation benefits,” said Jon Waller, Contracts Manager at Ondeo Industrial Solutions. “Ondeo has improved the effluent treatment plant system substantially, and it is now considered the ‘go to’ brewery in the Western European region for biogasutilisation best practice.”

For more information contact Ondeo Industrial Solutions Tel : 0191 491 4274 Email : Sophie.ONEILL@ondeo-is. com Web: www.degremont-industry. com

TRIPLE VALIDATION OF SLUICE LEVELS FOR THE EA BY PULSAR Pulsar Process Measurement Ltd have helped the EA measure and validate water levels within two vital sluices that protect Manchester and other population centres along the River Mersey from the risk of flooding. To validate the measured levels, Pulsar supplied three dBi Intelligent Transducers at each location, programmed via HART modems, with analogue signals routed through PLCs to confirm the measurement.

The River Mersey was once the most polluted river in Europe. Now, after projects led by the Environment Agency (EA), the Mersey is clean enough to have, not only a wide range of wildlife including salmon, but a scuba diving centre near the centre of Liverpool. It is, however, still prone to flooding within the basin of the River Mersey, and a key factor within EA flood alleviation schemes are the sluices that allow flow into designated flood plains. In these sensitive areas, accurate and validated river level measurement within the sluices is vital, and the EA turned to Pulsar for a non-contacting solution.

Pulsar’s answer was the cost-effective, self-contained dBi Intelligent Transducer, which provides, as standard, a 4-20mA output proportional to level, with a choice of RS485 digital communications. For a fixed purpose application such as this, the IP68 unit offers simple programming via a proprietary HART programmer (a Profibus version is also available), and the benefit of Pulsar’s world-leading DATEM echo processing software. dBi transducers are robust and extremely reliable, but three transducers mounted together provides confidence that, should one fail or lose accuracy, the other two will maintain control.

The dBi is a compact, non-contacting ultrasonic device, available in a choice of 3m, 6m, 10m or 15m range. Loop powered, dBi Transducers are very easy to install and calibrate, and measurement is communicated either through the 4-20mA analogue output or through the digital protocol (HART or Profibus).

For more information contact: Pulsar Process Measurement Ltd, Tel: +44 (0) 1684 891 371 E-mail: info @pulsar-pm.com / Web: www.pulsar-pm.com

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APPLICATIONS ROMI SECURES MACHINE SLOTS AT EXTENDED INJECTION MOULDINGS The decision to buy two Romi Machines broke the monopoly of a rival supplier at Injection Mouldings in Cheltenham.

Last year the company doubled its factory space to 15,000sq ft and it has housed the latest Romi EN 200 in the new area, the EN 70 in the established working space.

A 21 year old business with on-going growth ambitions, Injection Mouldings diversified about ten years ago from serving only the building supplies trades to a much wider customer base, including many well-known engineering and electronics companies.

The 70 tonne Romi was a direct replacement for a similarly sized rival machine but the 200 tonne model bridged a gap between the company’s 150 and 270 tonne models.

Injection Mouldings is looking to add a larger 500 tonne machine and Romi is on the short-list after a good experience with the first two models.

“Romi has a good and growing reputation, says Steve Rawse, MD of Injection Mouldings. “They keep a good supply of spare parts in the UK and the machines are very energy efficient.”

Injection Mouldings has invested about £200,000 with Romi over the past six months. It currently operates with 16 injection moulding machines and offers a 24/5 service.

For more information contact Romi Machines, Rugby, Warks.

Tel: 01788-544 221 E-mail: suem@sandretto.co.uk Web: www.sandretto.co.uk

BLACKPOOL VICTORIA HOSPITAL SAVES £274,000 ANNUALLY TO HEAT WATER Spirax Sarco is helping Blackpool Victoria Hospital to substantially reduce its energy and maintenance costs and lower its carbon emissions.

The acute hospital has upgraded the heating and hot water supply in ten plant rooms to Spirax Sarco’s EasiHeat™ steam-to-hot-water solutions. It has also installed a Spirax Sarco Reverse Osmosis (RO) system and has modernised the site’s steam trap population.

The EasiHeat systems alone are forecast to save Blackpool Victoria Hospital more than £240,000 per annum (p.a.) in energy plus an additional £34,000 p.a. in maintenance costs. The Spirax Sarco RO system will bring further savings by reducing water use and energy losses.

Carla Wilson, energy manager at Blackpool Victoria says “there has been a noticeable drop in steam use at the hospital. Additionally, conditions in the plant rooms have improved. EasiHeat’s compact design and superior heat exchange technology mean just 18 units were needed to replace 25 calorifiers. This increased the available space in the plant rooms and reduced the air temperature, making the rooms much more pleasant for staff”.

In total, the energy-saving measures are forecast to cut carbon emissions at Victoria Blackpool Hospital by more than 1,400 tonnes p.a.

For more information contact Spirax Sarco, Cheltenham Glos.

Tel: 01242 521361 E-mail: ukenquiries@spiraxsarco.com Web: www,SpiraxSarco.com/uk

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ARC ENERGY RESOURCES CREATES A ‘FULL-SUPPLY’ RISER FOR AQUATERRA ENERGY NORTH SEA CUSTOMER Weld overlay cladding specialist Arc Energy Resources has successfully completed a contract for supply of two riser joints for Aquaterra Energy, the provider of world-class and award-winning offshore solutions.

The components are part of two low pressure risers for an oil platform. The finished risers were destined for a set of twenty wells being drilled in the North Sea off the coast of Norway. It is a brand new development for a low pressure section of pipes to deal with any drill fluids and shallow gas that they may encounter while drilling the first top-hole section of a well.

Commenting for Arc Energy Resources, director Andrew Robinson says: “This project played well to our core strengths, a full supply contract for which we secured the material for both components (a flange and pipe for each), applied the weld overlay cladding, welded the flanges to the pipes, organised the pressure testing, completed radiographic testing requirements and arranged final coating of both items all within a very tight delivery schedule.”

Matt Hugo, Aquaterra Energy Project Engineer comments: “We were at Arc Energy Resources’ site when the testing was carried out and were very impressed with the way they conducted the demanding procedures, whilst maintaining their high levels of health & safety.”

For more information contact Arc Energy Resources, Eastington, Glos.

Tel: +44 (0)1453 823523 Fax: +44 (0)1453 823623 E-mail: sales@arcenergy.co.uk Web: www.arcenergy.co.uk

HBM ANNOUNCES CONTRACT FOR PHASE II OF THE ITER PROJECT HBM FiberSensing is pleased to announce it has been awarded the contract for Phase II of the International Thermonuclear Experimental Reactor (ITER) project, as part of a joint agreement with Smartec.

The ITER project for fusion is a large-scale scientific experiment that aims to develop a new, cleaner, sustainable source of energy, by producing commercial energy from fusion – the process that occurs at the core of the sun.

Nuclear fusion – as opposed to fission where atoms split – has remained the elusive Holy Grail for physicists over the past half century, offering the promise of virtually unlimited power supply without the production of radioactive waste.

Successfully awarded as a result of HBM and Smartecs joint experience and ability to supply FBG (Fiber Bragg Grating) technology and FabryPerot interferometers to measure strain, displacement and temperature in the cryogenic environment found in the ITER magnets, the tender is one of the largest single orders ever received at FiberSensing.

Following the first phase of the project, which involved the adaption and qualification of sensors, measurement units and software for the particular constraints of the ITER superconducting magnets, the second stage of the project is now underway. This stage focuses on series production, delivery and installation of the sensing systems.

In total, HBM predicts the delivery of approximately 900 sensors and the related data acquisition systems, as well as complementary accessories, such as cables and software.

As HBM are confident that the sensors qualified in this programme will be suitable for other applications at ITER and for applications further afield where measurements in cryogenic and high-radiation environments are required, the market opportunities available for fiberoptic solutions and HBM are considered to be widespread.

For more information contact HBM on Tel.: +44 (0) 208 515 6000 E-mail: info@hbm.com / Web.: www.hbm.com

PROCESS INDUSTRY INFORMER March - April 2015

APPLICATIONS GOOD MIXING CONTRIBUTES TOWARDS SWEET SUCCESS Background The AD (Anaerobic Digestion) process is now recognised as an effective and viable method of turning production ‘residues’ into renewable energy and there are a growing number of positive results being achieved at numerous sites which support this. A recent example is at Nestle’s confectionery factory at Fawdon the former Rowntree site near Newcastle, home to fruit gums, pastilles and Rolos.

The first output results a year after commissioning their AD plant confirm that they are now converting 200,000 litres a day of feedstock into renewable energy.

Previously, production residues from Fawdon were discharged to sewer or fed to pigs in the locality. However, following their investment in AD plant, which was designed and installed by UK renewable energy market leader Clearfleau, all biodegradable residues are being converted into renewable energy on the factory site.

Positive Results The biogas produced is fuelling a combined heat and power (CHP) engine, which produces 200kW of electricity, used in the confectionery process. This represents about 8% of the factory’s power needs, cutting their electricity bill by about £100,000 pa. In addition, the site has registered for the Feed-in Tariff and will receive annual payments of around £250,000.

The Challenge to Improve and Optimise Efficiency As with any production process the focus is about optimising efficiency and this increasingly applies to the AD process. The reality is that AD operators now have to achieve higher gas yields, reduce foaming and minimise maintenance issues as part of the drive to maximise the sustainability benefits of their AD process plant. The steps that can be taken to achieve these objectives are often a source of comment and opinion, although it is widely acknowledged that regardless of the technologies being used, the efficiency of the mixing process is fundamental to the success of the process.

Why the Mixing Process is Important Huntingdon based SYSTEM MIX LTD in conjunction with P&M Pumps, who market theRotamix System incorporating the Vaughan chopper pump are an established supplier of digester mixing systems to Clearfleau and many other private sector food waste AD plants in the UK including Fawdon. The basis of the success of these plants depends on a durable mixing technology supported by reliable Vaughan Chopper Pumps.

EFFLUENT APPLICATION HIGHLIGHTS THE BENEFITS OF NOV MONO PUMPS

A single NOV Mono progressing cavity pump has replaced a number of centrifugal pumps and improved performance on a New Zealand agricultural effluent duty.

Castle Glen Farms had previously used various centrifugal pumps to deliver animal effluent through a 4” diameter pipe, over a 3.7km distance. “Replacing these with a single MonoTM pump has allowed us to supply several irrigators located over the length of the pipework, and still deliver the same pressure and flow rate at every nozzle, while also reducing our energy costs,” comments Castle Glen’s Rob Mather. “We were also able to use our existing power supply and not have to upgrade the transformer to cope with a different power requirement.”

The Mono Epsilon pump delivers 35 cubic meters of effluent each hour. It creates significant cost savings by enabling small-bore pipework to be used when pumping over long distances or with high head requirements. It can be used on domestic, industrial and agricultural duties, and features Mono’s Flexishaft drive shaft connection. This eliminates wearing components between the drive end and the pumping element. No lubrication is required, while a low speed capability reduces wear and extends maintenance intervals and working life.

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

For more information contact: System Mix Ltd, Sawtry, Huntingdon Tel: +44 (0) 1487 830123 E-mail: matt@pumpmix.co.uk Web: matt@pumpmix.co.uk

SPIROFLOW LTD IS PLAYING AN IMPORTANT ROLE SAFELY AND EFFICIENTLY CONVEYING A YEAST PRODUCT THROUGH THE PROCESSING STAGE FOR ONE OF IRELAND’S LARGEST FOOD COMPANIES Shifting the many tonnes of yeast extract produced every day required a dust-free system that was flexible and offered a free flowing operation. Spiroflow’s conveying equipment provides significant health and safety benefits by reducing the hazards associated with dust and manual handling, as well as boosting production efficiency.

The company installed a Flexible Screw Conveyor and a Bulk Bag Filler at the customer’s plant to transport the powdered substance, which can be used in the dairy industry and a variety of processed foods. Maintaining the quality and consistency of ingredients while in transit through a processing facility is vital to ensure that the end product is in mint condition for packaging and distribution.

Spiroflow’s project engineering manager, Chris Brennan, explained: “It was a challenging project due to the tight headroom and conveyor path needed so we designed a customised system to meet the customer’s requirements. Flexible Screw Conveyors are ideal for fitting around existing plant or awkward routes.”

Spiroflow’s weighing and filling stations are installed in food and process plants worldwide, providing dust free and highly accurate filling of 1-2 tonne bulk bags. They incorporate an inflatable spout neck seal, bag inflation prior to filling to ‘pre-form’ the bag and product compaction and de-aeration during the filling cycle to provide a stable load for storage or transport. Conveying equipment from Spiroflow fulfils the very highest levels of hygiene and dust containment, while the main advantage of the flexible screw conveyor is its simplicity, which results in short installation times and low maintenance. It suits powdered, granular and flaked materials with a bulk density up to 2.5kg/1 and can carry material to a maximum distance of 20 metres, although multiple units can extend to greater distances as required.

Spiroflow offers the food and process sectors innovative equipment that helps to eliminate dust contamination and material flow problems. In addition to Bulk Bag Fillers and Flexible Screw Conveyors, Spiroflow manufacturers bin activators, Aero Mechanical Conveyors, Tubular Cable and Chain Drag Conveyors, Vacuum Conveyors, Bulk Bag Dischargers, 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 state-of-the-art control systems.

For more information on Spiroflow’s products and services visit www.spiroflow.com or call +44 (0)1200 422525.

PROCESS INDUSTRY INFORMER March- April 2015

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FEATURE

FOOD INDUSTRY AT ROBOTICS TIPPING POINT

By John Rainer, Regional Sales Manager, FANUC UK In the last 12 months there has been a noticeable uptake in robotics in the food processing sector.

Although way behind the rest of the EU and US markets in terms of sales, global food security, volatile commodity prices and the much reported grocery price wars are all driving manufacturers towards the same conclusion; efficiency is paramount and introducing robotics provides that all-important competitive edge.

Several important surveys, including the Food & Drink Global Ambitions report 2014* prepared by pressures, with 83% of respondents citing it as an issue.

According to the World Bank report**, food commodity prices, which have declined by 20% since 2011, are projected to drop by a further 4% in 2015.

Wheat prices are expected to stabilise; Sugar is projected to maintain an upward trajectory; Cocoa futures are likely to remain under pressure; Coffee prices are forecast to remain elevated; Corn prices may increase slightly.

Fact is, when it comes to these basic commodities, we are at the mercy of the weather, harvests, exchange rates and a global supply chain, which can cause significant price swings. It’s a worry for manufacturers. With retailers promising customers further price cuts in the first quarter of 2015, this will continue to squeeze food and drink producers on pricing margins, making the efficiency argument even stronger.

Robotics plays a major role in boosting production capacity, reducing waste as well as protecting product quality. Having powered through the recession, now’s the time to capitalise on new opportunities by making further efficiency improvements, another point reinforced by the EEF/Aldermore report*** released in January 2015.

HUMAN / ROBOTIC FACE-OFF

The matter of human vs. machine is a long-standing conundrum. We are reaching the tipping point where the true potential of a robot worker is being recognised. Well known for their ability to increase yield, lift and shift bulk products, and provide repeatable and consistent product pick and placement, robotics are now taking on more light-touch and delicate duties such as adding decorative features to cakes.

Fig.: IP69K certified full wash down pick & place system The food and drink sector is probably the most prone to innovations, where product quality and contamination top the list of concerns for professionals according to the Lloyds GlobalAmbitions report.

In recent years we’ve seen significant advancement in hygienic and sanitary solutions for food processing and primary packaging applications. Only in the last 12-18 months have IP69K certified robots hit the market, meeting the toughest of hygiene standards and helping to protect brand reputation. It’s an area that we have been especially proactive in. As an example, the range of 20+ palletising and pick and place systems, many of which are IP67K certified, now

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include two new IP69K certified full wash-down models, adhering to the most stringent hygienic production regulations. Aside from not contracting illnesses, washdown robots help to eliminate foreign bodies, such as hair or nails, which could fall into and contaminate food products.

The advancements in vision technology also address another regular concern expressed by food producers; that of replicating human quality checks. In reality, adding ‘sight’ to a robot can aid quality control. With vision systems such as iRVision, vital inspection, positioning and orientation tasks can be automated.

What’s more, packaging code reading capabilities can play a key role in meeting product traceability requirements, further enhancing quality control.

Performance and output aside, there’s also the issue of safety. For many food processors with arduous, labour-intensive manufacturing processes, it’s the robot’s ability to reduce injuries to their workforce which matters most, particularly within harsh environments. Robots can also carry out work that would be impossible for humans.

SETTING OUR SIGHTS HIGHER

So, what does this mean to the brilliant minds that have created these robots?

If our workforce is becoming more autonomous, are we at risk of being taken over by this artificial intelligence?

There are obviously divided opinions about whether Artificial Intelligence is a long-term threat. Bill Gates in a recent Reddit Ask Me Anything (AMA) seems to have shifted his seat into the Stephen machines. While the march of the robots seems inevitable, people whose positions become redundant due to automation are invariably given roles elsewhere within the business, often in engineering and development fields.

Right now, specialist knowledge and skills in food and drink manufacturing is one of the greatest challenges facing the industry. A report by the Food & Drink Federation suggests that in order to continue growing, innovating and meeting future challenges, such as developing healthier options and increasing resource efficiency, the food and drink manufacturing sector must recruit 170,300 new recruits between 2010 and 2020****. The federation’s research suggests that more than 41,000 (24%) of these roles will be in managerial positions and other professional occupations. In our view, automation safeguards the roles of the majority, making the business more efficient and enabling it to maintain and hopefully expand local and export contracts through improved quality and production throughput.

Figures also show that the industry suffers from a number of skills gaps, namely in science, technology and engineering related roles. On the upside, Apprenticeships are growing in popularity among both employers and young people according to figures released by the NationalApprenticeship Service in 2014, increasing by a quarter year on year. And a BIS-commissioned survey has found that the number of 11-14 year olds thinking about working in engineering has jumped by six per cent, with greater interest from females too. What’s more, more parents are encouraging their children to look at careers in engineering.

In our view, the opportunities of automation are too great to ignore. The key is to maintain control of this machine progression. As with most businesses today, the global marketplace beckons food producers. The efficient ones that can offer improved quality and high production throughput through automating processes are the ones that will survive and thrive.

REFERENCES * Food & Drink Global Ambitions report 2014 https://resources.lloydsbank. com/insight/food-and-drink-report/ ** http://www.worldbank.org/en/news/press-release/2015/01/22/commodity-prices-expected-continue-declining-2015-wb-report

PROCESS INDUSTRY INFORMER March - April 2015

APPLICATIONS TWO DECADES ON - THOROUGHLY MODERN CHEMINEER AGITATORS KEEP WORKING IN KSA Twenty one years on since it first designed and supplied agitators for a major shampoo manufacturer based in Saudi Arabia, Chemineer has just seen the latest installation of its proven HT models.

Utilised for both mixing and storage tank applications in the manufacture of household name brand shampoos, a total of 25 Chemineer agitators had to meet very short on-time delivery deadlines. Agitators were supplied by Chemineer during an upgrade to the plant in 2007, but the first order goes back 21 years when a new manufacturing facility was opened on the Kingdom’s east coast.

With motors ranging from 7.5kW to 18.5kW, this latest order for Chemineer was captured in part due to the agitators’ dry well feature, which prevents contamination of the product.Chemineer provided all technical support for its HT Agitators, which are designed for long life, flexibility and ruggedness. A minimum of moving parts means ease of maintenance for end users, with numerical control (NC) machining of the housing and the subassemblies ensuring troublefree interchangeability

For more information contact Chemineer on Tel: 01332 363 175 E-mail: chemineeruk@nov.com Web: www.chemineer.com

SEALS GEAR PUMP HIGH PRESSURE, TEFLON SHAFT SEAL CAN BEAR OVER-PRESSURES OF OVER 210 BAR. A system of radial sealing at the shaft that can bear enormous internal over-pressures without resulting in damage. This radial sealing is particularly useful in single direction hydraulic motors when, in certain conditions of use, high over-pressures will be generated at the motor output. With bi-directional motors, the area adjacent to the seal ring of the drive-shaft is maintained at atmospheric pressure by the drainage circuit. In single-direction motors, this area is directly connected to the output so any over-pressure impacts directly on the seal ring, causing the lip to turn over or the ring to be expelled from its seat with a consequent leakage of fluid.

Validation tests have revealed that the system is able to work on a continuous basis at a constant pressure of 30 bar (430psi) without the spilling of fluid and without the ring and the shaft exhibiting wear. Tests performed at higher pressures also demonstrated the possibility of the system functioning for short periods of time (several minutes) with over-pressures of up to 140 bar (2,030psi).

If the operating conditions must be maintained with extremely high overpressure values (80-100 bar / 1,160 - 1,450psi) for prolonged periods of time (over 30 minutes), the heat generated by the friction between the ring and the shaft can result in temperatures of over 300°C. This inevitably plays a part in deteriorating the structure of the P450 material used in the seal ring, as well as compromising the ground profile on the shaft, and thereby reduces its sealing function. In the presence of pressure peaks, for example caused by errors of manoeuvre or an incorrect timing of the valves of the hydraulic circuit, or in static conditions, with the shaft immobile, this sealing system can bear over-pressures of over 210 bar (3,050psi) without leading to any loss of fluid or deformation of the components.

One of many excellent features of the wide range of gear pumps available from jbj Techniques Limited: http://www.jbj.co.uk/MarzocchiTeflonSeal.html

PROCESS INDUSTRY INFORMER March- April 2015

AUMA ELECTRIC ACTUATORS SELECTED FOR MICROPOLLUTANT ELIMINATION SCHEME AUMA has supplied more than one hundred electric actuators to a pioneering micropollutant elimination facility at Steinhäule sewage treatment plant in Ulm, Germany. The electric actuators provide fully automated sewage water control within the activated carbon system of the STP. A primary objective of the new facility is to eliminate drug residues, hormones and biocidal products from sewage water.

The new purification facility is the largest plant in Germany using an activated carbon adsorption process. The scheme includes several contact reactor basins in which activated carbon is mixed with sewage water: the mixture is directed to a sedimentation basin and a sand filter with 20 chambers.

At the inauguration of the plant, which was attended by AUMA representatives, Franz Untersteller, Environmental minister of Baden-Württemberg confirmed the project is one of Germany’s most advanced schemes of its kind. Approximately 400 million cubic metres of sewage water per annum produced by around 440,000 inhabitants of the Ulm region are treated by the facility.

Reliability and robustness for outdoor operation and low operating costs were key factors that led to AUMA being awarded the prestigious electric actuator contract. Latest control technology also appealed to the customer as actuators were easily integrated via PROFIBUS into the central process control system and line topology implementation reduced cable length requirements to a minimum. AUMA’s established track record dating back over thirty years as a supplier of electric actuation technology to Steinhäule STP confirmed the manufacturer’s credentials for quality and service.

For more information go to AUMA Actuators Ltd, Tel: +44 (0) 1275 871141 E-mail: mail@auma.co.uk www.auma.co.uk

AIR COMPRESSORS COMPACT DATA LOGGER FOR COMPRESSED-AIR SYSTEMS BEKO TECHNOLOGIES introduced the METPOINT BDL data logger, Now it’s little brother“, the METPOINT BDL compact, is released.

The METPOINT® BDL compact data logger allows for the connection of 2 - 4 transducers or sensors in a user-defined manner. With pressure transducers, for example, or with pressure dew point transmitters, volumeflow sensors, temperature sensors, clip-on ammeters, etc. Four limit values on the whole can be freely defined and assigned to two different alarm relays.

At the device, the measured values are indicated on a 3.5” colour display with a zoomable touch panel. It allows for tabular, graphic, and combined presentations. Saving potentials become transparent via daily, weekly, and monthly reports. Any exceeded limits are highlighted in red. An early detection of deviation from set parameters secures highest precision and process safety.

With a weight of only 3.5 kilos and a housing made of powder-coated aluminium, the METPOINT®BDL compact can be integrated easily into existing and new compressed-air systems. A connection to a server for networking with other systems is optionally possible. Due to the employment temperature of up to 50°C, installation points close to the production areas do not pose an obstacle to the BEKO data logger.

For more information contact BEKO Technologies Limited Tel: 01527 575778.

E-mail: Info@beko-technologies.co.uk Website: www.beko-technologies.co.uk

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FEATURE

THE GREAT FOOD MANUFACTURING INDUSTRY DAM BURST John Moxon, business development director at Clegg Food Projects, has seen a ‘dam burst’ with an

influx of new work coming into the sector post-recession. Here he tells us the reasons why and talks about how the food building industry has changed.

The sector in which we operate – design, engineering and construction for the food manufacturing industry - has seen some big changes in the last six years.

Representing more than 18 per cent of manufacturing turnover and employment, the food and drink industry is a core element of the UK manufacturing economy.

Through the recent recession, according to government figures it was the sector that reduced its output the least and has returned to pre-recession output levels the fastest. Since this time, there has been a dam burst in investment towards factory expansion and building services as confidence has grown.

The amount of expansion work being done across the UK’s factories in the food industry has increased significantly over the last 18 months. Compared to how the food and drink manufacturing industry was functioning pre-recession, its needs have now altered drastically.

To meet the demand for an emerging ready-meal seeking audience pre 2008, new factories were built regularly with production and output at an all-time high. Manufacturers required more space and advanced machinery to meet a rapidly snowballing need for packaged meals.

The industry appears to have now reached the capacity necessary for this significant increase in demand for prepared food.

Although the industry has been steadily recovering since 2008, it was not until mid-2013 that the sector saw a substantial increase in capital investment and growth – creating a ‘dam burst’ type effect. Manufacturers are again looking to invest to improve processes and outcomes in factories and be best in their industry. In particular within their existing manufacturing estate.

A crucial part of this development needs to be that production is maintained throughout the transition process. It is key to the food and drink manufacturing industry that output remains at peak levels throughout any building work.

If you take what is happening in the Midlands for example - an area where Clegg Food Projects serves a large client base – manufacturers are looking to invest in their already established sites. A pattern which is being replicated across the UK. The demand for the extension and improvement of units has recently outstripped supply. This type of work creates more jobs and is a great opportunity for the food and drink sector to develop.

The future is unclear but looking forward to 2015 the peak in demand for capital investment has eased off and appears to be plateauing. Manufacturing is an important industry for the Midlands and I think the market will only continue to demand these types of services and investment going into 2015.

Clegg Food Projects provides design, engineering and construction expertise on creating processing and distribution facilities for the UK food and drink industry.

It has more than 30 years’ of experience and has delivered £500 million worth of projects in the field. Providing everything from new methodologies and manufacturing processes through to complete turnkey solutions - using its specialist team and extensive expertise .

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TIPS FOR FOOD & DRINK INDUSTRY INFRASTRUCTURE CAPITAL INVESTMENT 1. Focus on products and processes first – It’s pretty obvious but as the

food and drink products manufactured are the basis for the business then these need to be what the customer wants, any changes to the facilities need to reflect this. Start from the product then consider the process and finally design the structure and services to meet the needs of these.

2. Treat the building services and structure with equal importance as the

process – Once the product and process design are right, whilst it may be the latter part of developing the project, give an equal amount of effort to the building and services, not just a last minute review. If possible re-visit the process to see if small changes that have no adverse impact could have a significant effect and benefit to the building.

3.

Work with specialists with a proven track record - Whether it’s a multimillion pound new food facility, or you are looking to improve your existing manufacturing processes, it is important to involve a team of specialists who can help come up with the best solutions for your project. It is always beneficial to get the technical know-how and engage with a third party, their experience of similar challenges you face can be invaluable.

4.

Involve design and construction partners early and extract their practical knowledge - Partner with specialist construction companies at the very beginning of a project, ideally at the ideas stage when a new food or drink product is being developed. By getting involved right at the start, the process runs so much more smoothly and you will have that continuity to discuss everything from feasibility – right through to design, planning and completion.

5. Create an open and collaborative working relationship – It is important

to build up strong working relationships in the industry. We have worked on several projects doing repeat business. We find that by building up a working relationship, we understand client products and processes and how they work, they in turn benefit from our ability to ask the pertinent questions. You can build a better trust with partners and achieve better results.

6. Accept that change of product or process will impact on capital projects, acknowledge and communicate the change to your delivery partners quickly - At the core of all projects are the products for your customers whose expectations are constantly changing. Acknowledge and accept the impact this may have on your plans and discuss them with the team straight away. An early response and change can prevent costly project or operating impacts later. If the method is right, and the equipment is right, then your business will thrive.

PROCESS INDUSTRY INFORMER March - April 2015

TEST & MEASUREMENT HBM PACES AHEAD WITH ITS NEW COMPACT FORCE TRANSDUCER As precise measurements of especially small forces in a given measuring environment often place high requirements on force transducers, HBM - a market leader in the field of test and measurement - has responded to these demands by developing the new CFT-25kN force transducer with a nominal force of 25kN. Featuring a compact design, without compromising on accuracy, the new CFT25kN is only 3% the size of other transducers on the market using similar sensors, which is particularly suitable for use when space is constrained.

Manufactured to the highest quality using Gallium Phosphate, the CFT-25kN produces twice as high an output signal for the same measurement load in comparison to Quartz, which is the standard material on the market. This makes it possible to measure extremely small forces reliably.

Featuring a high degree of rigidity and a rugged design, the CFT-25kN is particularly useful for use in adverse industry environments. Customers who expose their products to extreme climatic conditions, such as sealing and reshaping processes and component tests, can benefit from the wide temperature range of -40°C to +120°C. Elimination of drift, which is often seen as a frustrating effect, is also dramatically reduced, providing the user with more accurate results.

Designed with the user in mind, the mechanical connection has a flange screw on both sides and a central bore, meaning that the new CFT-25kN force transducer can be easily and quickly integrated into existing systems, offering substantial time savings.

The CFT-25kN is the latest offering from the PACEline range of products now available from HBM. The PACEline range is suitable for use in force and strain measurement technology and is based on the piezoelectric effect.

For further product information & the complete technical documentation available for download visit www.hbm.com/paceline.

Alternatively please contact HBM on Tel.: +44 (0) 20 8515 6000 E-mail: info@uk.hbm.co.uk

NEW DRIVER FROM HBM OFFERS SIMPLE INTEGRATION

HBM INTRODUCES UPDATED VERSION OF COMMON API FOR FLEXIBLE INTEGRATION HBM, a market leader in the field of test and measurement, is pleased to announce the updated and improved version of its Common Application Programming Interface (API), which offers users one programmable environment for several data acquisition systems Version 2.0, which is suitable for integrating QuantumX, PMX and MGCplus into NET based software, enables automatic alignment from several devices, which in turn provides clear and concise results in a structured and intuitive layout, minimising the possibility of interpreting errors.

Customers using different acquisition systems from HBM can now also save time, as general commands, such as device scan, channel selection and measuring, are the same for all systems, so that no re-programming of these components is required when changing over to the new hardware Additional improvements to the latest version, which now supports the QuantumX High Speed mode (MX410, MX403), also means that access to digital inputs and outputs and analogue outputs is also now available for control and diagnostic tasks.

Designed to suit all levels of programmable knowledge and available to download free of charge from www.hbm.com/interfaces, HBM has supplied detailed examples and documentation on the latest version of the Common API, to ensure users are quickly and simply guided to the desired measurement results.

Suitable for use on test benches, QuantumX, PMX and MGCplus are flexible data acquisition systems which provide reliable results. Whatever your application, mobile or stationary, on a test cell or under extreme environmental conditions, HBM has a suitable measurement data acquisition system solution to suit your needs.

For further information contact HBM on Tel.: +44 (0) 20 8515 6000 Email: info@uk.hbm.co.uk Web: www.hbm.com

HBM DEVELOPS TIM-EC INTERFACE FOR A FLEXIBLE SOLUTION

Now available from HBM – a market leader in the field of test and measurement – is the LabVIEW Driver, which for the first time allows HBM’s QuantumX, SomatXR, PMX and MGCplus data acquisition systems to be conveniently integrated into LabVIEW measurement and control system design software.

The new Driver simplifies instrument control and reduces test programme development time, meaning data from multiple devices and channels can now be acquired with only eight Virtual Instruments (VIs). These VIs come complete with ready-made user interfaces for device scan and channel selection, which help make this software extremely suitable for users.

Designed to suit all levels of programming knowledge, HBM has supplied detailed examples and documentation on the new Driver, as well as a video on how to use LabVIEW with HBM Data Acquisition Systems, to ensure users are quickly and simply guided to the desired measurement results.

Customers using different data acquisition systems from HBM can also save time, as general commands such as device scan, channel selection and measurement are the same for all systems, so that no re-programming of these components is required when changing over to the new hardware.

Device specific LabVIEW Drivers are also available from HBM, including the QuantumX CANape Driver which, when integrated with QuantumX data acquisition, allows users to record high-speed signals from external sensors with measurement rates of up to 96,000.

The recently upgraded TIM-EC interface, developed to provide a flexible solution for transmitting torque and speed signals digitally via the EtherCAT fieldbus system is now available from HBM Test and Measurement specialists.

Designed to significantly enhance performance and the field of applications in field bus automation and control systems, such as in test benches for electric motors, combustion engines, gears, pumps and compressors, the recently enhanced module also permits the use of simulation models for performing early tests in the test bench before a prototype is available.

Designed to achieve dynamic measurements, the advanced TIM-EC module provides accurate and fast data transmission with low delay times. In addition to providing angle of rotation and power output data, the most recent module also provides torque and rotational speed signal on the module’s backplane bus. This offers extreme flexibility and modularity which is a real advantage, particularly for integration into higher level control and automation systems.

The recently developed TIM-EC module supports a sampling rate of up to 20,000 measured values per second on the bus and is characterized by a low group delay of approximately 100µs. Signals are transmitted digitally and without loss of accuracy and both the angle of rotation and the performance can also be captured.

It also features an integrated coupler functionality or TIM-to-TIM communication that facilitates the integration of the torque transducer into independent industrial Ethernet networks, so that measured values can be independently adapted to the respective measurement task. This opens up a whole new range of new possibilities for high-precision control and analysis of measurement series, particularly for dynamic tests.

For more information contact HBM Tel: +44 (0) 20 8515 6000 E-mail:info@uk.hbm.co.uk Web: www.hbm.com

For more information contact HBM on Tel: +44 (0) 20 8515 6000 E-mail: info@uk.hbm.co.uk Web: www.hbm.com

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PROCESS INDUSTRY INFORMER March - April 2015

TEST & MEASUREMENT PMX SYSTEM WITH INTEGRATED CONTROL UNIT OFFERS SIMPLE SOLUTION HBM, a market leader in the field of test and measurement, is pleased to announce that the PMX measuring system now features an integrated control unit, in compliance with the international standard IEC 61131, to simplify automation tasks with Programmable Logic Controllers (PLCs).

In line with the new standard, which represents the union of noise free measurement technology and worldwide standardised control technology in process and factory automation, PMX users can now utilise the Codesys V3 software platform. Based on the IEC61131-3 programming system the new software platform enables programming, fieldbus and I/O configuration, MotionControl and other tasks. Additional benefits to the user mean that Codesys software can also be used to create their own plug ins.

Codesys is a software platform specifically designed to fulfill the many different requirements of modern industrial automation projects and offers integrated, simple solutions to support users in the development of tasks. The new system which enables professional engineering in an expandable platform means that users can now use the CANopen interface to receive data or send CAN data in PMX. In addition, users can also create visualisation interfaces, which can be easily integrated into the PLC programming system and displayed onto a PC or in a web browser, providing a simple and cost effective solution.

Eliminating the need for complicated software licensing, the Codesys runtime license is included in the WGX001 PMX device from HBM. Compared with other conventional measurement inputs available on the market, the PMX system features high measurement accuracy and long term stability, which greatly increases production line efficiency. In addition, it is also able to perform measurement, preconditioning and analysis in real time using the 32 internal computing channels, offering additional cost saving benefits to the user.

In an industrial environment, the slightest malfunction can lead to costly repairs and production delays; however, by implementing the PMX system, machine errors are quickly detected, minimising unplanned and costly downtime. The PMX system from HBM sets ground breaking standards for use in production and test standards and offers the latest benchmark in measurement technology.

For more information contact HBM on Tel.: +44 (0) 208 515 6000 E-mail: info@uk.hbm.co.uk Web: www.hbm.com

INSPECTION & VISION SYSTEMS WITH A 14.5CM LCD TOUCHSCREEN, THE FLUKE TIX EXPERT SERIES TAKES INFRARED CAMERAS TO A WHOLE NEW LEVEL With a full 180° articulating lens and 14.5cm touchscreen, the new Fluke® TiX520 and TiX560 Infrared Cameras allow thermographers to easily navigate over, under, and around objects to preview and capture images.

The new Expert Series cameras are ideal for predictive maintenance, in R&D, oil and gas, and utility applications, where flexibility and higher resolution are essential, and they enable users to share their data in real time via Fluke Connect™.

The responsive LCD touchscreens of the TiX520 and TiX560 offer a large viewing area, which enables thermographers to quickly identify issues while still in the field, as well as easily edit images directly on the camera, eliminating time in the office.

SuperResolution mode boosts resolution four times, so the normal 320 x 240 pixels resolution of the images captured increases to 640 x 480 pixels, revealing even greater detail. Optional telephoto and wide-angle lenses add versatility to meet a wide variety of applications.

For more information contact Fluke (U.K.) Ltd. Norwich, Norfolk Tel: 0207 942 0700.

E-mail: industrial@uk.fluke.nl Web: www.fluke.co.uk

PROCESS INDUSTRY INFORMER March- April 2015

19

FEATURE

ONLY THE COMBINATION OF FUNCTIONAL SAFETY & CYBERSECURITY ENSURES THE OVERALL SAFETY OF INDUSTRIAL PLANTS Productivity has the highest priority for companies. It is generally acknowledged that functional safety protects systems and thus helps maintain this productivity.

Autonomous safety controllers also help to significantly reduce security risks and thus significantly reduce lifecycle costs. Properly setting up the safe controller is the last line of defense against cyber attacks.

By Stefan Ditting & Thomas Janzer - Product Managers with HIMA Paul Hildebrandt GmbH As cyber attacks on plants via networks increase, it becomes essential for functional safety and safety-related automation solutions to support cybersecurity. The trend of linking office IT with automation IT in an open network architecture only increases the security risks to plant automation.

There is good news. SIL 3 controllers designed especially for functional safety include features that are also quite helpful for cybersecurity protection.

The basic requirements that current and future security standards impose on the integration of safety controllers, and how autonomous safety systems— such as HIMax® from Paul Hildebrandt GmbH—can help reduce the security risk in plants, are presented below. The robustness and reliability of autonomous safety systems simultaneously increase the availability and productivity of plants.

Functional safety is the basis for any type of process plant, since without mastery of the functional safety risks, operation of the plant is not allowed.

In addition to safety, productivity is a crucial factor for the enterprise. To ensure productivity a safety system must be integrated in the plant process control system. However, such integration increases the risk that safety products will be negatively influenced via interfaces and networks. An attack on the integrity of the safety controller also jeopardizes the integrity of functional safety. Consequently, the same demanding requirements imposed on functional safety features must also be imposed on the security features of a safety controller.

INTEGRATED SOLUTION CANNOT BE EASILY MASTERED

At first glance, economic reasons can be a persuasive factor for implementing an integrated safety system from the same company that manufactured the process control system. After all, a uniform system concept and a common bus, as well as a single engineering tool for the standard automation and

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functionally safe automation, promise several advantages. The advantages of convenience, however, come with disadvantages in the areas of functional safety and security, as anything that a user or the controller can do, an attacker can also do. A larger attack surface is the consequence.

With an integrated control system and safety system from a single source, all automated processes and convenience advantages must be critically tested. The more open and integrated a safety controller is, the more effort is required for organization and security. Security attack vectors in this area include automated processes, such as diagnostic displays, the automatic interaction between engineering tool and controller, and the interaction between the visualization of the control system and the safety system.

STANDARDS REQUIRE SEPARATE LEVELS OF PROTECTION

To reduce systematic errors, standards IEC 61511-1 (Safety) and IEC 624433-3 (Security) require separate levels of protection and autonomy of the operating equipment and protective equipment. By design, an autonomous process control system and a safety system from different manufacturers require different engineering tools, databases, and operating procedures.

Such systems from different manufacturers avoid common cause risks and reduce the security risk through diverse technology.

Diverse technology also ensures a clear separation of the areas of responsibility and supports the different handling of operating equipment and protective devices, in practice. With operating equipment the focus is on daily optimization, updating, and change; in contrast, risk is reduced when protective equipment is operated rarely, and then only by qualified personnel. Each access to protective equipment constitutes a risk, and changes are only permitted via a management of change process.

The international standard IEC 62443-3-3, “Industrial communication

PROCESS INDUSTRY INFORMER March - April 2015

networks – Network and system that contains the data for the project generated with the engineering tool security,” requires compartmentalization as well as the encrypted user ID and of production networks. To accomplish passwords.

The function-relevant this, individual zones are determined project parts are then additionally (enterprise network, control room, protected via a separate CRC so that a safety system, process control system, change in the project data can also be etc.) that are connected via defined detected and traced with the available transitions (conduits). In accordance secure code comparison. with the respective data or protocols Two-level user management for project that must be exchanged, protection is access and controller access ensures installed at each conduit in the form of additional protection. The first level a firewall. For this concept it is strictly includes the right to access the project required that exchanged data be data. At this level personalized users clearly defined. Appropriate protective can be created with individual user measures can only be provided if this password and assigned to user groups. structure is known to the user.

In the second level the access rights are The forthcoming revision of standard defined per controller. From among the DIN IEC 61511-1, “Functional created user groups the administrator safety – Safety instrumented systems can select which group may access for the process industry sector,” the respective controller. An individual moves in this direction. It advocates password is defined in each case. testing, evaluating, and ensuring the This password can be as complex as independence, diversity, physical desired because it does not need to separation, and avoids common cause be known by the user. Advantages of errors between levels of protection. this procedure are that the user knows Moreover, it includes the clear only his own password, and if there is statement that a safety system should be a change of individual users or their physically separated where feasible. passwords the controller itself is not Current discussions in standardization changed. Thus the security protection bodies such as NAMUR and DKE is increased, and if there is a change likewise address the topic that in employees or a password update, autonomous secure separation and it is not necessary to make changes an appropriately defined conduit in the safety controller. Accesses are required for mastery of security Fig. 2: The international security standard IEC 62443-3-3 requires a should be recorded in the project risks. If there is doubt in this regard, compartmentalization of production networks. log and in the controller diagnostics, automatic convenience functions must which enables easy traceability. also be deactivated to reduce the complexity and thus the security risks.

Technical measures reduce security risks A safety system must have a variety of security features to harden it against COMMUNICATION: SEPARATE LEVELS OF PROTECTION safety-security risks or to reduce the risk in plants. The technical measures For high-level cybersecurity different levels of protection with a virtual or affect different areas: physical separation must be set up for the communication. The HIMax® • PC environment CPU module, for example, executes the safety application and can handle • Engineering tool communication tasks. Both areas are separated on the CPU through • Communication SIL3-certified protection of the memory and of the timing between the • Secure control communications area and the safety area. If an insecure data transmission •Safety application is directly connected on the CPU, an integrated firewall ensures a virtual separation because only the protocols and data configured by the user PC ENVIRONMENT: AVOID COMMON CAUSE ERRORS are supported. Invalid or unknown protocol queries or read/write of nonThe BIOS password is the outermost security layer to protect the PC configured address ranges are simply ignored by the controller. and the engineering tool of the safety system against unallowed access. For further risk reduction a physically separated communications module In accordance with the basic principle of supporting only that which is can be used. The module has the same security firewall characteristics as the required, the operating system environment user guidelines and group processor module and is connected to the CPU only via the internal system guidelines must be set up with reduced access rights. bus. Because the communications module cannot influence the CPU the The use of a firewall and antivirus software, or better yet an Application safe function is physically separated from the non-secure communication.

Whitelisting, further improves the security protection. In this regard These features result in stable, robust an Application Whitelisting is indeed more complex in configuration. system behaviour.

However, it offers better security protection, particularly against previously unknown malware, than is offered by antivirus software. That’s because CONCLUSION only the programs released by the user are allowed to be executed.

In order to properly configure the various security measures, the required There is no safety without security. If ports and user rights for the engineering tool must be known. In addition, a security risk exists via interfaces or the engineering software must be compatible with the security software integration, the integrity of functional of other manufacturers. Thus the user can flexibly implement the security safety is in jeopardy. Security products that are prescribed or that are most suitable. The principle of deserves this same high level of diversity also applies for these levels of protection, as use of products from attention that is devoted to the topic of safety. Properly structured different manufacturers avoids the same type of errors. to be autonomous and as separate as possible to avoid random and ENGINEERING TOOL: COMPREHENSIVE PROTECTIVE systematic errors, the safety controller constitutes the last line of defense.

MEASURES The engineering tool for the safety system should be compatible with a The security standard IEC 62443standard Windows PC and the software should be compatible with all 3-3 and the forthcoming revision major antivirus protection programs. MD5 checksums for the installation of safety standard IEC 61511-1 data should be available to the user to check the correctness of the support this approach by requiring installation. Furthermore, the engineering tool has to protect itself against separate layers of protection. By Fig.3: Even in the basic settings, the faulty installation and manipulation via CRC (cyclic redundancy check) that design, autonomous safety systems HIMax safety controller satisfies is executed each time the software is started or code generation takes reduce security risks through the the requirements imposed on cybersecurity. place. Additional features that promote security could be a database file use of diverse technology.

PROCESS INDUSTRY INFORMER March- April 2015

21

FEATURE

DIVING DEEP INTO PROCESS SAFETY

To some, a Process Safety Management (PSM) audit that uncovers no issues is cause for celebration, but should it be? According to ABB Consulting’s Conrad Ellison*, it’s likely that there’s still plenty more that could be done to improve your company’s process safety performance.

A Process Safety Management System (PSMS) provides a framework of high level procedures (or risk control systems), in order to maintain protective equipment and operations in a healthy state. It is often expected that a PSM audit showing year-on-year improvement is good news. However, it can be an indication that performance has reached a plateau, and it is in fact a cause for concern. A serious incident could happen at any time. Operators therefore need to consider ways in which their process safety performance can be made even more thorough and comprehensive.

To begin with, thought needs to be given as to whether the issues covered by the audit on a yearly basis are even the right ones. If they are not, you won’t see any improvements in the number of process safety incidents (PSIs). You’re likely to find that leading process safety performance indicators are not consistent with the audit performance, and the lagging indicators show a concerning trend with the number of process safety incidents remaining the same or even increasing. A notable limitation of PSM audits is that they’re constructed around distinct generic elements, which are audited in turn without consideration for how they interact with each other. At the PSM audit level, this potential interaction between barriers is often not visible. Interactions may be missed in accordance with the ‘Swiss Cheese Model’ of accident causation. This demonstrates that although many layers or barriers of defence lie between hazards and accidents, there can be flaws in each layer. It’s when these flaws combine that accidents can occur.

THE DEEP DIVE AUDIT

Taking this into consideration, auditing PSM system elements may not actually identify the potential for a process safety incident. Instead an assessment of specific accident scenarios and the verification of specific barriers is required. A Deep Dive audit is the answer.

This approach can provide assurance that process safety is being managed appropriately.

It aims to complement conventional, (but not replace PSM audits); taking them to the next level and identifying issues that wouldn’t normally be picked up on from a regular audit (Figure 1). This type of audit can be undertaken in approximately three days whereas the PSM audit can take up to three weeks. This makes it a rapid and practical assessment process. Crucially, it identifies if PSM is delivering on site and does so in a collaborative way, which requires minimal preparation from the operators.

A TYPICAL DEEP DIVE AUDIT AGENDA DAY 1 – UNDERSTANDING

How does the site manage its process safety?

A range of hazard analysis reports such as HAZID and HAZOP reports must be reviewed to identify major accidents and the required barriers. Based on these, a list of varying high-risk scenarios for the detailed Deep Dive audit can be established with a view to assessing the different types of prevention, control and mitigation barriers.

DAY 2 – VERIFICATION AND FIELD VISIT

What layers of protection are in place for the key scenarios?

Verification is then sought for the effective functioning of each scenario and its associated barriers. There are three foci to this stage: barrier verifications; processes and the people operating them.

Experience has shown that the best results can be obtained by deploying two process safety specialists as assessors; one with a PSMS and operations background and the other with a plant engineering and asset integrity management background.

Onsite process engineers, operating managers and maintenance engineers, also provide a valuable source of knowledge to help with the understanding of major accident scenarios. Part of this process is conducting a field visit, which focuses on verifying specific barriers. Firstly, the barriers are visually checked to ensure that they are in good condition and have been installed as per design. Photographs of any deficiencies can provide excellent, high-impact evidence to site management.

Following this we hold discussions about the barriers with operators and maintenance technicians. This is to test their understanding of the potential for major accidents on the site and their role in maintaining the barriers. We’ve had several cases where we’ve found operators are unaware of the emergency procedures necessary for preventing the escalation of incidents. Other issues regularly highlighted at the verification stage have included: inhibited alarms, non-Atex approved equipment in hazardous areas and gaps in earth and lightning protection testing (Figure 2).

DAY 3 – REPORTING

Carrying out additional verifications and forming feedback The audit report provides details of the assessment for each barrier, along with a decision on whether it is working effectively or whether a related weakness needs to be addressed.

This could relate to the plant, processes or people involved.

Figure 1: Outlines the main differences between the two types of safety audit The main focus of a Deep Dive audit is to analyse major accident scenarios and their associated barriers and to provide rigorous assurance that they are working effectively.

This type of audit is designed to: • establish all major accident scenarios; • confirm the basis of safety (BoS) is robust; • check that the design of barriers allows for the required risk reduction and that they are installed correctly; • ensure barriers are appropriately maintained and tested; and • confirm workforce competency with barrier management.

Collectively the above provides an overview of the process safety ‘vital signs’ and ensures that best practice in management systems is being achieved. A benefit of the Deep Dive approach is that it’s applicable to Seveso Directive and non-Seveso Directive facilities with process safety issues. It identifies specific actions relating to scenarios as well as generic site-wide issues and the methodology aligns to that employed by regulatory bodies during interventions. It’s an approach which can be used to benchmark across a number of sites.

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Figure 2: The top 10 common findings uncovered by conducting a Deep Dive Audit

CONCLUSION

Preventing process incidents from occurring is at the heart of process safety management.

Therefore it makes sense to devote some assurance effort directly to the scenarios themselves, focusing on the specific risks and layers of protection.

A Deep Dive audit of key process incident scenarios can be a very direct and costeffective way to provide this assurance. This approach is fast becoming a necessary accompaniment to the traditional audit, as it takes process safety even further and provides operators with a high degree of confidence that barriers are working as effectively as possibly. *Conrad Ellison is Principal Safety Consultant at ABB Consulting, UK

PROCESS INDUSTRY INFORMER March - April 2015

HEALTH & SAFETY SFC’S INTERLOCKS WITHSTAND TEMPERATURES OF 1000°C GL and QL interlocks compliant with API and ISO Standards Smith Flow Control’s GL and QL interlocks withstood temperatures of up to 1000°C in recent tests.

Performed by Score Group plc, the tests found the QL and GL to be compliant with the temperatures and conditions specified in API Standard 607 Sixth Edition – 2010 and ISO

10497:2010.

The interlocks were exposed to a 30 minute burn, with temperatures maintained above 750°C at all times. This verified that, in the event of a fire, the hardware will continue to function and the integrity of the locking mechanism will be maintained.

During the test the lock had one key inserted and one free; following cool-down, the lock remained secure on the valve. Only when the other key was inserted could the lock be moved to the open/closed position, as should happen.

The test and temperature was witnessed by Lloyds Register.

For more information contact Smith Flow Control Ltd, Witham, Essex Tel: +44 (0)1376 517901 Fax: +44 (0)1376 519720 E-mail: enquiries@smithflowcontrol.com Web: www.smithflowcontrol.com

FREE CHLORINE SENSORS FOR WATER TREATMENT AND DISINFECTION Real-time free chlorine measurement with FCL Series sensors from Sensorex Sensorex’s FCL Series free chlorine sensors use amperometric measurement technology to provide highly accurate monitoring of free chlorine in process applications. FCL sensors are ideal for use in drinking water disinfection and distribution applications, and are compliant with EPA method 334.0 for measuring drinking water. They are also well suited for providing accurate free chlorine monitoring in cooling tower water, an important application for industrial water treatment system providers.

With three models available covering the 0-2ppm, 0-5ppm and 0-10ppm ranges, the FCL Series meet a broad range of performance requirements. Its membrane design features a mesh reinforcement clamp for increased stability and added durability. The integral 4-20mA isolated signal output is enhanced to eliminate ground loop errors, reduce noise, and block high voltage transient surges.

For real-time free chlorine monitoring, FCL Series sensors interface directly with PLC, SCADA and other process control systems via the standard 4-20mA output. A large electrolyte reservoir with an easy-to-replace membrane cap and electrolyte solution reduce maintenance intervals and maximize sensor life. A specialized acrylic flow cell (FC72) is available to provide a controlled flow environment for measurement stability.

To learn more, visit www.sensorex.com E-mail sales@sensorex.com Tel: +1 714-895-4344.

FORTRESS AND TROAX PARTNER UP FOR PERIMETER GUARDING Fortress Interlocks and Troax have combined forces to create a new perimeter guarding system to protect workers from dangerous machinery. The system utilises a unique new bracket for fitting Fortress interlocks to Troax perimeter guarding panels, enabling the safeguarding of virtually any machinery installation.

Very easy to install for both end users and OEMs, the brackets are 100% compatible with Fortress’ modular amGardpro and tGard ranges of modular interlocks and Troax’s modular mesh panels. This means that whatever configuration of interlocks or mesh panels is specified first, the brackets will always fit. Both the amGardpro and tGard interlocks combine solenoid or nonsolenoid safety switches with full control functionality in one device, allowing their use across a vast array of industrial applications.

Not only is the new perimeter guarding system easy to install, it is also impact resistant to 1600 joule, making it highly robust. Watch the video(http:// bit.ly/1DgK7Ya) to see the impact test in action!

“This alliance between Fortress and Troax offers a simple, modular and very tough machine guarding option for virtually any application,” commented Fortress’ Managing Director Rob Lewis. “We’re delighted to have partnered up with Troax in this way and believe it offers a great alternative to existing guarding systems.”

For more information contact Fortress Interlocks Ltd, Wolverhampton Tel: +44 (0)1902 349000, Fax: +44 (0)1902 349090 E-mail: sales@fortressinterlocks.com Web: www.fortressinterlocks.com

PROCESS INDUSTRY INFORMER March- April 2015

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HEALTH & SAFETY COMBINING MECHANICAL INTERLOCKS WITH PROCESS SAFETY SENSORS SmartTrap+ ensures process vessels and pipework are safe to open

In the process industry, mechanical interlocks guarantee strict adherence to procedures and help avoid human error. They are particularly useful for highly dangerous operations such as pigging and valve changeover procedures.

While interlocks ensure extremely high safety levels, they usually function as stand-alone safety systems. New digital technologies are now emerging that enable traditional interlocking to be combined with digital process control and instrumentation systems.

Smith Flow Control is the first company to combine these mutually beneficial technologies in the development of the SmartTrap+, which incorporates signals from sensors into the interlocking sequence.

During a pigging operation certain safety conditions need to be met: the vessel pressure should be at a safe level and all dangerous gases and residue must be removed before opening the pig door. Mechanical interlocking guarantees that all required valve operations are performed, but cannot guarantee the outcomes of these operations.

For example, opening and closing a vent valve does not give real time information that the vessel pressure has actually reached a safe level; while opening and closing a drain valve does not guarantee that all residue has been removed.

By incorporating signals from other field devices like pressure or H2S/CO2 sensors into the interlocking sequence, the SmartTrap+ ensures interlock keys can only be released if particular process conditions have been met. So, for example, this could mean that the key for opening the vessel closure door will only be released when the pressure inside the vessel is acceptable and no dangerous gases or residue are detected.

SmartTrap+ incorporates permissive signals and a door lock proximity switch (4-20mA) as standard. The signals can include (but are not limited to) pressure detection, gas detection, flow/ level and pig detection.

Some of the factors contributing to pipeline pigging incidents include: • Lack of training or complacency • Lack of hazard awareness • False sense of security and reliance only on pressure gauges SmartTrap+ effectively deals with these factors, making pigging a safer operation and grants full traceability in real time.

The process industry’s standard preventive actions include: • Hazard identification and risk assessment including management of changes • Awareness, training and competencies of personnel • Procedures that address normal and upset conditions SmartTrap+ reinforces these actions and implements genuine physical control on any pigging operation.

For operators needing to ensure higher levels of process safety, the SmartTrap+ is an ideal solution. By incorporating the best of traditional mechanical interlocking with process sensor information to ensure all vessels are safe to access, it will help to reduce accidents and reduce downtime.

For more information contact Smith Flow Control Ltd, Witham, Essex Tel: +44 (0)1376 517901 / Fax: +44 (0)1376 519720 E-mail: enquiries@smithflowcontrol.com Web: www.smithflowcontrol.com

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DUST & FUME CONTROL DEALING WITH DUST AND FUME Dust Control Systems Ltd specialise in providing dust and fume extraction solutions across many industries, including major projects in solids handling, food and beverage, pharmaceuticals and recycling and waste management.

Saving energy and increasing production efficiency while ensuring a safe working environment are key requirements of most processes and the company’s reputation has been built on its ability to provide the most suitable and cost-effective solution, whatever the project.

DCS aim to improve their customers’ profitability by providing the best in current technology, reducing energy usage and ensuring that expectations for reliability are met by focusing on system reliability. And, the DCS commitment doesn’t end there, but extends through lifetime service programmes customised to meet customers’ specific needs.

To assist companies with compliance of COSHH Regulations, DCS offer comprehensive LEV (Local Exhaust Ventilation) testing and examination packages that include inspection and service to ensure extraction systems continue to comply with regulations.

For more information contact DCS Ltd, Dewsbury, West Yorkshire.

Tel: 0800 040 7116 E-mail: sales@DCSlimited.co.uk Web: www.DCSlimited.co.uk

NETWORK & COMMUNICATIONS HARTING OFFERS EXPANDED preLink® FAMILY TO PROVIDE CABLE TERMINATION TECHNOLOGY WITH ENHANCED RELIABILITY HARTING has extended its preLink® pre-wired connector system with a number of additional components that allow easy, quick and reliable installation under extreme environmental conditions. preLink® offers a robust and installer-friendly connection technology that is equally suitable for PROFINET communication and Gigabit requirements in industrial applications. Wiring is greatly simplified by using the preLink® terminal block, which accommodates up to eight wires and is connected in a single operation involving the preLink® assembly tool. This simple and very fast installation process is identical for all preLink® products.

Feedback from the assembly tool confirms to the installer that assembly has been properly performed – making the preLink® installation process error-free.

In addition to the existing preLink® RJ45 jacks, HARTING has added the preLink® RJ45 connector in IP20 design and the Han PushPull® connector for V.14 (PROFINET and AIDA compliant). The preLink® RJ45 connectors in IP20 are exceptionally well suited for connections from field devices such as datacollection terminals, controllers and wireless access points.

The preLink® range is supplemented

by D-coded M12 connectors for Fast Ethernet (100 Mbit/s) and X-coded M12 connectors for Gigabit Ethernet and 10 Gbit/s.

For more information contact HARTING Ltd, Northampton Tel: +44 (0) 1604 827500 Fax: +44 (0) 1604 706777 Email: gb@harting.com Web: www.harting.co.uk

PROCESS INDUSTRY INFORMER March - April 2015

AQE 2015

TO FOCUS ON WAYS TO IMPROVE AIR QUALITY & EMISSIONS MONITORING The organisers of AQE 2015, the international Air Quality and Emissions show, have announced a comprehensive programme of events that will take place in Telford, UK, on 22nd and 23rd April. Created to provide an update on the latest regulations, technologies, methods and research in air quality and emissions monitoring, AQE 2015 will take place at a time when concern with air

pollution and climate change has never been greater.

Organiser Marcus Pattison says: “At the last AQE show we introduced ambient air quality as a major theme for the event, and this dramatically increased the number of organisations and attendees that took time to participate, and registrations are already running at higher levels than ever before, so we are looking forward to an exciting two days! “Visitors to AQE 2015 will be able to find new ways improve the quality and reliability of monitoring, whilst ensuring compliance with all relevant regulations and standards, but importantly, they will be able to find new ways to do so, whilst also lowering costs.”

AQE 2015 (www.AQEshow.com) is the eighth in a series of specialist air monitoring events and will take place at the International Centre in Telford, UK. In common with the previous events, AQE 2015 will also include over 50 free walk-in/ walk-out workshops and an exhibition featuring hundreds of the world’s leading organisations in air quality and emissions monitoring products and services. The Conference and Workshops at AQE 2015 have been approved for Continuing Professional Development (CPD), providing delegates with further reassurance that their visit will be worthwhile.

Visitors to AQE 2015 travel from all over the world and come from a wide variety of sectors including central government, local authorities, industrial process operators, test houses, consultants, researchers, academics, instrument manufacturers, the media and anyone with a professional interest in air quality.

CONFERENCE, WEDNESDAY 22ND APRIL: ‘EMISSIONS MONITORING CHALLENGES FACING OPERATORS AND MANUFACTURERS’ The first day’s conference will commence with David Graham from E.ON Technologies explaining how stacks are defined under legislation that aggregates units together. He will also provide a regulatory update on the Industrial Emissions Directive and the Medium Combustion Plant Directive. Jonathan Clark from Syngenta will then outline the challenges facing operators with small stacks in relation to periodic monitoring and compliance with standards. Continuing this theme, Dan Jones from E.ON Technologies will address issues facing the operators of large stacks, particularly in relation to staff safety and sample representativeness.

In the afternoon, Derek Myers from REC will provide an overview of the challenges facing test laboratories and others, when sampling dust from wet stacks, and finally, Rod Robinson from NPL will explain the measurement and calculation of stack flow rate for mass emissions reporting purposes.

CONFERENCE, THURSDAY 23RD APRIL: AIR QUALITY - LATEST DEVELOPMENTS AND TOOLS Ambient air quality issues are of course extremely localised, and Stephen Stratton from Ricardo AEA will provide a summary of a study on exposure to pollution at buggy height, adult height and air quality station height. Jacqueline Barr from IBI/ Transport Scotland will then deliver a presentation on a Sensor Rotation Project in which a network of new monitoring technologies has been applied to traffic management and control systems. In the final presentation of the morning, David Green from Kings College London will report on a series of PM Speciation Studies looking at the makeup of particulate matter measured across the UK and how it varies.

In the afternoon, Martine Van Poppel from VITO Belgium, will explain the results of the CARBOTRAF EU Project which examined ways in which Black Carbon and carbon dioxide levels can be reduced by the latest monitoring technologies and effective traffic management. In the final presentation, David Carslaw from King’s College London will describe ‘OpenAir’ (open-source software) which is a free software tool for the analysis and visualisation of air quality data.

INTERNATIONAL EXHIBITION With more than 90 stands featuring hundreds of the world’s leading organisations in air quality monitoring, the AQE exhibition will provide a unique opportunity to see all of the latest developments in instrumentation and monitoring services.

On the following pages you can see information from just a percentage of the

PROCESS INDUSTRY INFORMER March- April 2015

exhibitors participating and these are companies that are particularly keen to meet with visitors from the process industries. Having said that, with so many stands in the arena there will of course be many more companies that are well worth the visit.

AQE 2015 TO FEATURE AIR POLLUTION POSTER COMPETITION There will be a poster competition under the theme: ‘Air Pollution is bad for our health – the impact of personal responsibilities and local action to deliver clean air.’

Environmental Protection UK (EPUK) and Environmental Technology Services are sponsoring the competition which will take place within the event’s exhibition hall.

Shortlisted authors will be given the opportunity to display their posters, make a short 5 minute presentation to the judges, and answer questions on their topic.

They will also benefit from free attendance at the event and a complimentary invitation to the Gala dinner, where the winner will receive the EPUK 2015 Poster Award. All shortlisted entrants will also receive membership of EPUK and a copy of ‘Essential Environment’. The closing date for poster submission is 7th April, and visitors to AQE 2015 will have the opportunity to view the posters during both days of the event.

WORKSHOPS

Over 50 free walk-in workshops, mostly provided by exhibitors, will address a wide variety of air quality monitoring themes including ambient air, stack emissions, occupational safety, nuisance dust, fugitive emissions and boundary monitoring.

On the first day of AQE, the workshops will cover the measurement of particulates, nitrogen oxides, TOC, dioxins and many other toxic gases. These presentations will cover stack emissions as well as fugitive and fenceline monitoring. Intriguingly, Quantitech’s workshop will pose the question ‘VOCs why speciate?’ and there will also be presentations on dust modeling and the employment of the ‘Internet of Things’ in environmental monitoring.

The second say’s workshops will include an explanation of a wide variety of applications for FTIR (including rocket science), as well as a presentation on engine emissions monitoring and optical gas imaging for fugitive VOCs. Air Monitors will unveil the latest trial data on AQMesh pods and there will be presentations on metals and dust monitoring in addition to a wide variety of other parameters.

DEMONSTRATION ARENA A section of a ‘life-size’ chimney stack will be constructed in the demo area, fitted with a range of different CEMS (Continuous Emissions Monitoring Systems), providing visitors with an insight into the latest online monitoring systems.

Under a ‘Monitoring on the Move’ theme, the ambient air quality monitoring section of the arena will feature an exciting variety of monitoring applications highlighting the latest wireless, battery-powered monitoring technology. For example, a mannequin will be fitted with a range of ambient and personal monitors and an electric car will feature a new high-speed multiparameter monitoring technology that will be ideal for surveys requiring spatial and temporal data. For the first time, AQE will also provide live demonstrations of air quality monitoring at different heights; a remote control quadcopter and hot air balloons will carry monitors to different heights whilst feeding live data to iPads.

Marcus Pattison has reminded visitors to plan their visit carefully: “There is a great deal to see and do at AQE 2015, so I advise everyone to study the Conference and Workshop schedules carefully before they arrive, in order to ensure that they attend the most relevant presentations, whilst also allocating time to visit the exhibition and the demonstration arena.”

The charge for attending the Conference is £55 +VAT per day or £100 for both days. However, entrance to the exhibition and workshops is free and pre-registration guarantees free lunch, free refreshments and free parking. Online registration

for AQE 2015 is now open at www.aqeshow.com.

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STAND 1 & 2 NEW RANGE OF ANALYSERS INTRODUCED

Signal Group Ltd has recently launched a new range of analysers for emissions monitoring. Bringing together well-established reference method detectors with state-of-the-art functionality and features it represents a new generation in gas analysis.

The Solar range of FIDs includes dual detector and methane only/non-methane options to extend the range of industry standard analysers for measuring VOC from stacks. This complements our recently updated portable FID range, the 3010 MiniFID. Our flagship product in this Series 4 range is the Pulsar range of multigas NDIR analysers. With up to 5 detectors in one box, it is an extremely cost effective way to utilise IR analysis methods to their full potential with individual cells optimised for the target gas species and range.

The entire range is supplied with an open source software platform for use over Ethernet. It can also be supplied with a touch screen including on-board datalogging with a supplied SD card. This is all in addition to the standard 0-10V and 4-20mA analogue outputs.

Come and take a look at our stand 1&2 at AQE2015 and see what competitive solutions we can offer for your application.

For more information contact Signal Group Ltd, Camberley, Surrey Tel: 01276 682841 E-mail: Susannah.wrenn@signal-group.com Web: www. www.signal-group.com

STAND 14 THE HIQ EXPERT TEAM FROM BOC UK (A MEMBER OF THE LINDE GROUP) WILL BE AT THE 8TH INTERNATIONAL CONFERENCE AND EXHIBITION ON AIR QUALITY AND EMISSIONS (AQE)

STAND 5 & 6 EXPERTS IN AIR QUALITY MONITORING At ET, we’ve been doing things better since 1983.

Undoubtedly technology has come a long way since then so at AQE our experts will be on hand to talk you through our latest cutting-edge technology.

We’ll be focusing on better ways to measure NO2 in our workshop entitled ‘Innovative Solutions for Ambient NO2 Monitoring - Chemiluminescence and beyond’ (Room 6, April 22nd at 10am) and Cooper Environmental will be discussing the World’s first real-time metals speciation and measurement system for stack or ambient air in the workshop entitled ‘Beyond PM - Near Real-Time MultiMetals Monitoring, from Fence Line to CEMs’ (Room 2, April 23rd at 10am) We’ll also have the ground-breaking Ultraportable Greenhouse Gas Analyser from Los Gatos Research on our stand. It reports measurements of methane, carbon dioxide and water vapour simultaneously in a package that is compact and crushproof, one of our best sellers!

Last, but not least, you can see a T500U CAPS NO2 analyser in action. The cost effective, low maintenance analyser is the next generation of criteria pollutant monitoring technology for the direct measurement of Nitrogen Dioxide in air.

It’s not to be missed!

We look forward to speaking to you about all these products and more on stands 5&6.

For more information contact Enviro Techology, Stroud Glos.

Tel: 01453 733200 Fax: 01453 733201 E-mail: info@et.co.uk Web: www.et.co.uk

STAND 18 ALPHASENSE - FOR A WIDE RANGE OF GAS SENSOR TECHNOLOGIES

With the focus on air quality monitoring, M-Certs standards and aspects of air quality protection and treatment BOC will present a variety of products including the ECOCYL portable gas cylinder with built-in regulator and a range of small cylinders for a variety of applications and ISO/IEC17025 UKAS accredited calibration gas mixtures.

We will also be available to talk about our SPECTRA-SEAL treatment process which BOC provide with cylinders for use in Air Quality Monitoring with uncertainties of +/-1%. Specialty gas equipment used to maintain the integrity of specialty gases during usage in laboratories will be also featured.

Ismail Erilhan, Global Product Manager will also be presenting a workshop on “Gas Analysis Implications of the IED (Industrial Emmissions Directive) and new BREF (Best Available Techniques Reference Documents) on ELV (Emission Limit Values). There will also be a case study from the Glass Industry.

BOC UK will be welcoming you at stand number 14.

Alphasense manufactures a range of Oxygen, Toxic, PID, NDIR, Solid State, Catalytic, Particulate and Metal Oxide Sensors to our own unique design and plug-in replacements for other brands.

Our sensors are used by many OEMs in Safety, Industrial and Air Quality applications. Further product releases, some utilising alternative technologies, are always under development.

Alphasense is a totally independent Sensor Manufacturing and Technology Company, founded in response to an overwhelming demand from Gas Detection OEMs and End Users for better quality gas sensors, a higher level of support and a viable alternative to existing suppliers.

Our management team has over 100-year’s combined experience in all aspects of the Gas Detection Industry as Sensor and Instrument Developers/ Manufacturers. This means we understand the issues affecting our customers.

Supporting our customers is one of our highest priorities. We are not only improving our products continuously, but also our internal procedures to ensure we offer the highest possible levels of Customer Support.

Alphasense has invested heavily in state-of-the-art automation and process equipment to ensure that sensors are produced and validated in volume to tight specifications. We use Kanban and Cellular Manufacturing Techniques to ensure we deliver the right quality of product, when you need it.

For more information contact BOC UK & Ireland, Guildford, Surrey Tel: 01483 244 470 E-mail: hannah.whelan@boc.com / Web: www.boconline.co.uk

For more information contact Alphasense Ltd, Great Notley, Essex Tel: 01376 556 700 E-mail: sensors@alphasense.com Web: www.alphasense.com

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PROCESS INDUSTRY INFORMER March - April 2015

STAND 27 FLUIDIC - A UK SUPPLIER OF INDUSTRIAL PROCESS INSTRUMENTATION WITH OVER 20 YEARS OF EXPERIENCE

STAND 30 ENVITECH NEW ENOVATION SOLUTIONS CONTINUE INTO 2015-2016

We offer instruments for the measurement of Pressure; Flow; Temperature; Level; Moisture and Analytical analysis. This includes safety critical SIL and hazardous area ATEX applications.

Fluidic also offer modular control systems, data loggers and ISA100 wireless instrumentation and are able to help with your instrumentation applications including product selection and instrument assemblies where appropriate.

As the UK distributor of Kurz Instruments we will be showcasing their range of Thermal Mass Flowmeters.

These are ideally suited to the sometimes arduous demands of stack flow monitoring, having excellent tolerance to moisture and to particulates, and offering superior performance at lower operating velocities when compared with other technologies. Specifically the Kurz K-BAR 2000B product, along with the associated ADAM flow computer now carries QAL 1 approval via TUV Rheinland, and MCERTS approval (conversion via SIRA) is imminent.

In addition to devices for fixed installation there will be a typically robust hand held flow meter on display.

Fluidic are ISO9001 accredited and FPAL registered and are a companion company of the Institute of Measurement and Control (IMC.) We have product trained field engineers covering the length of the UK.

Envista ARM V7 Enhancements Continue to Roll Out while development is underway for Version 8 of Envista ARM, while new enhancing features are being added to version 7.

Dynamic Tabular Displays now feature one click access to Station Reports, Alerts, Calibrations, Diagnostics, Digital Monitor Status and Log-book entries for any measurement in the table.

Dynamic Maps have had the image background map deleted and the ArcView GIS layers map enabled. AQI Map Display now use the PM10 Gravimetric logic when the UK AQI type is selected as Forecast.

Envista ARM Web Edition supports public Internet and private Intranet web sites. Easily branded to match agency and company look and feel requirements, Web Edition is in use in agencies all over the world Several States and private companies host their sites on the Envitech Europe Cloud servers. New API functions offer flexable solutions for sharing air Quality Data with government bodies and 3rd party companies Envista ARM Mobi Solutions offer New Websites and Apps available to Mobil devices so that Air Quality Data is accessible at all times. Area map displaying Air Quality Stations, Tables and Graphs showing live AQI status.

If you are not able to visit us at AQE and would like more, contact Fluidic Ltd, Warrington, Cheshire.

Tel: 01925 572401.

E-mail: howard.feather@fluidic-ltd.co.uk Web: www.fluidic-ltd.co.uk

For more information contact Envitech Europe Ltd, Glasgow.

Tel: 0141 416 2099 E-mail: info@envitech-europe.co.uk Web: www.envitech-europe.co.uk

STAND 34

STAND 35

MATTS MONITORS LIMITED OFFER AIR AT THIS YEAR’S AQE SHOW PERMA PURE AND MONITORING PRODUCTS AND SOLUTIONS FLUID CONTROLS IS INTRODUCING THE NEW FOR DIFFERENT APPLICATIONS WITHIN MD-700 LARGE DIAMETER NAFION® DRYER FOR AEROSOL ANALYSIS TO THE UK MARKET THE AIR MONITORING SECTOR Based in Gloucestershire and Devon, working nationally and internationally, we specialise in the supply, technical support, service and repair of gas and dust analysers for indoor and outdoor air quality monitoring as well as stack emissions samplers.

With an extensive range of equipment we are able to make these available by way of sale, hire purchase, contract hire, finance leasing or hire packages.

Matts Monitors Limited prides itself in being an engineer based company offering our customers the latest available equipment and technology backed up with quality service and aftercare.

Alongside our supplier Tecora we will be demonstrating the Isostack G4 stack emissions sampler as well as ambient air samplers. Matts Monitors are the UK distributor for Tecora products.

In addition to this, we will be exhibiting an innovative roadside air monitoring enclosure, a replacement for the Romon stainless steel enclosure, which is designed with careful consideration for ease of use and access.

As the UK distributor of Thomson Environmental products we will be displaying dust and diesel particulate samplers; these are used in construction dust and roadside monitoring applications.

We welcome you to our stand where our expert team will be available to talk to you.

For more information contact Matts Monitors, Stroud, Glos.

Tel: +44 (0) 1453 807 470 E-mail: katrina@ mattsmonitors.co.uk Web: www.mattsmonitors. co.uk

PROCESS INDUSTRY INFORMER March- April 2015

The MD-700 was developed with the cooperation of our customers specifically to control sample gas humidity for aerosol and particulate monitoring analysers. The MD-700 is the first product that enables particle analysers to dry the inlet sample – a critical requirement for the analysers to function properly – without particle losses. The MD-700 enables ambient particle monitoring stations to operate in wider environmental conditions – particularly in areas where the air is hot and humid. The product offers the following features and benefits: • Low particle losses due the large diameter 17mm (0.700”) Nafion® tubing .

• Eliminates the need for heating the sample gas stream, preserving the volatile particulate component.

• Grounded Stainless Steel Tube and Shell Construction eliminates buildup of static electricity and provides long service life outdoors.

• Dryer is continuously regenerating, eliminating the need to repeatedly replace desiccant.

• Designed to be used with the vacuum reflux purge gas method where no dry or instrument air is available.

• Available in 5 lengths to match common analyzer flow rates from 1 lpm to 16.67 lpm.

For more information contact Fluid Controls Ltd, Aldermaston, Berks.

Tel +44 (0) 118 970 2060 Fax +44 (0) 118 970 2065 Web: www.fluidcontrols.co.uk

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STAND 42

STAND 43 A BREAKTHROUGH IN AIR MONITORING

DESIGN IMPROVEMENTS AND MCERTS INSTRUMENT TESTING FOR CEMS NPL can support your instrument development programme, and final testing to the MCERTS Performance Standards, using a dedicated suite of test and calibration facilities, which include: • Variable temperature test cells that can operate up to 400 ºC, where accurate concentrations of stack gases and water vapour can be introduced to simulate stack conditions.

• A patented gas dilution system to generate a wide range of required gas concentrations.

• An environmental chamber for testing monitoring system components exposed to controlled indoor or outdoor conditions.

• The ability to test two instruments in parallel, including in-stack, cross duct and extractive instruments.

We have supported many manufacturers with their instrument development programmes (CEMs and CAMs), using our facilities and scientific expertise, and by carrying out ‘pre-testing’ in accordance with the requirements of the MCERTS standard to identify technical areas where final instrument optimisation may still be required.

Manufacturers seeking to put forward instruments for testing under MCERTS should contact NPL for technical advice and help in the development of a test programme. We also offer to translate the final report into German for further submission to TUV. For more information contact NPL, Teddington, Middlesex Tel: 0202 8977 3222 E-mail: nick.martin@npl.co.uk Web: www.npl.co.uk

STAND 46 AIR PRODUCTS- WHEN YOU WANT THE MOST ACCURATE TEST RESULTS, YOU NEED THE MOST RELIABLE GASES For over 40 years, the Air Products specialty gases business has been driven by a single, critical objective: helping our customers achieve consistently reliable performance in analytical and process applications.

Visit Air Products at AQE (Air Quality and Emissions) exhibition from April 22nd to 23rd in Telford, stand 46 and discover how our specialty gases range has been optimized for users across the air quality and air emissions sector. Chosing Experis® gas mixtures, with their high accuracy, stability and full traceability gives control of the process and protects our customer’s investment. For the ultimate in accuracy and traceability, Experis® mixture cylinders can also be supplied with calibration certificates from one of our ISO17025 accredited laboratories, confirming their suitability for the most demanding analytical applications across a wide range of industries; automotive, environmental, natural gas industries, and more.

Our ISO 17025 scope now includes gas mixtures with all of the components NO, SO2, CO and CO2 in the same cylinder. We are looking forward to seeing you For more Information copntact Air Products PLC, Walton-onThames, Surrey Tel: 0800 389 0202 E-mail: apukinfo@airproducts.com Web: www.airproducts.co.uk

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The PerkinElmer Elm™ air sensing network is a breakthrough air monitoring service that provides customers and communities with micro-scale, real-time air quality information for better insights into the air people are breathing.

The Elm service enables the visualization and understanding of relevant realtime air quality detail, providing data that can be immediately accessed. The Elm network contains devices with multiple air monitoring sensors. The units are placed outdoors where individuals can benefit from real-time air quality information, such as in industrial areas, neighborhoods, parks and schools.

The sensors measure patterns of seven air quality indicators, including ozone, particulates (soil or dust materials) and nitrogen dioxide (NO2). Each device connects to the secure Elm data network to send readings from the sensors every 20 seconds, enabling viewing of up-to-the-minute air quality conditions.

The Elm service provides customers an important perspective of their air quality by offering access to relevant and localized data. This approach provides insights on air quality patterns and pollution trends, complementing current conventional monitoring methods.

For more information on Elm contact PerkinElmer LAS (UK) Ltd, Beaconsfield, Bucks.

Tel: 01494 874515 E-mail: sara.osman@perkinelmer.com Web: www.elm.perkinelmer.com

STAND 54 EXPERTS IN INDUSTRIAL, LABORATORY & MEDICAL GASES

Air Liquide UK Limited, part of the world leading Air Liquide Group, provides your single source of expertise for the full range of industrial, laboratory, medical gases and related technologies. Air Liquide constantly strive to improve our offer to our customers and have created readily available, off the shelf, stock gas mixtures and pures for emissions and ambient air monitoring, including: • • • • • •

Wide range of common calibration gas mixtures HCl calibration gases Pure gases FID fuel gases FID control gases Span gases

We also provide a comprehensive range of binary and quaternary ISO17025 accredited gas mixtures and gas control equipment.

For further information: Tel.: 01782 822061 Fax: 01782 826850 Email: specgas.ALUK@airliquide.com Web: www.uk.airliquide.com

PROCESS INDUSTRY INFORMER March - April 2015

STAND 60 NWG ENVIRONMENTAL SOLUTIONS - A FRESH APPROACH TO AIR QUALITY We have one of the largest dedicated teams of MCERTS qualified consultants in the UK for over 22 years (previously known as AES). Our services include: MCERTS stack emissions monitoring, workplace noise, environmental noise, sound insulation, acoustic camera and air quality.

Operating across the country and internationally we can carry out a range of testing with analyses at our in-house UKAS accredited laboratory to help you assess your compliance. We guarantee to produce accurate and reliable results using the latest analytical equipment and best practice techniques.

When it comes to air monitoring you can breathe a sigh of relief that you’re in safe hands.

STAND 64 & 75 CONTINUOUS PARTICULATE EMISSION MONITORS FOR INDUSTRIAL PROCESS PCME Ltd, leading specialist in the development, manufacture and supply of continuous particulate emission and flow monitors introduce new product developments in three key areas: Ultrasonic Flow Monitoring: the new MCERTS and QAL1 approved STACKFLØW 400, engineered with in-built self-checks and high quality assurance features, is designed specifically to monitor the flow rate of emissions from industrial sources complying with the European Monitoring Standard EN ISO 16911-2.

Controller/ DAHS with high speed Ethernet: the new advanced ProController powers central communications for PCME’s dust, leak and flow measurement sensors and I/O, combined with a High Speed Ethernet connection for rapid data transfer for Emissions reporting.

Bagfilter Performance Monitoring: the new LEAK LOCATE 320 PLUS digitally networked multicompartment baghouse monitoring system, enables remote observation of bag and cartridge filter condition and as a filter maintenance tool, provides valuable advance warning of filter deterioration.

For more information contact PCME, St Ives, Cambs.

Tel: 01480 468200 E-mail: lindaf@pcme.co.uk Web: www.pcme.com

STAND 70 & 71

For more information contact NWL, Pity Me, Durham, E-mail: Kathryn.cherry@nwl.co.uk Web: www.nwg-solutions.co.uk

STAND 67 FIRST CLASS SOURCE FOR PRECISION OPTICAL COMPONENTS Global Optics (UK) Ltd are suppliers of custom manufactured Precision Optical Components which are typically in the form of Lenses, Windows, Prisms, Mirrors and Optical Filters. These are produced from a range of UV, Visible and Infrared transmitting optical materials, all operating in different regions of the optical spectrum.

These range from a large selection of optical glass to a complete range of optical crystals, including Calcium Fluoride, Magnesium Fluoride, Sapphire, Quartz, Fused Silica, Germanium, Silicon and Zinc Selenide. Applications are very varied, including many different types of analysers and environmental instruments.

For more information contact: Global Optics UK Ltd, Bournemouth, Dorset Tel: 01202 530609 Email: info@globalopticsuk.com / Web: www.globalopticsuk.com

STAND 80

ABB TO UNVEIL LATEST EMISSIONS TECHNOLOGIES AT AQE 2015

ENABLE YOUR ANALYSIS WITH M&C TECHGROUP GERMANY GMBH

ABB will be exhibiting its latest range of air and gas analysers at the Air Quality and Emissions (AQE) Show at the Telford International Centre (22nd-23rd April 2015). Stands 70 and 71 will feature a comprehensive selection of ABB equipment including laser, zirconia and FTIR spectrometry.

A main feature will be ABB’s new ACF5000 hot/wet extractive continuous emissions monitoring system for combustion applications. Using FTIR technology, the ACF5000 enables simultaneous analysis of up to 15 different gas components including SO2, CO2, CO, NH3 and VOCs using a single sample probe system.

Completely self-contained, the ACF5000 offers a turnkey solution for combustion process monitoring in municipal and hazardous waste incineration and power plants using coal, oil or waste. The system is also currently undergoing MCERTS certification for use in process plants for applications including DeNOx and DeSOx plant optimization and HCL scrubber monitoring.

Other products on show will include the stand-alone LS4000 laser gas analyser, Endura AZ20 zirconia oxygen gas analyser, the EasyLine EL3000 range of photometers for gas analysis and the StackFlowMaster in-situ device for measuring flows in stacks up to eight metres in diameter.

ABB will also be hosting a workshop entitled ‘Obtain the highest availability in emission monitoring with extractive operating CEMS’ (12.00 - 12.30pm, April 22nd, room 2; 12:00 – 12:30pm April 23rd, room 4).

M&C TechGroup leads the way in providing high quality sampling and conditioning solutions for gas analysis. With a worldwide presence and over 30 years of experience, M&C has an unrivalled knowledgebase in the field of gas sampling and conditioning.

This is shared with our customers from the outset and supported locally. From filters to flow meters, heated parts and gas coolers, M&C offers a comprehensive catalogue of products to deliver solutions from component to system level.

M&C helps customers to develop new systems for new markets through close cooperation and active R&D. Added value is offered to System Integrators through logically designed components. Plant Operators looking for longlasting, rugged measurement equipment will appreciate the well-renowned longevity of M&C products.

We invite our customers from all industrial sectors to discuss their experiences, issues and requirements during AQE 2015, or at any time throughout the year at their works.

For more information, Email: moreinstrumentation@gb.abb.com Tel.: 0870 600 6122 ref. ‘AQE 2015’.

PROCESS INDUSTRY INFORMER March- April 2015

For more information contact M&C TechGroup Germany GmbH, Belper, Derbys.

Tel +44 (0)8445 617503 Fax +44 (0)1773 303606 Email paul.keeling@mc-techgroup.com Web: www.mc-techgroup.com/e_home.html

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FEATURE

PUMP CAVITATION & HOW TO AVOID IT

Pump cavitation problems are on the rise in the UK. Bob Went, an expert in cavitation issues at Xylem UK, outlines the cause of the problem and offers some solutions.

WHAT IS CAVITATION?

Cavitation can have a serious effect on pump operation and lifespan. It can affect many aspects of a pump, but it is often the pump impeller which bears the brunt of its impact. A relatively new impeller which has suffered from cavitation will often look like it has been in use for many years; the impeller material may be eroded and it can be damaged beyond repair.

Cavitation occurs when the liquid in a pump turns to a vapour at low pressure.

It occurs because there is insufficient pressure at the suction end of the pump, in other words, there is insufficient Net Positive Suction Head available (NPSHa).

When cavitation occurs, air bubbles are created due to low pressure. As the liquid passes from the suction side of the impeller to the delivery side, the bubbles implode. This creates a shockwave that hits the impeller creating pump vibration and mechanical damage, possibly leading to complete failure of the pump at some stage.

WHY IS IT A PROBLEM?

Cavitation is not a new phenomenon, but it is a growing phenomenon.

Whilst no official figures exist, it is not misleading to say that in the last five years, cases of pump cavitation have increased markedly in the UK. All too often the pump itself is unfairly blamed.

Pumping system problems, including cavitation, often manifest themselves at the pump but are rarely caused by it. In fact, nine out of ten pump problems are not caused by the pump itself but by issues such as cavitation, poor system design and lack of maintenance. Pump problems caused by cavitation, such as vibration, can be severe and may lead to mechanical damage to the pump.

Cavitation related problems also have the potential to reduce pump life from circa 10-15 years, down to just two years in extreme cases.

WHY IS IT ON THE INCREASE?

I believe one of the causes may lie in the fact that design engineers in some industries, such as the water industry, are now expected to deal with a very wide range of different technologies. It is therefore impractical for them to be expert in areas such as system design and cavitation problems. The truth of the matter is that cavitation is primarily due to poor pump system design and a lack of awareness about how cavitation is caused.

WHAT CAUSES CAVITATION?

Cavitation occurs in a pump when the temperature and pressure of the liquid at the suction of the impeller equals the vapour pressure. Cavitation can occur at low pressures and normal operating temperatures. Locally it results in the liquid turning to a vapour and creating very high temperatures and pressures, which can reach circa 10,000K and 1GN/m2.

When cavitation occurs bubbles are formed. As the pressure in the pump increases, those bubbles collapse in the form of an implosion, which is equally as violent as an explosion. The implosion causes shockwaves to travel through the liquid and hit the impeller causing mechanical damage.

THE IMPACT OF CAVITATION ON A PUMP

Cavitation causes pump performance deterioration, mechanical damage, noise and vibration which can ultimately lead to the complete failure of the pump.

Often the first sign of a pump problem is a symptom such as vibration. It should be noted that vibration causes problems for many pump components including the shaft, bearings and seals.

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HOW TO AVOID CAVITATION

Assuming no changes to the suction conditions or liquid properties during operation, cavitation can be avoided most easily during the design stage. The key is to understand Net Positive Suction Head or NPSH and take this into account during design. In order to understand this term more easily it is helpful to break it down into its constituent parts. Net refers to that which is remaining after all deductions have been made, Positive is obvious and Suction Head refers to the pressure at the pump inlet flange.

NPSH is defined as the difference between the pressure available at the pump inlet and the vapour pressure of the liquid. It is important to bear in mind that vapour pressure is different for different liquids and varies with pressure and temperature.

It is also important to remember that the pressure available at the pump inlet is that which remains after account has been taken of all the friction losses, velocity head losses and inlet and outlet losses in the suction pipework of the pumping system. During design it is therefore necessary to calculate all the friction losses, inlet and outlet losses and process unit losses in the suction pipework and then deduct those losses from the suction head available to the pump. Therefore, at the point where the pump is installed, we are left with a net pressure remaining and available for the pump.

HOW IMPORTANT IS SYSTEM DESIGN?

There is no alternative to getting pump system design right at the design stage. During design the value of NPSHa (which is independent of the pump to be selected) can be determined quite easily. Having determined the NPSHa it can then be compared to the NPSHr (the suction head required by the pump) for the types of pumps being considered. If there is insufficient NPSHa it is much easier to make changes to the system at design stage rather than after construction and installation. It is strongly recommended that any changes necessary are made at design stage as any additional costs incurred may pale into insignificance compared to the costs of rectifying an installation with cavitation problems.

W H A T IF I HAVE CAVITATION PROBLEMS ON AN EXISTING SYSTEM?

In the event that pump cavitation is a problem on an existing installation there are essentially only two routes that can be followed to rectify the problem.

These are to increase the NPSHa to the pump or decrease NPSHr by the pump.

Options available to increase the NPSHa will depend upon the nature of the system in question. This can include increasing the pressure on the suction end of the pump or reducing the friction losses in the pipework, thereby making more pressure available to the pump. Increasing supply pressure can be achieved by raising the static head of the supply, applying pressure to the supply vessel, using a booster pump, or reducing friction losses in the pipework by using larger diameter pipes or less components and fittings. Pressure could be supplied to the supply vessel with the use of a booster pump.

However, these are rarely viable options for an existing installation and nearly always impractical due to space issues, cost and potential disruption.

Similarly, it is rarely practical to replace the suction system pipework with a larger diameter. A second option is to replace the existing pumps with pumps that have a lower NPSHr or install parallel pumping using multiple pumps. In many cases the above options may not be viable, and in all cases they may involve considerable cost and disruption.

PROCESS INDUSTRY INFORMER March - April 2015

PROCESS MEASUREMENT

& INSTRUMENTATION

CONTREC 100 SERIES BRINGS AFFORDABLE QUALITY TO FLOW MEASUREMENT Electronics manufacturer, Contrec, has placed over thirty years’ experience in the development, manufacture and distribution of flow measurement equipment into a new cost efficient, high volume range of controls, monitors and totalisers.

The 100 Series combines the high standards of British manufacturing and the technical knowledge of this global company with the convenient lower cost units that are available in large numbers and which can be powered by off-theshelf batteries, rather than the more costly intrinsically safe batteries.

Pam Casson, Contrec Manufacturing Managing Director explains “Our products are recognised as the benchmark within our industry with literally tens of thousands of Contrec instruments being trusted in every continent and in most countries around the globe.”

In 2012, the manufacturing rights were purchased from the parent company Honeywell and a new company Contrec Manufacturing (UK) Ltd was started with production being moved from India to Contrec’s West Yorkshire facility, based near Halifax.

“Our supplier was moving in a different direction and was happy to sell the process instrument division. We bought the manufacturing rights and stock with a view to creating our own manufacturing business here in the UK,” added Mrs Casson.

“This gave us far greater control over design, production and quality. It also enabled us to invest heavily in research and development to improve and expand our product range still further. The 100 Series is part of the expansion.”

Designed to deliver highly accurate field instrumentation for the process industry the 100 Series is ideal for applications where a robust weatherproof IP67 unit is required. All models feature simple programming, large display and input linearization for increased accuracy.

Contrec provides flow instrumentation for the petroleum industry, off-shore pipelines, gas, air, water and energy, as well as the food and beverage industries.

For more information contact Contrec Manufacturing (UK) Ltd, Tel: 01422 829940 E-mail: admin@contrec.co.uk Web: www.contrec.co.uk

VISUAL LEVEL MONITORING INDICATION Valco’s visual level indicator offers both a simple and quick option for monitoring liquid level, especially in nonelectrical applications.

Machined out of aluminium and externally mounted this device with its acrylic double site tubes offers 360 visibility providing an extra level of protection and peace of mind.

For critical applications high and low switch points are available and for specific requirements or where compatibility may be a concern, different construction materials are available.

• Applications: water, petrol, hydrocarbon, mineral oils, vegetable oils, diesel oil, glycol • Standard mounting centres: 127mm, 254mm, 300mm, 350mm, 400mm, 450mm, 500mm, 600mm, 700mm, 800mm, 900mm, 1000mm • Optional built-in temperature gauge • Nickel plated brass connections For more information contact OEM Automatic Ltd, Whetstone, Leicester Tel: 0116 284 9900 Web: www.oem.co.uk

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PROCESS INDUSTRY INFORMER March - April 2015

FEATURE

UNDER PRESSURE –

SENSORS IN THE SPOTLIGHT Pressure sensors are used in a whole range of applications, but understanding the differences in design and operation is crucial when specifying a new sensor. These vital components can facilitate a variety of tasks from displaying process information and performing control functions to operating alarms.

Kieran Bennett, of process control specialist Bürkert, looks at the range of sensors available, the different technologies used in their design and how the application affects the specification.

When it comes to fluid control systems, very little can be achieved without the raw data supplied by sensors, which need to be carefully specified to ensure that they are suited to the application. Pressure sensors can be constructed using various designs depending on the target application. From simple and cost effective to bespoke, ultra high pressure components, it is important to make the right choice.

PIEZO-RESISTIVE

A piezo-resistive sensor is filled with hydraulic fluid to provide protection for the sensor. External pressure is sensed through the diaphragm by a change in the pressure of the hydraulic fluid. The sensor produces a pressureproportional signal which is converted to the conventional analogue 4-20 mA output signal. This type of design, as used in the Bürkert Type 8323, is very well suited to low pressure measurement, while also being able to withstand high overload factors.

THIN-FILM

A thin-film strain gauge provides very precise measurements as well as very high burst pressure characteristics. This design uses a thin-film Wheatstone bridge to measure changes in resistance caused by external pressure and converts these measurements into an analogue output signal which is proportional to the pressure.

CERAMIC CELL

For applications involving aggressive media or higher pressures, a thick-film ceramic measuring cell, such as the Bürkert Type 8316, could be used. In this case the Wheatstone bridge is bonded to a ceramic diaphragm, providing greater protection and improved chemical resistance. However, the measuring accuracy is not as high as that of the thin-film strain gauge.

Fig. 1: Thick-film ceramic pressure measuring

PRESSURE MEASUREMENT

When specifying a pressure sensor it is important to ensure that it will give you the readings you expect and this means understanding the terms used in pressure measurement. Absolute pressure is measured relative to a perfect vacuum. One example is atmospheric pressure.

Gauge pressure is measured relative to ambient pressure.

Blood pressure is a good example. Intake manifold vacuum in a car engine is an example of a vacuum gauge measurement (vacuum is negative gauge pressure). Differential pressure is the difference in pressure between two points of measurement.

The use of hydrostatic pressure measurements Fig. 2: Pressure can also determine fluid levels within a tank.

Transmitter Essentially, fluid within a Type 8323 tank generates a specific

PROCESS INDUSTRY INFORMER March- April 2015

hydrostatic pressure based on level and fluid density. By measuring this pressure with respect to a reference pressure, which is usually ambient pressure, the level can be determined, assuming that the fluid density is known.

It is also possible to use this method within a pressurised vessel by using a second sensor to measure the gauge pressure above the fluid level. Using these two pressure measurements, it is possible to evaluate an accurate level measurement. Accuracy is dependent on the precision of the pressure sensor; however, higher internal pressures within the tank increase the margin of error as will the use of two sensors, which compounds the original tolerance values.

Fig. 3: Gauge pressure

MATERIALS SPECIFICATION

While the design of the sensor measuring apparatus is crucial, it is also important to consider the media being measured and the conditions in which the pressure sender is expected to operate. Temperature and pressure are often closely linked, so understanding the operational parameters of each sensor is vital.

The next consideration is the sealing material that is used and its suitability to the media being measured. It is advisable to consult a chemical resistance chart, such as the one produced by Bürkert, which gives details of the suitability of many sealing materials against a large number of base chemicals, commercial products and liquids found in the food and beverage industry.

In some applications, such as food and beverage or pharmaceutical production, hygiene standards are of paramount importance. This requires the materials used to make the sensor body and any electrical interface to meet certain standards, such as those produced by the Fig. 4: Chemical EHEDG (European Hygienic Engineering & resistance chart Design Group).

SYSTEM INTEGRATION

The final aspect of specifying a pressure sensor is its compatibility with the surrounding control infrastructure. This may be a simple, single sensor, closed loop control system or it may be part of a much larger control system using bus communication and PLC modules. Whatever the situation, there will be a solution available.

Understanding the circumstances in which a pressure sensor is expected to operate is the most important step in finding the most suitable product. This information can then be used by an application engineer to determine the operating characteristics of the ideal pressure sender. This may even help when replacing a sensor, especially if these considerations were not followed in the first instance.

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PROCESS MEASUREMENT & INSTRUMENTATION FLEXIBLE ELECTRONIC DIFFERENTIAL PRESSURE VEGABAR 80 includes electronic Differential Pressure as a standard option in all sensors in the range. No special field electronics enclosures or transducers, it only requires a standard device with a‘slave’ electronics module in the other. Simply connect them together for your e-DP system.

This means any two VEGABAR 80’s can be used, minimising cost, complexity and stocks. Mix housings: a level in a pressurised tank with a ‘submersible IP68’ sensor in a flooding bund with a standard housing on the top. Mix materials: a flush ceramic diaphragm on a filter with abrasive liquid and a recessed metal one after it. Select the sensor design: suspended, submersible ‘hydrostatic’ transmitters across screen differential in intake channels. The standard interconnecting distance is 25m, but can extend to over 100m. Connection sizes from ½” BSP/NPT (flush) upwards.

The accreditation portfolio includes ATEX, SIL, FDA, EHEDGE, 3A and Marine.

Communications: 4-20mA, HART, Profibus and Foundation Fieldbus. Nominal sensor pressure ranges from 50mbar up to 1000 Bar (same/similar ranges must be used to suit the e-D.P. application) temperature range -90 to +400 °C. Electronic DP has a host of advantages for the user, particularly over conventional ‘Remote capillary’ based DP systems; faster easier installation, higher accuracy in suited applications, no oil-filled capillaries, smaller connection sizes, better temperature performance, faster response, lower costs and easier maintenance.

It is especially useful in lower pressure applications: filter monitoring, level differential and pressurised vessel levels. So what’s stopping you from changing the way you measure differential pressure?

For more information contact VEGA Controls Ltd, Burgess Hill, West Sussex.

Tel +44 1444 870055 E-Mail: info.uk@vega.com Web: www.vega.com/uk

GEMS SENSORS & CONTROLS ANNOUNCES GLOBAL MARKET LAUNCH OF HIGH-RELIABILITY OEM PRESSURE TRANSMITTERS AND SWITCHES FOR HAZARDOUS AREA ENVIRONMENTS The new Gems Model 3800/3820 Series is a family of reliable, accurate, compact OEM pressure transmitters and switches for hazardous area and other hostile environments.

The new Model 3800 Series pressure transmitter is available in seven unique ranges from 0 to 10,000 PSI (0 to 689 bar), with choice of loop powered (4-20 mA) or low power (1-5 VDC) output. They offer a ±0.25% URL (BFSL) linearity, hysteresis and repeatability specification, with less than 5 millisecond response times.

Depending upon selected range, burst pressures extend from 4x up to 40x FSPR, with 2x or 3x overpressures. Model 3800 Series units also feature NEMA4X IP66 housings, all stainless steel wetted parts and hermetically sealed enclosures without O-rings. Dual seal approval and flush mounting are optional. They are also field adjustable with a 5:1 turndown ratio (2:1 for 100 PSI). Zero and span calibration adjustments may be achieved via a Gems calibration kit and a USB communication cable, sold separately. The new Model 3820 Series is an all stainless steel OEM pressure switch-transmitter For more information about the new Model 3800/3820 Series or other pressure sensing instrumentation offered by Gems Sensors & Controls, please contact us via Email at info@gemssensors.com Web: www.gemssensors.com.

Automate your process with

Digital Pressure Controllers u Pressure ranges from 2...100 mbar up to 8...400 bar absolute or gauge u Thru-flow design u Suitable for liquids and gases u Metal sealed and/or down-ported versions available u High accuracy, excellent repeatability u Analog / RS232 / FLOW-BUS / Modbus / PROFIBUS DP DeviceNet™ / EtherCAT® Innovation - Experience - Responsibility

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

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PROCESS INDUSTRY INFORMER March - April 2015

PROCESS MEASUREMENT

& INSTRUMENTATION

REACTOR VESSEL PRESSURE CONTROL AND DATA LOGGING Bronkhorst has developed a specialised combination of electronic pressure and thermal mass flow controllers for automated pressure control of reactor vessels. This standard solution can be applied for low flow lab reactor systems as well as for high flow industrial applications as for instance in hydrogenation processes in the food and pharma industry or at chemical plants, at either low or (very) high pressure (up to 700 bar). To optimize a chemical reaction, chemists must find the best combination of compounds and introduce these in precise proportions into the reaction chamber.

This reactor may be kept at a certain pressure and temperature and a catalyst may be added to accellerate the reaction. The input of the reaction gases must be accurately measured at all times, also while pressurizing the reactor. An overshoot in flow (outside the scale of the mass flow meter) should be avoided, because this will introduce inaccuracy Important topics essential to the success of the application include : • Accurate measurement of gases • Reaction and process pressure • Programmable pressure profil • Batch control The standard configuration may slightly vary per application as many options are available.

Furthermore, the instruments used may be in ‘laboratory style’ or with rugged industrial housing, with protection to IP65 and with ATEX Zone 2 approval. The scripted programme is available as part of the Freeware package of software tools available via the website. Another important feature within this suite of programmes is the ability to send the measured data, and multiple parameters, directly to a spread-sheet or to a unique file. This eliminates the need for an operator to manually record such data.

In summary, simple straight forward pressure control solutions are available for a great many applications across the process industry. These tried and tested solutions are built upon technical expertise, knowledge and experience.

Commonly a standardized solution is already available, however, with the great many options available it is possible to design bespoke assemblies to meet the requirements of virtually every need.

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

MOUNTABLE PRESSURE SWITCHES Suco’s heavy duty pressure switch range is manufactured out of aluminium and is suitable for high voltage applications.

With the capacity to handle up to 250V these switches also offer SPDT contacts with seal material options for various media and temperatures thus offering application flexibility all in an IP65 rated switch.

Unlike other pressure switches this range has surface and manifold mountable versions in G1/4 female thread making it ideal for extreme environments including rail and mobile hydraulics applications.

• Adjustable set point ranging from 0.1 up to 400 bar • High overpressure safety up to 600 bar • Vibration resistance 10g / 5 – 200 Hz sine-wave • Shock resistance 294 m/ s², 14 ms half-sine-wave For more information contact OEM Automatic Ltd, Whetstone, Leicester Tel: 0116 284 9900 Web: www.oem.co.uk

PROCESS INDUSTRY INFORMER March- April 2015

35

ENERGY EFFICIENCY’S AUTOMATION LENS

By Jonathan Wilkins - Marketing Manager - European Automation If there is one objective manufacturers around the world need to take seriously this year, it’s improving energy efficiency and sustainability. Regardless of an organisation’s size and field of activity, the commitment to more efficient energy use is a burning demand in industry.

In the midst of international summits and governmental policies, companies from across the industrial spectrum are beginning to understand the importance of saving energy, reducing carbon footprint and developing more eco-friendly products and processes. The obvious benefits of energy efficient manufacturing include reduced operational and production costs, increased competitiveness, environmental gains and improved customer welfare.

This special report analyses how industrial automation can help manufacturers become more energy efficient. It also analyses the industry impact of the European Union’s Ecodesign Directive, the Energy Savings Opportunity Scheme (ESOS) and relevant ISO standard.

ECO-DRIVEN DESIGN In 2009, the European Union revised its Ecodesign Directive. The framework ensures designers of energy-using (EUPs) and energy-related products (ERPs) reduce the energy consumption and environmental impact of these products.

EUPs use, generate, transfer or measure electricity. The label includes anything from boilers to computers, transformers, motors or fans. ERPs are products that don’t use energy, but can contribute to saving it, for example windows, insulation material or taps.

Estimates show that over 80 per cent of a product’s environmental impact can be determined during the design phase. Ecodesign ensures products

36

have a reduced environmental impact and lower energy consumption throughout their lifecycle, while maintaining the same levels of functionality.

Despite inevitable criticism, often related to common household items like hair dryers and kettles, the directive has helped reduce energy consumption in a multitude of areas. Take lighting for example. It might come as a shock to many, but lighting accounts for between a fifth and a quarter of general electricity consumption globally. By replacing the more traditional, inefficient incandescent light bulbs used in domestic, office and street lighting, up to 39 terawatt-hours (TWh) can be saved every year in the EU alone.

According to the European Commission, the first 13 measures of the Ecodesign directive will result in annual savings by 2020 equivalent to more than 12 per cent of the electricity consumption of the EU in 2009.

When it comes to industry, the potential for energy saving is staggering.

It is well-known that induction motors use about 30 per cent of all the electricity generated in the world, which means they have great potential for energy savings. In fact, simply by estimating the right size and capacity of a motor, you can save up to 10 per cent on electricity consumption.

Controlling the motor speed in a variable speed application using a variable speed drive (VSD) can further increase the energy savings to as much as 60 per cent. These numbers make it clear that, simply by correctly estimating and controlling electrical motors, manufacturers can reduce their energy consumption.

As motors have evolved, manufacturers have managed to achieve better efficiency. The International Electrotechnical Commission constantly

PROCESS INDUSTRY INFORMER March - April 2015

updates its international standard defining the energy efficiency classes of single speed, three-phase motors. The standard has also been adopted in the European Union and UK and is known as the BSEN 60034-30:2009.

According to the 640/2009 regulations of the Ecodesign directive starting June 2011,motors manufactured in and operating in the EU have to meet at least the efficiency level IE2 (High efficiency).

From January 1, 2015, IE3 (Premium Efficiency) became mandatory for motors from 7.5 to 375 kW. The next phase starts on January 1, 2017, when IE3 requirements extend to all motors between 0.75 and 375 kW; with one exception: IE2 motors can still be bought, but only if installed with a VSD. This exception should be enough to demonstrate just how important VSDs are for industry. Not only would fitting a VSD allow manufacturers to minimise the costs of complying to new Ecodesign regulations and future proof operations, it also brings enormous energy savings, reduces motor wear by using soft start and stop technology and opens up new technological opportunities. In terms of industrial automation, VSDs also allow an additional level of communication between the motor and the control system, resulting in valuable information, such as operating or maintenance data. This also allows manufacturers to identify where and how the greatest energy savings can be made.

Although the Ecodesign directive only applies to the European Union, it accurately reflects other international standards. In fact, it is a relatively late adoption of energy-saving techniques. Looking strictly at electric motors, the Unites States paved the way by introducing a law on IE2 classification in 1997 and one on IE3 in 2010. Mexico, Australia, India, China and Brazil also introduced the IE2 class as a regulatory requirement.

The Ecodesign directive highlights the importance of product design when it comes to energy efficiency and continues the global race to make manufacturing eco-friendly. Manufacturers that fail to get on the bandwagon in the next couple of years will find themselves overwhelmed by energy costs and unable to engage on the global market.

ESOS: CONTINUOUS ASSESSMENT As is always the case with megatrends, energy efficiency brings with it a complex, and sometimes bewildering body of legislation and directives.

Energy efficiency is not the goal; it is a basic principle that should guide the actions of governments, organisations and individuals everywhere.

Continuous assessment of what has been achieved and what can still be done is essential, which is why ISO standards and energy efficiency directives are constantly under revision.

The same level of periodic assessment is now being required of organisations around the globe, particularly large energy users. A recent example from the United Kingdom is the Energy Savings Opportunity Scheme (ESOS).

The scheme originated from the EU’s Energy Efficiency Directive that came into force in 2012. One of the articles of the directive requires every member state to introduce a mandatory energy auditing scheme for large enterprises.

ESOS calls for large UK undertakings to carry out energy usage assessments every four years. A large undertaking is defined as an organisation that employs at least 250 people or has an annual turnover in excess of 50 million euro. Companies that met these qualifications before December 31, 2014 need to comply with the new regulation.

An ESOS assessment is a four step process. It involves a calculation of the total energy consumption of buildings, industrial processes and transport. The next two steps refer to identifying areas of significant energy consumption and evaluating energy saving opportunities. The final step is to store relevant data and notify the scheme administrator.

Each organisation must appoint a lead assessor to carry out and oversee all energy audits. The first confirmation of ESOS compliance needs to be submitted to the Environment Agency before December 5, 2015 with regular updates every four years after that.

To avoid duplication in existing regulation and requirements, ESOS is aligned with other energy assessment schemes like ISO 50001. Organisations that have already undertaken energy audits to ESOS standards or align themselves to the Carbon Trust Standard can use existing records to support ESOS compliance. The point isn’t to make organisations do things twice, but to build on existing energy practices that work.

On another positive note, expert support and detailed guidance is available for companies that need to comply with ESOS, with the best starting point being the Environment Agency website.

Once again, ESOS revealed the potential for energy efficiency is astounding.

Initial evaluations estimate the scheme to have a £1.6bn net benefit for the UK over the next 15 years, primarily felt by businesses through lower energy bills. This is a conservative estimate, calculated on an average of 0.7 per cent saving on energy bills. In reality, the savings have proven to be significantly higher than that.

If ESOS proves anything, it’s that processes and mechanisms are now

PROCESS INDUSTRY INFORMER March- April 2015

being put into place to make companies more energy efficient. ISO 14001 and ISO 50001 are frameworks for organisations that want to develop a policy for more efficient use of energy and continually improve energy management. Although they are highly regarded certifications and are required by certain industry branches, the standards have not yet been made mandatory.

ISO 50001: BEYOND COMPLIANCE For organisations that want to go beyond compliance and see the true value of energy management, ISO 50001 is a viable route, although it is more expensive and time consuming than ESOS or Display Energy Certificates (DEC).

ISO 50001 enables organisations to follow a systematic approach to achieving continual improvement of energy performance. The standard helps establish, implement and maintain a system and relevant processes and procedures within an organisation. ISO 50001 is unique standard in the ISO family because it goes beyond improving the effectiveness of a system and aims to enhance energy performance – and this is where organisations can truly reap the benefits.

The major components of ISO 50001 are also more complex than those of similar schemes like ESOS. They include, but are not limited to establishing management responsibility, an energy policy, an energy action plan, performance audits and management reviews. These tools ensure an organisation has a much more complex framework that allows it to develop a policy for more efficient energy use, fix realistic objectives to meet the policy, use data to better understand energy consumption, measure results and continually improve energy management.

It’s probably fair to say that while ESOS is proof an organisation is compliant with energy efficiency standards, ISO 50001 ensures energy management is at the very heart of the business.

Regardless of what level of compliance a manufacturer decides to go for, it is crystal clear that new energy management standards and legislation are reshaping industry. Certifications like ISO 14001 and ISO 50001 are becoming more and more important for businesses that want to become, and be perceived as, industry leaders, responsible corporate entities and sustainable endeavours. More than fostering sustainability, energy efficiency also helps lower operation and maintenance costs and optimises processes and products.

ENERGY EFFICIENCY AUTOMATION

THROUGH

INDUSTRIAL

Navigating the maze of ever-changing directives and legal terminology can be tough, but luckily resources and specialists are never too far away.

What manufacturers need to be asking themselves is how to become more energy-efficient.

Industrial automation is able to offer solutions to achieve high productivity and energy savings, while also monitoring and recording the process.

The first step is an in-depth analysis of existing systems and processes.

Organisations should realistically evaluate what savings can be achieved by modernising existing systems and what new investments need to be made.

Intelligent measurement technology, process automation and electric drives technology are only some of the solutions for skilful energy management.

The road to energy efficiency starts with the basic principles of energy storage, energy recovery and optimised processes and products.

When discussing the core technologies that can help the manufacturing sector become energy efficient, integrated communication is first on the list. This refers to creating components that can be connected in an open architecture, components able to gather real-time information and take instructions from intelligent control systems.

Secondly, advanced control methods like Programmable Logic Controllers (PLCs) should monitor, diagnose, increase system efficiency and solve problems. The data gathered and stored should then be analysed and used to make further enhancements to the system.

The technologies necessary for implementing intelligent industrial automation systems are already available and their capabilities are always improving.

Accurate sensors and measurement devices, control and monitoring methods, Ethernet or other Internet-based industrial communication standards, as well as simple, safe user interfaces are already in operation.

These intelligent automation solutions have been tried and tested. Some, like VSDs, should really be on the verge of becoming the norm but in reality are still only used in around ten per cent of applications, according to an estimate from GAMBICA, the UK trade body for automation. To gain a competitive advantage, comply with ever more demanding environmental regulations and set up more flexible, sustainable operations, manufacturers must get on board the industrial automation train before it is too late.

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FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves ENHANCED FUNCTIONALITY FOR ROTORK CMA BOOSTS ELECTRIC PROCESS VALVE CONTROL

EVER WONDERED HOW YOU CAN BENEFIT FROM ENERGY SAVINGS – EVEN IN HIGH VISCOSITY APPLICATIONS?

Rotork has announced an extensive advancement of CMA electric actuation technology for the operation of process control valves, introducing new options to meet evolving customer and market requirements. With the latest developments, the innovative CMA design can now be specified with increased functionality encompassing local controls, LCD positional display and programmable fail-toposition performance.

Designed for quarter-turn, rotary or linear operation, robust Rotork CMA actuators perform numerous process control 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. Explosionproof certification to international standards is available for hazardous area applications.

Local controls now offer manual operation at the valve, combined with a vivid LCD display of valve position which also incorporates critical and non-critical fault symbols. Control selection knobs enable selection of Local, Stop or Remote operation and Open or Close input commands in the Local control mode. Each mode can be locked in place to prevent unauthorised operation. The LCD display shows the valve position as a precise percentage of total valve travel.

For fail-to-position performance, a reserve power pack provides the actuator with the ability to perform a predetermined action on power failure. The power pack also preserves position indication on the LCD display Fig.: The innovative CMA process control during power failure. Upon restoration actuator can now be specified with increased functionality encompassing of mains power, the power pack is local controls, LCD positional display swiftly recharged to ensure continued and programmable fail-to-position fail-to-position functionality. Action on performance. power loss is easily configured with the standard CMA HMI interface as part of the user-friendly actuator set-up menu, utilising a 6-segment LCD display and push button configuration.

The maintenance-free CMA drive train, environmentally protected to IP67 and permanently lubricated for operation in sub-zero temperatures as standard, can be mounted in any orientation. Accepting an industry-standard 4-20mA control signal, the CMA provides accurate, repeatable and backlash-free positional control. Resolution is 0.2% on linear and quarter-turn applications, 2 degrees on the multi-turn models. All CMA actuators have output speeds that are adjustable down to 50% of full speed in 10% increments and manual operation is provided as standard. Network compatibility encompasses Rotork Pakscan, HART®, Profibus®, Modbus®, DeviceNet® and Foundation Fieldbus®.

The latest CMA developments follow other recent refinements including upgraded electronics, HMI enhancements and a user selectable increased seating torque/thrust option, enabling a more tailored and cost-effective sizing regime to be applied to the combination of modulating and tight seating demands often found in control valve applications. A new rotary model size has also been introduced.

The combination of all these improvements represents a comprehensive advancement of CMA actuator technology and functionality, focussed on precise process valve control, system simplification and reduced maintenance.

In addition to traditional control valves, successful CMA applications include choke valves on shale gas installations, stroke adjusters on metering pumps, precision metering on chemical dosing and the operation of dampers.

Florian Walter, Product Manager at MasoSine Process Pumps (part of the Watson-MarlowFluid Technology Group) explains how…

“Every business we talk to is driven by the double-edged sword of increasingly stringent environmental legislation (such as the Energy Savings Opportunities Scheme, and the Carbon Reduction Commitment) along with the ever-present need to reduce manufacturing costs”.

According to the BPMA, pumps account for no less than 10% of the world’s electricity consumption and two-thirds use up to 60% too much power. And, as energy represents 95% of a pump’s life cycle cost, the opportunities for savings are substantial. Here at Watson-Marlow Fluid Technology Group, we sign up to the premise that improving energy efficiency enables manufacturers to increase profitability and remain competitive in today’s cost conscious markets.

But first it is important to understand the technical challenges faced by manufacturers. Many have the need to pump a large range of products, from mayonnaise to meat, or surfactants to silicone. Handling products with such a wide range of viscosities presents a real challenge. The torque required to drive the pump increases in line with viscosity, thus resulting in the need for large electrical motors. These larger motors draw more power, even when not operating at capacity.

We are often asked, “What is the solution?” On one hand, you can use higher efficiency motors with your existing pump technology. With a higher energy efficiency class motor, the saving in electrical power can be increased, but a change in technology can save even more. Alternatively, you can look to replace existing technology with a more efficient principle, such as the replacement of traditional lobe pumps with energy efficient sinusoidal pumps such as ourMasoSine technology. These pumps are not affected by viscosity in the same way and can use smaller motors compared with established technologies For example, one customer has reported that they can now use a 4.6kW motor as opposed to 11kW motor for a 1200cp dairy product pumped at 10 bar. What’s more, the exclusive sinusoidal rotor overcomes the limitations of conventional pump technologies. This is a technology which is able to deliver powerful suction with low shear, low pulsation and gentle handling, without the need for high power drives.

It is the energy efficiency characteristics of our MasoSine sinusoidal technology that have led us to launch the concept of MasoSine Energy Efficiency (known as ‘mee’) to our customers. In basic terms, mee enables us to prove (by way of a set of performance curves and calculations) the energy-saving benefits of these pumps to our customers. We can also show how energy savings increase as the viscosity increases.

“Businesses who have already used this information to justify changes to a MasoSine solution are already enjoying a range of operational benefits including: lower energy consumption, higher quality and faster processing, with low shear, high suction, low pulsation, gentle handling of whole foods or highly viscous products. This increases the sustainability of a customer’s manufacturing process through a powerful combination of economical operation and maintenance”.

Watson-Marlow Fluid Technology Group will be publishing a White Paper on this subject later this year.

For more information contact ROTORK PLC Brassmill Lane, Bath, BA1 3JQ, UK Tel: +44 (0)1225 733200 Web: information@rotork.com

For more information contact Watson-Marlow Fluid Technology Tel: 01326 370370 E-mail: info@wmftg.com Web: www.wmftg.co.uk

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PROCESS INDUSTRY INFORMER March - April 2015

FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves COMPACT TURBINE PUMPS IDEAL FOR LOW FLOWS, HIGH PRESSURES When a reliable and economic pumping solution is required for applications involving low flows (130 lit/min) high pressures (up to 70 bar) and heads up to 600 metres, MTH regenerative turbine pumps are the ideal choice. A good example of this is the MTH M52 pumps recently supplied by PUMP ENGINEERING for a mechanical seal lubrication and pressurising application in oil production where the benefits of very low NPSH combined with a smooth, balanced performance have been appreciated.

The MTH range of pumps is ideally suited to applications such as boiler feed, high pressure cooling, refrigeration and CIP process. These compact pumps, which are available in direct drive, bareshaft, magnetic drive and canned rotor options, can replace multistage pumps, generating high heads in only a single stage. This design allows the pump to handle hot liquids,refrigerants, liquefied gases and liquids with entrained air, for example gas dissolution systems, where the pump will self-vent carrying air bubbles with the fluid to the discharge port.

The regenerative turbine pump is characterised by its unique impeller, which has a large number of blades machined into both sides of its periphery. Fluid enters the impeller at its outside diameter and is accelerated as it passes from blade to blade exiting the pump, at the same radius as the inlet. The row of blades located on each side of the impeller minimizes axial thrust; in effect, it is two impellers in one, operating within identical channels on the casing and the cover which allows the impeller to float freely and find its own equilibrium.

Another important advantage of the regenerative turbine pump is its ability to generate a very steeply rising head curve between minimum and maximum flow ensuring accurate flow control and very stable operation.

The standard range of MTH pumps includes models which cover capacities from 1 to 500 lit/min and pressures up to 70 bar. Construction materials include iron, bronze and 316 stainless steel.

For more information contact Pump Engineering Ltd, Tel: +44 (0) 1903 730900 E-mail: sales@pumpeng.co.uk Web: www.pumpeng.co.uk

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FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves WHEN THREE PUMPS ARE BETTER THAN ONE

GEAR PUMP SETS NEW STANDARDS FOR HYGIENIC PUMPING A new range of hygienic internal gear pumps which provide the all-important features and benefits for pumping in food, brewing, pharmaceutical, fine chemicals and o t h e r ‘sensitive’ h y g i e n i c applications has been introduced by gear pump specialists Viking Pump.

Engineers at Wanner have designed a high flow rate skid that incorporates three of the Company’s Hydra-Cell G35 pumps operating in parallel.

The system can pump up to 420 litres per minute at 83 bar pressure or up to 200 litres per minute at 100 bar pressure. Installing three Hydra-Cell pumps means three times the flow as they are true positive displacement pumps. This is not the case in a centrifugal pump system. With Hydra-Cell pumps the flow is maintained but the friction losses manifest themselves in increased system pressure.

The multiple pump system where all three pumps take suction from a common manifold and discharge into a common header is reported to be ideal in situations where some flow needs to be maintained continuously and system shutdown is not an option. Minimal routine maintenance requirements can be easily accommodated while maintaining up to 60% of the rated flow and should a pump or motor go down it can be replaced while the rest of the system is still functioning.

The system produces a virtually pulseless flow and is extremely accurate, exceeding the performance requirements of API 675 in terms of flow repeatability, steady state accuracy and linearity.

Some users choose the three pump option using two pumps to achieve service while keeping one for back-up. In many instances, where footprint is not an issue, the three pump approach can save on acquisition costs and energy costs while improving the overall reliability and efficiency of the system.

For more information contact: Wanner International Tel +44 (0)1252 816847 Email: NHerrington@wannerint.com Web: www.hydra-cell.eu

Available in the UK through MICHAEL SMITH ENGINEERS the positive displacement Viking Hygienic Series represents a significant breakthrough in combining the superior reliability and ease of maintenance of an internal gear pump, with the exceptional clean-ability of a hygienic pump.

The pump’s status as a genuine hygienic pump and suitability for clean-inplace (CIP) is confirmed by certification to Type EL Class 1 from the European Hygienic Engineering and Design Group (EHEDG). The Hygienic Series is also third party certified to display the 3A Sanitary Standards Symbol for positive rotary pumps (3-A Sanitary Standard 02-11) a globally recognised standard for hygiene within the food and dairy industries.

Features include only one shaft seal, unlike the two usually found in most other types of hygienic positive displacement pump, which reduces the possibility of unplanned downtime and associated costs, internal wetted surfaces polished to a minimum of Ra 0.8µm and internal angles machined to a minimum radius of 0.8mm. The Hygienic Series has sealed bearings with food grade grease, so no need for an oil reservoir or oil changes.

For more information contact Michael Smith Engineers, Woking, Surrey.

Tel: 0800 316 7891 E-mail: Info@michael-smith-engineers.co.uk Web: http://goo.gl/kpnfO1

EMERSON LAUNCHES FREE GUIDE TO PROPORTIONAL CONTROL VALVES Leading global technology provider, Emerson Industrial Automation is pleased to announce the launch of a new technical guide to proportional control valves. Designed to help ASCO Numatics’ customers select the correct proportional valve for their specific needs and application, the new guide is available to download free at the company’s website www.asconumatics.eu/ proportional-technology.

Ideal for a wide range of applications, for example welding and materials testing equipment, gas burners, filling and cooling systems and medical equipment, proportional control valves are a cost effective and compact solution for controlling flow or pressure at low flow rates.

Jean-Francois Morier, Vice President of Sales for the ASCO Numatics range of products, comments: “We’re always keen to share our expertise with our customers, whether that be through free technical guides such as this, consulting during project scoping, or via our customer service team.

“Feedback from our customers suggested that with multiple providers and valve options on the market, it can be challenging to select the most appropriate proportional control valve for a particular need. Our new free guide solves this issue by providing a quick reference of the most important criteria for valve selection, including operation methods, positioners and key applications. In our industry, choosing a supplier with specialist knowledge and proven technologies can really make the difference, too.”

For more information about the comprehensive ASCO Numatics range of proportional control valves please visit Web: www.asconumatics.eu/proportional-technology

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PROCESS INDUSTRY INFORMER March - April 2015

FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves INTERLOCKING SMALL DIAPHRAGM VALVES

NEW GRUNDFOS PRODUCT CENTER – REPLACEMENT MADE EASY

Applications in the Food, Beverage, Pharmaceutical & Personal Care Industries For manufacturers in the food, beverage, pharmaceutical and personal care industries, locking off diaphragm sampling valves can be problematic. Usually located in wash-down areas, these small valves commonly control the flow of high purity water in closed loop systems. Because of the valves’ small size, conventional stainless steel interlocks are usually too big and heavy.

To solve this problem, Smith Flow Control, a specialist in valve interlocking equipment, has developed a new interlock for use with diaphragm valves in these and other hygiene-critical applications.

The new interlock uses a simple, rotational Ellis lock mechanism that is ideal for this application due to its compact design. It has an Acetal plastic body, which is lightweight and well suited for use with small diaphragm valves. It is also highly resistant to moisture, solvents and many other neutral chemicals. Despite this, it is tough, hardwearing and has a high resistance to repeated impacts.

The Ellis key has a spring-loaded rubber seal, preventing water ingress during washdown or sterilisation procedures.

“Smith Flow Control is renowned for its heavy duty mechanical interlocks for the oil and gas industries, but this new lock design demonstrates our ability to provide interlocks for specialist applications, such as small diaphragm locks,” commented Dan Kelly, the company’s North American General Manager.

Since Grundfos launched their new Product Center last year it has continued to gain in popularity.

This could be because much thought and consideration went into re-designing and developing this pump selection tool, in order to make choosing the right pump solution as easy as possible.

This ease of selection is also true when a replacement pump is required. By logging onto www. grundfos.co.uk and choosing the Product Center link you can select the REPLACEMENT option on the home page. From here simply enter the name of the old pump into the Quick Search field or alternatively, you can enter the pumps name and other data into the Classic Search field.

The Product Center will then display the top three replacement pump choices and you can filter your selection by choosing the option of the pump with the lowest purchase price; the option of the pump with the lowest energy consumption or the option of the pump with the lowest total lifecycle costs.

Additional requirements, such as fluid type, lifecycle costs and evaluation criteria provide additional filtering options and will ensure that finding the best pump replacement choice is there waiting for you, whenever you need it.

For more information contact Smith Flow Control Ltd, Tel: +44 (0)1376 517901, Fax: +44 (0)1376 519720 E-mail: enquiries@ smithflowcontrol.com Web: www.smithflowcontrol.com

For more information contact Grundfos Pumps Ltd, Leighton Buzzard, Bedfordshire.

Tel: 01525 850000 Fax: 01525 850011 E-mail: grundfosuk.com Web: www.grundfosuk.co.uk

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DRIVES & MOTORS WEG’S CFW11W OFFERS UP TO 40% HIGHER POWER THAN CONVENTIONAL INVERTER DRIVES The CFW11W water-cooled drive from WEG, a leading supplier of drive technology, offers up to 40% higher power in a more compact size than standard air-cooled inverters, enabling manufacturers across a wide range of industries to increase efficiency and optimise processes.

Space on production plants is often limited, with only minimal room available for the installation of automation components.

Furthermore, increasingly powerful drive systems require modern and efficient cooling methods. The modular, water-cooled CFW11W frequency inverter from WEG offers a solution to these challenges.

With power ratings from 450 kW to 2,800 kW, CFW11W is suitable for low-voltage applications and is ideal for critical and support drive systems. As the inverter is water-cooled, there is no need for fans, which offers significant size and cost savings compared to air-cooled models.

Available with an IP54 protection rating as a minimum, the CFW11W is robust, with enhanced cooling efficiency enabling it to operate without power loss at temperatures of up to 45°C. Additionally, the modular architecture of the CFW11W allows up to five power modules to be incorporated in a switchgear unit and controlled using a single operator panel, allowing the inverter to be optimally adapted to specific customer power requirements.

“Our water-cooled CFW11W inverters are used wherever space is tight and suitable process water is already available,” says Johannes Schwenger, Head

of Drive Systems Product Management at WEG. “Compared to conventional models of the same size the CFW11W inverters deliver significantly higher power. For example, a water-cooled inverter with a 2.8 MW power rating has smaller dimensions than an air-cooled model with a 2 MW power rating.”

Aside from water cooling, the CFW11W inverters are structurally identical to WEG’s standard CFW11M models in the same product family. The inverters support open-loop vector control or field-oriented motor control with rotary transducer feedback for extremely high speed and torque accuracy. This enables precise torque settings even at low motor speeds, virtually up to the stall limit of the motor.

All functions for the effective protection of low-voltage motors are integrated in the devices. This makes the drives suitable for any task which requires precision and energy savings. The CFW11W is extremely easy to operate as it has an integrated user interface (HMI) with a backlit graphical display and softwareconfigurable function keys. With a wide selection of plug-in extension modules as well as plug-and-play functions, it can be adapted to customer needs quickly and easily using the USB port.

For more information contact WEG Electric Motors (UK) Ltd Tel: +44(0) 1527 513800 E-mail: wegsales@wegelectrinmotors.co.uk Web: www.weg.net/uk

SPECTRAL SENSORS TINY LOW-COST SPECTRAL SENSOR FROM OCEAN OPTICS SUITED TO OEM INTEGRATION AND BENCHTOP USE Spark’s solid state optical encoders bring spectroscopy to more applications than ever before Ocean Optics’ new Spark spectral sensor uses optical technology advances to shrink instrument size, making it the smallest on the market to date. The SparkVIS is the first offering in the Spark line of versatile spectral sensors, delivering high-resolution measurements over the visible wavelength range of 380-700 nm.

Available in both OEM and stand-alone configurations, the compact lowcost Spark-VIS is suitable for simple absorbance, fluorescence and emissive colour measurements. It can be embedded to power next-generation portable and internet-connected sensing devices for environmental, food, agriculture, biomedical and quality control applications; integrated directly on processing lines; or used as a benchtop instrument in teaching, research, medical and quality control labs.

The Spark-VIS is the first Ocean Optics spectral device to replace traditional diffraction gratings with a solid-state optical encoder. The resulting unit size and cost are comparable to that of a less robust RGB filter diode detector, but with the ability to take full spectral measurements. Compatible with Ocean Optics’ Raspberry Pi development kit, the Spark-VIS can be purchased off the shelf for applications engineering. The same spectral sensor can then be bought economically in bulk for use as a component in portable and internet-enabled devices.

The stand-alone Spark-VIS is easy to use, with plug and play USB connectivity.

Its low cost makes it a good option for budget-conscious student labs. The even smaller OEM version runs off the host device’s driver and communication electronics, connected by ribbon cable. A line of Spark accessories, including clip-on cuvette holders, diffusers, and light sources, is compatible with both versions.

Spark has remarkable performance for a spectral sensor of its kind. Its aperture design optimizes light throughput. Robust optoelectronics ensure thermal stability over a -10° – 60° C operating range, for accurate analysis even in harsh environments. Unlike comparable devices, Spark delivers optical resolution of 4.5-9.0 nm (FWHM), making it viable for a wide range of applications.

To learn more about the Spark-VIS contact Ocean Optics Applications Scientist at Email: info@oceanoptics.com or Web: www.OceanOptics.com.

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PROCESS INDUSTRY INFORMER March - April 2015

WASTEWATER & EFFLUENT TREATMENT BENEFITS OF MEMBRANE FILTRATION TECHNOLOGY FOR WASTE WATER AND EFFLUENT TREATMENT Membrane filtration is a valuable technology for the effective treatment and purification of effluent with proven success across a wide spectrum of industries as the process delivers stable operation delivering consistent performance without the use of chemicals to effect separation; critical requirements for factories intent on secure 24/7 operation.

The technology, which provides a physical controllable process for the recovery of both particulate and soluble elements, also ensures the filtrate quality to be normally consistent and protected from the day to day variations in feed constitution, a big plus for many manufacturers.

Axium Process specialises in the design and build of wastewater and effluent treatment systems utilising membrane technology which can, in some instances, produce recovery levels of up to 95% and return crystal clear, commercially sterile, warm water, for further use. With a correctly designed system, manufacturers using Axium’s waste water and effluent treatment technology may also benefit from reduced charges under the Mogden formula with a reduced chemical impact on the environment, contributing to further cost savings in terms of chemical purchase, storage, handling and disposal.

Axium Process maintains a comprehensive range of mobile pilot plants which are available for customers wishing to carry out trials on their own specific feed material. This service is especially suitable for companies wishing to evaluate membrane filtration as a technology to upgrade their processes, treat effluent and conserve water.

For more information please contact Axium Process Ltd, Tel: +44 (0) 1792 883 882 Email: info@axiumprocess.com Web: www.axiumprocess.com

PROCESS INDUSTRY INFORMER March- April 2015

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

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FEATURE

SELECTING THE RIGHT GRE

Often overlooked by engineers, selecting the most suitable grease for a rolling bearing can prevent premature bearing failure, while also ensuring high reliability and optimum operating life, says Dr Steve Lacey, engineering manager at Schaeffler UK. Rolling bearings play a vital role in the process industries, helping to ensure the smooth uninterrupted operation of production lines, machines and other process-critical equipment such as pumps, fans, compressors, electric motors and gearboxes.

Selecting the correct lubricant for a rolling bearing is a critical factor in ensuring the functional reliability and optimum operating life of that bearing, which in turn, maximises machine and process uptime.

Indeed, failure statistics show that a significant proportion of premature rolling bearing failures are directly or indirectly related to the lubricant used. The main causes of failure here are unsuitable lubricants (20%), aged lubricants (20%) and insufficient lubrication (15%).

CAUSES OF FAILURE FOR ROLLING BEARINGS [SOURCE: ANTRIEBSTECHNIK, 93]:

(1) Lubricant starvation, (2) unsuitable lubricant, (3) aged lubricant, (4) material and production defects, (5) unsuitable bearing selection, (6) secondary damage, (7) mounting defects, (8) liquid contaminants, (9) solid contaminants.

GREASE SELECTION

When selecting a suitable grease for a rolling bearing, a numberof application-related factors need to be considered. These include the type of bearing, operating speed, temperature and load. Other factors such as mounting position, sealing, shock and vibration, and legal/ environmental regulations may also need to be considered.

GREASE CHARACTERISTICS AND CLASSIFICATION

The characteristics of a grease fundamentally depend on the following three properties: Base oil type & viscosity The viscosity of the base oil is responsible for the formation of the lubricant film. As a base oil, mineral oils or synthetic oils are commonly used. It is important that synthetic oils are differentiated according to their type (polyalphaolefin, polyglycol, ester, fluoro oil, etc.), as these possess very different characteristics.

Thickeners Typical thickeners used include metal soaps or metal complex soaps.

Organic or polymer thickeners such as polycarbamide are becoming increasingly important.

Additives All greases contain additives. A distinction is made between additives that have an effect on the oil itself (oxidation inhibitors, viscosity index improvers, detergents, etc.) and additives that have an effect on the

44

bearing or the metal surface (e.g. anti-wear additives, corrosion inhibitors, friction value modifiers).

Greases are classified in terms of their principal components: thickener and base oil. Greases are produced in various consistencies, which are defined as NLGI grades. These are determined by the ‘worked penetration’ of the grease according to ISO 2137. The higher the NGLI grade, the harder the grease. Preferred greases for rolling bearings are those with NGLI grades of 1, 2 or 3.

FACTORS INFLUENCING GREASE SELECTION Bearing type A distinction needs to be made between point contact (ball bearings) and line contact (needle roller bearings and cylindrical roller bearings).

In ball bearings, each overrolling motion at the rolling contact places strain on only a relatively small volume of grease.

In addition, the rolling kinematics of ball bearings exhibit only relatively small proportions of sliding motion. The specific mechanical strain placed on greases in bearings with point contact is therefore significantly less than in bearings with line contact.

Typically, greases with a base oil viscosity ISO VG 68 to 100 are used.

In rolling bearings with line contact, higher requirements are placed on the grease. Not only is a larger grease quantity at the contact subjected to strain, but sliding and rib friction is also to be expected. This prevents the formation of a lubricant film and would therefore lead to wear. As a countermeasure, greases should be selected that exhibit a higher base oil viscosity (ISO VG 150 to 460 or higher). Anti-wear additives may also be required and consistency is normally NLGI 2.

Speed The speed parameter of the bearing should always be a good match for the speed parameter of the grease. This depends on the type and proportion of the thickener, the base oil type and the proportion of base oil.

The speed parameter of a grease is not a material parameter but depends on the bearing type and the required minimum running time.

As a general guide, for rolling bearings rotating at high speeds or with a low requisite starting torque, greases with a high speed parameter should be selected. For rolling bearings rotating at low speeds, grease with a low speed parameter is recommended.

Temperature The temperature range of the grease must correspond to the range of possible operating temperatures in the rolling bearing. The operating

PROCESS INDUSTRY INFORMER March - April 2015

EASE FOR ROLLING BEARINGS TO

MAXIMISE PROCESS UPTIME

temperature range is dependent on the type and proportion of thickener, the type and proportion of base oil, the production quality and production process. The stability of the grease at high temperature also depends primarily on production quality and production process.

In order to achieve reliable lubrication and an acceptable grease operating life, it is generally recommended that greases should be selected according to the bearing temperature that normally occurs in the standard operating range.

Other factors to consider include the upper operating temperature of the grease, the dropping point (i.e. the temperature at which slowly heated grease passes from a semi-solid to a liquid state and the first drop of grease falls from the standardised dropping point nipple), and the lower operating temperature.

Load For a load ratio C/P <10 or P/C > 0.1, greases are recommended that have higher base oil viscosity and anti-wear additives.

These additives form a reaction layer on the metal surface that provides protection against wear. These greases are also recommended for bearings with an increased proportion of sliding motion (including slow running) or line contact, as well as under combined radial and axial loads.

Water & Moisture If the application is in a damp environment, moisture can enter the bearing. Water may condense within the bearing if there are rapid temperature fluctuations between warm and cold. This is a particular problem if large cavities exist in the bearing or housing.

Water can cause severe damage to the grease or bearing and is often due to ageing or hydrolysis, interruption of the lubricant film and corrosion. Barium and calcium complex soap greases have proved favourable in these conditions as they provide good water resistance and act to repel water. The anti-corrosion effect of a grease is also influenced by additives.

Oscillations, shocks and vibrations Oscillation loads can have a considerable effect on the structure of thickeners in greases. If mechanical stability is not sufficient, changes in consistency may occur. This leads to softening, de-oiling on an isolated basis, but also hardening of the grease with a corresponding reduction in lubrication capability. It is therefore recommended that a grease should be selected whose mechanical stability has been tested accordingly. Options here include the expanded worked penetration, the Shell Roller Test in accordance with ASTM D 1831 and a test run on the FAG AN42 test rig.

Seals If hard contaminant particles penetrate the bearing, this will not only lead to increased noise but also to wear. Appropriate sealing of the bearing should prevent this. The grease can assist this sealing effect by forming a stable collar on the seal. In this case, more solid type greases are more suitable, as greases that are too soft tend to favour the escape of grease.

Mounting position & adjacent components Even where an axis of rotation is vertical or inclined, lubricant must remain at the lubrication point. In addition to appropriate seals, flowing away of the grease can be prevented by using a more viscous grease.

If several lubrication points are located close together, unintentional contact can occur. Attention must therefore be paid to compatibility of the lubricants with each other. However, where possible, the optimum solution is to use only one grease, which should also be compatible with the cage and seal material.

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Legal & Environmental

Depending on the application and the industry sector, legal and environmental factors must be considered when selecting a suitable grease. In the food processing industry, for example, the use of greases with appropriate authorisation is specified. A worldwide standard that can be used is approval in accordance with the NSF (National Sanitary Foundation) H1 or H2, listed in the so-called White Bookâ&#x201E;˘ A lubricant with the code H1 (food-grade lubricant) may be used where occasional, technically unavoidable contact with foodstuffs cannot be eliminated. This means that the grease must be non-toxic, rapidly broken down by the organism and neutral in terms of both odour and taste.

Such lubricants often comprise aluminium complex soap thickeners and polyalphaolefins or medicinal white oils as a base oil.

H2 lubricants are intended for general use within the food processing industry where no contact with foodstuffs occurs.

Greases with biological degradability must be provided where the lubricant can pass directly into the environment.

Multi-point lubricators Once the correct grease has been selected, companies can install single or multi-point automatic lubricators for rolling bearings on processcritical plant and machinery. These lubrication systems automatically supply the required lubricant to a single bearing or m u l t i p l e bearings, without the need for manual intervention.

This type of installation is particularly effective in high speed processing lines, where machine uptime is critical.

These systems are suitable for a wide range of industrial applications, including pumps, fans, compressors, gearboxes and electric motors and provide up to eight separate lubrication points for dispensing precisely metered quantities of lubricant to rolling bearings. There are four pairs of lubrication points (eight in total), which are controlled by four individual dispensing pumps.

We are of course not the only company offering these lubrication systems but taking as an example our FAG CONCEPT8 enables users to uniquely control each individual pump in order to optimise cycle times and volumes of dispensed lubricant. It means the system can be adjusted to meet up to four different bearing sizes, each with varying lubrication requirements. Rather than having to purchase multiple single point lubricators to cope with different bearing lubrication requirements it is possible to do so with a single lubricator.

45

DATA ACQUISITION HBM PROVIDES COST-EFFECTIVE MAINTENANCE CONTRACT FOR ENHANCED CATMAN RANGE

HBM – a market leader in the field of test and measurement – is now offering its customers a highly competitive software maintenance contract, incorporating free updates, for its newly enhanced range of Catman data acquisition software packages.

Customers benefit from rapid upgrades with new functionality or to the latest operating systems, such as Windows 7, together with swift access to the latest bug fixes. In addition, customers also receive an instant priority version of their software if, for example, any software error is rectified, which can occasionally occur prior to the subsequent version of the software becoming available for general release.

The new maintenance contract also provides direct access to HBM’s premium support facilities and offers customers rapid and accurate answers to some of the most commonly asked questions. The maintenance contracts last for 5 years.

Catman is HBM’s powerful data acquisition software which can be used for configuring, visualizing and analysing measurement. Users can now also easily and quickly export visualisations of processed measurement data to MS Word or MS Excel automatically to create reports and achieve a better interpretation of test results.

For more information contact HBM on Tel.: +44 (0) 208 515 6000 Web: www.hbm.com

MAINTENANCE SENSORS THAT LEARN: TAKE THE GUESS WORK OUT OF MAINTENANCE In the chemical and petrochemical industries, plant safety and process reliability often rely on analytical instruments operating correctly.

Maintaining process analytical instruments and keeping them in good condition can be cumbersome and costly.

Download METTLER TOLEDO’s latest white paper and discover how a new process analytical measurement system based on sensors that learn can help plants reduce costs and enable better process control decisions. See for yourself how sensors are performing and when they need to be calibrated, serviced or replaced.

Sensors that Learn™ is just one element of METTLER TOLEDO’s Intelligent Sensor Management (ISM®) digital technology platform.

Download the whitepaper at www.mt.com/uksensors-wp For more information contact Mettler-Toledo Ltd, Beaumont Leys, Leics.

Tel: 0116 235 7070 E-mail: enquiries.mtuk@mt.com Web: www.mt.com

PARTICLE SIZING THE NEW PARSUM IPP-80 IN-LINE PARTICLE SIZING PROBE: ROBUST, TROUBLE FREE GRANULATION MONITORING

CALIBRATION TIRED OF DELAYS WHEN INSTALLING NEW SENSORS IN YOUR POWER PLANT? Power plants have a large number of sensors, often at different locations including in the make-up water system. The task of manually inputting calibration factors when installing new or recalibrated sensors can be tedious and have serious consequences if the wrong values are entered.

Find out how METTLER TOLEDO Plug and Measure sensors with automatic upload of cell constants can provide you with fast, error-free startup and greater process reliability.

Download the latest Pro Insight at www.mt.com/uk-installing-sensors Plug and Measure calibration is just one element of METTLER TOLEDO’s Intelligent Sensor Management (ISM®) digital technology platform. Through easy handling, enhanced performance and real-time diagnostics, ISM gives you complete control of your analytical measurement systems to help you maximise efficiency.

For more information contact Mettler-Toledo Ltd, Beaumont Leys, Leics.

Tel: 0116 235 7070 E-mail: enquire.mtuk@mt.com Web: www.mt.com/ism

46

The new Parsum IPP-80 probe from Malvern Instruments brings easy to integrate inline particle size measurement for efficient process monitoring and control. Suitable for powders, pellets and granules the probe enables the real-time monitoring of agglomeration, coating and granulation processes. The resulting data provide a secure basis for pilot plant studies, process optimization and control. A robust, sanitary design delivers long-running operation with minimal attention and includes in-built self-diagnostic tools that ensure data quality.

The Parsum IPP-80 inline probe provides continuous particle size and size distribution data, via the technique of spatial filter velocimetry. Measuring in the range of 50 µm to 6000 µm the probe is able to robustly analyze powders as well as pellets and large granules. It has been fully optimized to meet the rigors of the process environment and has user-accessible components.

For more information contact Malvern Instruments Ltd, Malvern, Worcs.

Tel: +44 (0) 1684 892456 Fax: +44 (0) 1684 892789 E-mail: salesinfo@malvern.com Web: www.malvern.com

PROCESS INDUSTRY INFORMER March - April 2015

FEATURE

ELIMINATING DATA LOSS FROM REMOTE FACILITIES

By Mark Halder, MatrikonOPC, Product Manager Losing critical process data is a very real threat in the process control industry today, especially with sites that are remotely distributed. There can be any range of interruptions to the communications between these remote facilities. From satellite or microwave transmissions being interrupted, to Ethernet communications from an ISP going down, to power outages and regular maintenance, all these can cause this data to be lost and become very difficult to recover.

DATA CONTROL

The first thing that must be considered when evaluating a solution is how it will be used. Who is going to be looking at and accessing this data? Will it be used by the staff at the remote stations, or will it be used by people accessing a central repository? Most of the time it will not be necessary to collect and transmit all of the production data, as only data that is critical to needs and metrics should be transmitted. Once the data that is to be transferred is selected, the speed at which this data is to be collected needs to be considered. Is it absolutely necessary that the data be collected every second, or should it be considered at 15-second, minute or even higher update rates? This depends on several factors: - How fast does the data change?

- What data resolution is needed?

- How much storage space is available for the data?

Another thing that must be carefully considered is how critical this data is.

What will happen if the data connectivity is lost? There are two different ways to examine data criticality: 1. If the data needs to be accessible 100% of the time and cannot handle any interruption, 2. If the data needs to arrive at the destination with 100% of the data intact, however then having some type of redundancy solution in place to guarantee that this can be achieved needs to be consideredthere can be a delay on the arrival, then a store and forward type of data transfer method might be preferable

ARCHITECTURE

There are many different ways to design this type of system, and each has its advantages and disadvantages. Above all else, it is essential that the architecture that best fits the requirements is selected. The two main types of data architectures are a ‘push architecture’ and a ‘pull architecture’.

The push architecture has control of data movement located at the point where the data originates, which would be at the remote facility or some branch where remote data is localised. From here the data is sent across the network into the central data warehouse. Pull architecture has control of the data movement located at the central data warehouse, usually in a corporate headquarters where many different people or systems can access the data. The central differences between the two are: Push Architecture - More Secure: Since remote facilities are usually located within their own isolated networks, they have much tighter security restrictions for remote access than systems on an enterprise network. This makes it much harder for an external attacker to get access to the control systems and cause damage. As a general security policy, data flow should be from a more secure location in the network to a less secure location. This is because if a less secure location was ever to be compromised then the data would still be safe and not accessible by the attacker - Data Control: Having the data control maintained at the remote facility allows the staff at this remote location to have full control over what is sent to the

PROCESS INDUSTRY INFORMER March- April 2015

data warehouse. This can be very critical if the data warehouse systems are maintained by a different team within the company or even maintained by a different company entirely. This prevents unauthorised people from seeing data that have not been explicitly configured Pull Architecture - Central Configuration: Having everything controlled in the data warehouse means that there is a central configuration for all of the data. Maintaining this data and configuration from a single location means that fewer people would need to be trained on the solution - Less Cost: When only maintaining a single point of control there will generally be less cost for the overall architecture. However, these cost savings may not arise if communications to remote sites need to be more secure. Higher levels of security can be implemented, but this normally requires an additional security layer to restrict the tags that the central location can view and access. Another main architectural decision that needs to be made is whether a store and forward solution and/or a redundant solution is needed.

Both of these solutions may be used simultaneously; however this will impact the cost of the implementation.

DATA VISIBILITY

It can be very beneficial to have local operators using the data that has been collected to pull up KPIs and dashboards. If all of this data is being collected into a central historian and that connection is lost, these KPIs and local dashboards will fail as a live connection is needed to the main historian for this function, which may be located hundreds of miles away. In this type of situation, a store and forward solution that has a local buffer of data that can be accessed from the remote facility could be used. This allows all of the reports and dashboards to run locally, preventing outages if the main connection to the historian is lost, along with reducing the bandwidth being used because data is not being retrieved from the main data warehouse, it is being accessed locally.

ELIMINATING LOSS WITH AN INDUSTRIAL DATA LOGGER

A popular option to overcome such connectivity issues is implementing an industrial data logger. Such devices can connect to the SCADA system and transmit data directly to the historian automatically. Ideally, a data logger will be compatible with a wide variety of common historians or databases used to capture the data (including Oracle, PHD, IP21, PI, or any other data warehouse). If deployed in an industrial environment, it should also be a rugged piece of hardware to deal with wide ambient temperature swings and constrained spaces. As well as a challenging physical environment, a data logger must be secure and reliable, safe from malicious attacks yet enabling the transmission of the data across firewalls and over WANs to the centralised data warehouse.

In the modern industrial environment, losing critical process data can occur due to a variety of factors, human and technical, intentional and accidental.

Fortunately, data logger technology is available to safeguard against this and, when utilised in conjunction with a well-considered strategy and architecture, can ensure that any loss of data need not mean disaster.

47

PROCESS CONTROL

HEAT TRANSFER & ENERGY

FUNCTIONAL SAFETY - SIL2 CERTIFIED CLAMP-ON FLOWMETER

LIQUID COOLING HEAT EXCHANGER ASSEMBLY DISSIPATES OVER 10 KW OF HEAT

As the world’s first ultrasonic clamp-on flowmeters the FLUXUS series from FLEXIM has now been independently proven suitable for use in process control protection loops according to the IEC 61508 norm and are certified as “SIL 2 Ready”.

The FLUXUS F/G70X and F/G80X series meters have been independently audited and certified for permanent non-invasive installation on liquid and gas flow measurement applications. As the ultrasonic transducers are simply and firmly clamped to the outside of the pipe wall, the measuring system is not exposed to any abrasion from the inside flowing medium and is thus virtually maintenance free. Furthermore, the installation of the clamp-on flowmeter could not be easier as it does not require any pipework alteration, production or process interruptions.

Due to the ultrasonic transit-time technology, the measurement works bidirectionally with the same high degree of accuracy over an extremely high dynamic range. The FLUXUS clamp-on meters measure independently from the medium flowing inside the pipe, as well as the pipe material size, wall thickness and operating pressure. The available flow transducers cover a size range from 6 mm to 6.5 m.

The SIL2-certified measurement systems are also available for use in potentially explosive atmospheres (ATEX, IECEx Zone 1 and 2).

When used in conjunction with the patented “WaveInjector” transducer mounting fixture, the FLUXUS meter can also measure at extreme pipe wall temperature ranges from -170 °C up to 600 °C. Thanks to carefully matched transducer pairs, unique internal temperature compensation and sophisticated internal signal processing, the clamp-on ultrasonic FLUXUS meters are highly zero point stable and drift free, ensuring precise measurement data.

FLEXIM calibrates the paired transducers and transmitters independently from each other and can therefore guarantee that the highly accurate measurement uncertainties can be achieved, no matter which transducer combination is used with whichever transmitter.

For more information contact FLEXIM GmbH, Berlin, Germany Tel: +44 30 936676 915 E-mail: ofoth@flexim.com Tel: +49 30 936676 914 Fax: +49 30 936676 80 Web: www.flexim.com

ADVANCED PLC ADDRESSES EMERGING CHALLENGES IN MACHINERY CONTROL ABB’s AC500 PM595 features a multi-processor system with the performance to handle the most demanding machinery and motion automation control and communication tasks.

The AC500 PM595 Machinery Controller is optimised for robust, high performance industrial control, and is built around a 1.3 GHz processor with four 32-bit RISC processors plus an embedded double-precision floating point processor, 16 MB of user program memory and a large array of communications interfaces.

The controller can handle extremely complex control tasks, involving complexities such as precision coordinated motion with very large quantities of axes, and mathematics-intensive computation such as real-time trigonometric calculations for robotics or other advanced kinematic applications. The controller also has a built-in interface to allow ABB’s advanced safety PLC to be connected for high risk applications.

The machinery controller’s design allows it to be used with legacy systems and today’s networks - as well as provision that can handle future demands.

For more information contact ABB Limited, Discrete Automation & Motion Tel: 01925 741 111 Fax: 01925 741 212 E-mail: energy@gb.abb.com Web: www.abb.co.uk/energy

48

Compact AMETEK Rotron units mount in standard 19” electronic Compact Liquid cooling Heat Exchanger Assembly mounts in 19” rack; dissipates equipment racks A compact liquid cooling heat over 10 KW of heat’ exchanger assembly that can dissipate over 10 KW of heat in demanding shipboard, and industrial applications has been introduced by AMETEK Rotron (www.rotron.com). The assembly mounts easily in the standard 19” (48.26 cm) racks used for many kinds of electronic equipment. It supports any installation with a liquid cooling loop.

Applications: Shipboard, Maritime, Submarine Heat Exchangers • Equipment Rack Cooling • Electronics • Defense systems • Military weapon systems • Radio, radar • Aircraft Copper nickel heat exchanger cores are paired with Rotron MAXIAX vaneaxial blowers to dissipate heat from the electronic rack to the water supply. The assembly is enclosed in a ruggedized 6U (10.5”) aluminum chassis designed for years of dependable service in harsh environments.

The assemblies can be customized for different input voltages, heat transfer, chassis mounting and military grade environmental requirements. Models with power inverters allow use of 400 Hz AC or DC fans and blowers for increased volumetric flow and pressure while maintaining compact size.

AMETEK Rotron is a division of AMETEK, Inc., a leading global manufacturer of electronic instruments and electromechanical devices with annual sales of US$3.6 billion.

For more information contact: UK AMETEK Airscrew Ltd. Tel: +44.12.58.45.06.41 Web: www.ametekaerodefense.com Email: steve.galloway@ametek.co.uk

BUSBAR SYSTEMS RITTAL’S RiLINE BUSBAR SYSTEM FOR AC AND DC APPLICATIONS Efficient drive systems, idle power loss reductions and the renewable energy sector all require safe, reliable DC solutions and while they cannot replace AC applications across the board, they are definitely growing in importance.

Rittal is the world’s first manufacturer to offer an approved busbar system with standard components, optimised for both AC and DC applications. No other products are required.

DC busbar systems are increasingly deployed in converter buses, DC power backup systems, photovoltaics, galvanics, energy storage systems and in shipbuilding. The system has a current carrying capacity of up to 1600A, a nominal voltage of up to 1500V DC and a short-circuit rating of up to 40kA. Rittal’s RiLine is approved to IEC 61439 and UL 845 in conjunction with UL 508, making it suitable for a wide range of industries.

Depending on requirements, busbar systems can be made of copper, aluminium or cuponal, a copper-clad aluminium busbar from Rittal.

For more information contact Rittal Ltd, Hellaby, Rotherham Tel: 01709 704000 E-mail: information@rittal.co.uk Web: www.rital.co.uk

PROCESS INDUSTRY INFORMER March - April 2015

FEATURE

THE HYBRID HEAT EXCHANGER

By Geoff Mahoney - AxFlow Product Manager Plate Heat Exchangers - London

Within a great many sectors of industry, minimising energy consumption and maintaining plant uptime are essential to optimizing production costs. Process heat recovery is one significant approach to reducing energy consumption, whilst improving process performance will contribute to plant efficiency. Heat exchangers when used for heating, cooling, condensing or evaporation play a major role in recovering energy from process gases and liquids, so it follows that their efficiency will influence operating costs.

Although a mature and well proven technology, heat exchangers are having to evolve in order to meet the ever-changing demands of industrial processes and the environments in which they have to work. Plate heat exchangers using the plate corrugation pattern in combination with a relatively narrow gap between the heat transfer plates deliver higher heat transfer efficiency and cost effectiveness combined with low downtime. Their relatively small size and weight allows them to be used where there is a small footprint area.

However, they are rather limited to just handling clean liquids because the plates cannot handle solids or other contaminants very efficiently. Furthermore, the gaskets providing the seal between plates, limit the operating pressures and temperatures to around 20 bar and 200°C respectively.

This issue of limited pressures and temperatures can be overcome by heat exchangers incorporating semi-welded plates. In this design, two plates are laser welded together to form a leak-proof or gasket-free channel. The channels between the welded plate pairs are sealed via an elastomeric gasket. However, it too can only accommodate relatively clean fluids. Where more viscous liquids or those containing particles and solids are encountered the shell-and-tube heat exchanger has long been the answer for many applications. The only drawback to this is that its thermal efficiency is limited.

The ideal solution that accommodates the requirements of clean and dirty liquids, high temperatures and pressures and achieves high levels of energy efficiency is a heat exchanger that combines the benefits of both designs.

In other words, a hybrid. Making the plate heat exchanger more like a shell-and-tube heat exchanger without losing the inherent thermal efficiency advantages, means that a wider range of applications can benefit from improved heat transfer performance and reduced installed size. The solution comes in the form of welded plate technology. The hybrid design has optimized plate patterns on both the corrugated and tube sides, which delivers higher thermal efficiency than that of shell-and-tube heat exchangers and offer a more compact and efficient solution.

THE HYBRID

Hybrid fully-welded heat exchanger units (Fig. 1) offer a broad range of configuration options to optimize performance for a variety of thermal, physical and geometrical conditions. This means that the unit can be used for a wider range of applications than conventional plate and frame heat exchangers. Typical applications include heat recovery units, process heating and cooling, process condensers, steam heaters, vapors, gases highly viscous fluids, fluids containing particles and fouling fluids.

The hybrid heat exchanger delivers many process engineering advantages when compared to shell and tube heat exchangers. Its compact design allows a heat transfer area of up to 1.800m m², whilst the unique flow pattern design ensures enhanced gas and liquid heat transfer as well as significant savings on material costs due to enhanced operating efficiency. The extremely efficient use of the plate surface maximizes the heat transfer area, thus optimizing heat transfer performance. The elimination of dead spots provides for very efficient heat transfer at low pressure drop values, enabling a closer temperature approach.

The plate side flow and the tube side flow are arranged in a crossflow configuration with one or multiple passes over the plates (Fig. 2). The plate pattern forms elliptical tube channels on the tube flow side and wave flow passage on the plate side. Larger plate gaps are available to accommodate higher flow rates, reduced pressure drops, and media with larger particulates.

This facilitates optimum design for a wide range of process requirements.

Fig. 1 exchanger.

Hybrid fully welded heat

PROCESS INDUSTRY INFORMER March- April 2015

In the case of the APV hybrid plate heat exchanger, it can be designed for a pressure range from full vacuum to 40 bar.

At the heart of the heat exchanger is a heat exchanger block consisting of one or more plate packs.

The dimensions of the plate packs are determined by the length and number of plates included in the plate pack. Plates are welded together to form one or more gasFig. 2 - The plate side tight and pressure-resistant blocks. A hybrid flow and the tube side welded plate pack employs advanced pressing flow are arranged in a and welding technologies, absorbing alternating crossflow configuration loads on the welds. The welds are not subjected with one or multiple to mechanical loading during thermal cycling passes over the plates. (thermal expansion effects) and therefore are more resistant to fatigue.

Hybrid heat exchanger design features are designed to provide good performance. For example, fluids containing solids or contaminants can pass more easily through the tube side because there are no obstructing contact points. Complete accessibility to the plate pack, combined with true mechanical cleanability on the tube side, ensure rapid, effective maintenance when cleaning is required. In addition to the heating and cooling of liquids, applications involving vapors and gases, which traditionally have been handled by shell-and-tube heat exchangers, can benefit from the efficiency of the welded hybrid plate design.

APPLICATIONS

In process condensers, one hybrid heat exchanger’s profile is well suited for creating high U-values with a low pressure drop on the condensing side. A low pressure drop means a higher effective MTD and, thus, better recovery of vapors. The plate profile combined with a flexible connection size also allows gases to be heated as well as cooled. Also, a hybridplate heat exchanger is suitable for highly viscous fluids that benefit from the low-resistance flow channels combined with high film coefficients offered by both the tube side and corrugated plate pattern on the plate side.

In the case of heat recovery units, the high heat-transfer efficiencies of the hybrid design help achieve close temperature approaches and approaches of 1.8°F (1°C) are possible, thereby recovering more heat to reduce process operating costs and improve carbon footprint.

For applications involving high temperatures and pressures, a welded hybrid also can be used. Without gaskets to limit the temperature and pressure range, hybrid heat exchanger designs can accommodate temperatures from -40 to 350°C and pressures up to 40 bar pressure. The absence of gaskets helps to avoid compatibility issues and reduces the risk of leaks while making the welded hybrid design suited to hazardous or corrosive fluids. Plates can be produced in materials such as 304L and 316L stainless steels, highperformance austenitic stainless steels, Hastelloy and nickels to suit almost all corrosive product streams.

SUMMARY

Gasketed plate-and-frame heat exchangers deliver optimum thermal efficiency compared toshell-and-tube designs within a specific set of operating parameters. However, the range of applications for which they are suited is limited. Shell-and-tube units are more accommodating for high temperatures and pressures and high fouling or contaminant-laden fluids but are heavier, take up a larger installed area, and lack the heat transfer efficiency of plate technology. A hybrid welded plate heat exchanger, with its tube-like plate profile and true mechanical cleanability and efficient use of installation space, takes the range of applications beyond the gasketed plate-and-frame configuration into new areas.

47

ROTARY BLOWERS

ENCLOSURES

COMPACT, INTEGRATED ROTARY BLOWERS ENERGY-EFFICIENT ENCLOSURE COOLING IN COOL BUT DUSTY ENVIRONMENTS SAVE TIME AND MONEY The new compact Rotary Blowers recently introduced by HPC KAESER are supplied connection-ready with integrated mains power supply equipment and monitoring, including all sensors and star-delta starter, or with a frequency converter to enable flexible speed control. The range BB69C through FB791C rotary blowers deliver from 0.5 to 74 m³/min at up to 1000 mbar (g), or 500 mbar (partial vacuum) and are ideal for applications such as pneumatic conveying of powdered goods, water treatment, or wherever the generation of blowing air is required from a compact and efficient unit.

The complete system packages are CE and EMC certified which means less work for both the operator and system provider in terms of planning, installation, certification, documentation and commissioning. A range of motors is also available to accommodate various performance requirements, whilst noise and pulsation reduction measures ensure quiet operation at all times.

These innovative rotary blowers feature inherently intelligent design where system operators not only benefit from significant energy and operational cost savings, but are also able to take advantage of considerable savings for installation, planning, commissioning and certification.

Components such as control valves, which would normally be installed externally, are also incorporated into the units and controlled via the blower’s internal Omega Control® controller.

Transparency of future servicing and maintenance costs is also essential when considering the total life cycle costs of both individual blowers and stations as a whole. Therefore, by choosing HPC KAESER, planners and operators not only benefit from all the advantages that these impressive latest generation blowers provide, they also benefit from decades of experience in system planning and optimisation. As a result, they can enjoy the rewards of enhanced system efficiency and maximum dependability.

For more information contact HPC Compressed Air Systems Tel: +44 (0) 1444 241671 E-mail: mark.sharman@hpcplc.co.uk Web: www.hpccompressors.co.uk

Air/air heat exchangers are highly effective at lowering the temperature inside enclosures in cool environments. They are cost-effective and energy efficient while also being well suited to dirty or dusty settings - unlike traditional fan-and-filter units.

Air/air heat exchangers recirculate the air inside the enclosure, cooling it using the cooler ambient air which is passed over a cross-flow heat exchanger. The two air flows are kept entirely separate, thus ensuring any dust, dirt or other contaminants are kept away from the electrical or electronic equipment.

The greater the difference between the internal and external air temperatures, the more heat may be removed from the cabinet.

Rittal air/air heat exchangers need less maintenance than fan-and-filter units, in part thanks to their individual controls for the internal and external fans and easy-to-remove cassettes.

The internal temperature within the enclosure is also constantly displayed so users can tell at a glance that the unit is operating optimally. If temperatures within an enclosure get too high then a floating fault signal will sound to alert the user immediately about an impending problem.

For more information contact Rittal Ltd, Rotherham, South Yorkshire Tel: 01709 704000 E-mail: information@rittal.co.uk Web: www.rittal.co.uk

RITTAL EC FAN-AND-FILTER UNITS WITH SPEED CONTROL

Cell Pack Solutions Ltd, specialist in battery pack design and manufacturing, offer Rapid Reaction Prototyping for custom engineered battery packs to electronic device manufacturers.

With applications for remotely located and portable devices such as Security and Access Control, Smart Metering, Surveillance, Asset Tracking, Environmental Monitoring and Data Logging, battery and cell pack design is an integral part of the products development and production.

Cell Pack Solutions Ltd’s Rapid Reaction Prototyping services utilises the companies skills and expertise with over 3000 unique custom battery pack designs to date. As experts they take into consideration the devices specifications and put an emphasis on battery lifetime, power output, physical size and recharge times. Large stocks of many different battery types, components and connectors means that they can offer Rapid Reaction Prototyping and manufacturing. Battery test capability ensures that Custom Battery Packs are engineered and manufactured to the highest standards in accordance with our ISO 9001:2008 accreditation.

Rittal fan-and-filter units with EC (electronically commutated) motors should be the preferred choice for energy efficiency in enclosure climate control, as their operating ratio is significantly higher than standard AC fan-and-filter units.

Using fan-and-filter units always makes sense if the difference between the outdoor temperature and the internal enclosure temperature is large enough to dissipate the thermal output of the installed components. However, the fans mostly operate without regulation. In other words, they run constantly and always at full speed. In this situation, the savings potential offered by seasonal temperature fluctuations or temperature reductions in the building (e.g. on night shifts or through reduced waste heat in the enclosure) remains unused.

Further optimisation potential exists with an advanced solution using Rittal fanand-filter units with temperature-dependent speed control. With a new sensor for controlling the speed of the Rittal EC fan-and-filter units, inherently up to 30% more efficient than comparable AC fan-and-filter units, power consumption can be drastically reduced yet again. The sensor measures the temperature within the enclosure and controls the fan speed as needed, right up to independent shutdown at below 20°C. Replacing AC systems without speed control by EC systems with system control saves money, as shown in the following example: At a manufacturing plant with 50 fanand-filter units (700 m³/h), run at full load for two shifts per day and five days a week, needing only 20% of the fan speed at night and weekends with reduced enclosure temperatures (20°C), EC technology and intelligent controls, can more than halve the energy costs.

For more information contact: Cell Pack Solutions Ltd, Tel:: 0191 496 9999 E-mail:batteries@cellpacksolutions.co.uk Web:www.cellpacksolutions.co.uk

For more information contact Rittal Ltd, Hellaby, Rotherham Tel: 01709 704000 E-mail: information@rittal.co.uk Web: www.rittal.co.uk

BATTERY PACK DESIGN CUSTOM BATTERY PACK ENGINEERING WITH RAPID REACTION PROTOTYPING

50

PROCESS INDUSTRY INFORMER March - April 2015

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