Process Industry Informer February 2016 by Process Industry Informer

www.processindustryinformer.com

FEBRUARY 2016 Volume 12 No.1

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

ANALYSING PROCESS ANALYTICS…

see on page 22

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

CONTENTS. 4-6 News & Events

23 Weighing

7-8 Applications

23 Tank Cleaning

8 Maintenance

37 Process Measurement &

8 Powder Testing

Instrumentation

9 Infrared Cameras

38 Vibration Monitoring

9 Test & Measurement

38 Heat Transfer & Energy

15 Health & Safety

59 Products & Services

16 Materials Handling

Suppliers Directory

25 BPMA News

16 Seals & Sealing 19 Compressors 19 Welding & Cutting Products

DISASTER RESILIENCE: ONE-SIZE FITS ALL WON’T DO

ETHERNET IS MAKING INROADS INTO INDUSTRY

NEW YEAR’S RESOLUTIONS WORTH STICKING TO

STEAM versus THERMAL FLUID

KEEPING YOUR SYSTEM SAFE

THE GREAT OBSOLESCENCE DEBATE

FUELLING OPTIMISED SYNGAS

20-23 Fluids & Liquids Handling (incl. Pumps & Valves)

SHORT CUTTING FRONT END ENGINEERING & DESIGN

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

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NEWS & EVENTS ANDREWS CELEBRATES 50 YEARS AS HIRE SPECIALIST

Andrews Sykes this year celebrates 50 years in sector that has seen them grow to become a dominant player in the hire of industrial equipment. “Now firmly established as one of the UK’s leading specialist hire firms, we have much to celebrate as we look back on five decades of sustained growth,” says Paul Wood – Managing Director. “What started off as a humble heater and steam cleaner supplier in Wolverhampton and developed into a multi-million pound corporation that has only been made possible by the dedicated endeavours of our staff.” Originally a one-man operation in the mid 1960’s, Andrews now has over 600 employees with depots in Western Europe and the Middle East. Throughout its 50 years Andrews continually invested in modern plant and equipment as well as business premises. Today it operates from more than 25 depots across the UK with an extensive hire fleet ensuring fast local supply of equipment. For further information contact: Andrews Sykes Limited E-mail: james.duck@andrews-sykes.com Tel: +44 (0) 208 8305 4259 Web: www.andrews-sykes.com

ENGINEERED FOR ENGINEERS The Grundfos for Engineers Hub was launched recently. It was specifically designed to keep all engineering partners with an interest in pump technology informed about the latest developments in the industry, as well as briefed on the wider subject of fully integrated pump systems. One interesting aspect of this new engineering hub allows visitors the opportunity to see and hear from many Grundfos product specialists who discuss a number of industry related topics. The range of topics discussed is broad and covers areas such as heating systems and boiler feed; iSolutions – the Grundfos total systems approach – that offers the opportunity to make a significant impact on overall system efficiency; sensors are also in the spotlight as a topic as is the fact that through differential pressure, they can help reduce costs. This means there will be something just for you whether you are an engineer working within commercial building services, process industry applications or in water supply and/or treatment industries. In addition to these interesting insights there are also a range of technical White Papers, case stories and access to engineering tools that will all help to keep you informed and up to date. This is only a part of the wide range of information that is available at the touch of a button; check it out for yourself by visiting www.grundfos.co.uk/engineers For more information contact Grundfos Pumps Ltd, Leighton Buzzard,Beds. Tel: 01525 850000 Email: grundfosuk@grundfos.com Web: www.grundfos.co.uk

PROCESS INDUSTRY INFORMER January - February 2016

NEWS & EVENTS

TSE POWERS AHEAD WITH NEW DESIGN AND MANUFACTURING HEADQUARTERS

FORTRESS NON-CONTACT SWITCH GETS TÜV SÜD CERTIFICATION

A UK specialist in the design and production of high-quality control systems has relocated to larger manufacturing facilities in order to accommodate expansion.

Industrial safety specialist Fortress Interlocks has achieved TÜV SÜD certification for its new non-contact switch, the amGardncs. This means the device meets all the

necessary requirements of the European Machinery Directive as part of a safety system. “This is a big step forward for Fortress and is a welcome addition to our traditional product range, increasing our interlock capabilities,” commented Rob Johnson, the company’s senior electronics engineer.

The new premises for Trant Systems Electrical (TSE) is three times’ larger than the previous site, scaling up to meet strong commercial demand from industry, including power, water, oil and gas. TSE, headquartered on the western edge of Southampton, Hampshire, designs, manufactures, installs and commissions intelligent motor control centres (MCCs) and control panels. Capabilities include the design, manufacture, installation, test, commissioning and lifecycle support of electrical systems. An approved systems integrator, TSE’s work includes a software design service which marries up hardware with the computer systems of clients to ensure flawless operational integration of what is known as system logic. TSE operates out of Rushington Court business park, occupying new office and production space a stone’s throw away from its previous location. Clients include a number of water companies, Associated British Ports, the Ministry of Defence, ExxonMobil and National Grid. An open day was held for scores of guests from British industry to officially celebrate the opening of the production facility. Glen Fielder, TSE’s general manager, said: “We’re experiencing strong demand from industry, nationally and globally, for our high-quality control panels, MCCs and automation systems, which are all underpinned with compliance credentials.“ TSE’s one-stop shop, to coin a phrase, will help us in our aim to be the first-choice control systems company for our clients in the UK and overseas, with close collaboration reducing clients’ overall costs. For more information contact Trant Systems Electrical, Totton, Southampton Tel: 023 8042 8700 E-mail: info@t-s-e.co.uk

Designed as part of Fortress’ new amGardnctrange of safety interlocks, the amGardncs is a robust, coded, non-contact, safety proximity switch. Extremely long-lasting and requiring virtually no maintenance, it is ideal for applications where precise guidance of guards can be difficult. In addition it is resistant to shock and vibrations and offers coding as protection against tampering.

POWTECH 2016

Key features of the amGardncs include:

• Stainless steel IP69K housing, ideal for high purity applications such as food, beverage and pharmaceutical manufacturing, or anywhere where robustness is important • Long-lasting, requiring virtually no maintenance • Resistant to shock and vibrations • Copes with a high level of misalignment • PLe Cat 4/SIL3 safety rating • Can be used as a coded interlock in accordance with EN14119 • Integrated electronics monitor for faults and ensure safety relay does not enter a fault state • Local user indication • Monitor outputs for use in the control system • Available with a variety of termination options The amGard range of safety interlocks includes solenoid and non-solenoid safety switches and has an extensive range of additional options, including key control modules, internal and escape release, redundant sensors, lock out/tag out, push buttons, estops and indication lights, all assembled in one device. The robust construction of the amGard makes it ideal for a host of industrial applications when safety, strength and reliability are of paramount importance. For more information contact Fortress Interlocks Ltd, Wolverhampton Tel: +44 (0)1902 349000 E-mail: sales@fortressinterlocks.com

POWTECH - Trade Fair for Processing, Analysis, and Handling of Powder and Bulk Solids

The highlight for international experts from 19 - 21 April 2016 in the exhibition centre Nuremberg. Take advantage of the overall dynamics offered by POWTECH, the exhibition for experts in powder and bulk solids technology! This event provides a presentation platform for innovations and advancements in processes for the manufacture of quality products made and processed from powder, granules, bulk solids and liquids – also for the environmental and recycling sector. Already 823 companies have registered to exhibit at POWTECH 2016 from 19-21 April in Nuremberg. Together with the renowned PARTEC conference, some 15,000 trade visitors are expected to attend from more than 78 different countries. This group of technical experts will enjoy free access to lectures, product presentations and panel talks with a POWTECH trade visitor pass. Planning your visit to the show well in advance is essential for making the most of your trip copy the following link into your browser for more information - http://goo.gl/38OmRP

SMITH FLOW CONTROL NAMES NEW MANAGING DIRECTOR, TRACEY GOLDSMITH Safety interlock and valve management systems expert Smith Flow Control has appointed Tracey Goldsmith as its new managing director. In her new role, Goldsmith is responsible for the company’s strategic development and the performance of its global operations. The appointment follows the move of long-time Smith Flow Control managing director Mike D’Anzieri to take the role of president at sister Halma company Rohrback Cosasco Systems. Tracey has over 25 years of experience in accounting, finance and management roles. She joined Smith Flow Control in 2012 as Finance Director from manufacturer Elma Electronic U.K. Ltd. (Bedford, U.K.). Tracey is a member of the Chartered Institute of Management Accountants. For more information, please call 01376 517901 E-mail enquiries@smithflowcontrol.com

NEW ABB CALIBRATION LABORATORY GETS UKAS ISO 17025 ACCREDITATION ABB has received accreditation to ISO 17025 from the United Kingdom Accreditation Service (UKAS) for its new Measurement & Analytics Service laboratory at its Stonehouse facility. The accreditation recognises ABB’s technical

competence in the calibration of temperature, pressure and electrical measurement devices. As a globally recognised standard, ISO 17025 sets a recognised and verifiable level of best practice so that end users can be confident that a provider of calibration and testing services has undertaken the correct steps when calibrating their equipment. As a UKAS accredited facility, ABB’s Stonehouse laboratory has satisfied these requirements, enabling it to calibrate its own temperature, pressure and electrical equipment as well as those of third parties. The instrument calibration service is the latest offering from ABB Measurement & Analytics Service. For more information, Email instrument.support@gb.abb.com or call 03339 997996 ref. ‘Calibration’.

PROCESS INDUSTRY INFORMER January - February 2016

NEWS & EVENTS BRAMMER MOBILE CENTRE OF EXCELLENCE CLOCKS UP 600TH VISIT CROWCON SUPPORTS ‘TRAIL BY FIRE’ VOLCANO RESEARCH PROJECT WITH PORTABLE GAS DETECTORS

Key Facts: • Expedition is measuring gases expelled by volcanoes in the South American Andes • Extreme conditions and potentially lethal concentrations of gas make safety a priority • Lightweight, ruggedised Crowcon Gas-Pro portable detectors alert researchers to unsafe levels of multiple gases Crowcon - a leading manufacturer of portable and fixed gas-detection equipment – is sponsoring the ‘Trail by Fire’ scientific expedition to the volcanoes of the South American Andes with the loan of Gas-Pro portable gas detectors. The expedition is funded by the 2015 Land Rover Bursary, run by the Royal Geographical Society (IBG) on behalf of Land Rover, and is the first to attempt a large-scale estimate of volatile gases expelled by active volcanoes along 2500 miles of the South American Andes. The extreme conditions mean that personal gas detectors are a critical part of the expedition’s equipment. Crowcon portable Gas-Pro diffusion detectors are being used to monitor and alert team members to unsafe levels of carbon dioxide (CO2), hydrogen sulphide (H2S), carbon monoxide (CO) and sulphur dioxide (SO2). The detectors also monitor average exposure levels to protect members from the risks of longer-term exposure at lower levels of the target gases. On-board data-logging, performed by the Gas-Pro detectors, provides the expedition team with an additional source of data. During the initial stages of the Trail by Fire, the Gas-Pro detectors played a major role in the team’s ascents of the Ubinas, Sabancaya, El Misti, Ticsani and Tutupaca volcanoes, in addition to being used for protection in hydrothermal areas. “Crowcon was originally contacted by our sister company, Ocean Optics, who is supplying the expedition with spectrometers,” explains Louise Early, Strategic Industry Manager at Crowcon. “With extreme working conditions, at altitudes of up to 6,000m, the GasPro detectors combine the light weight and ruggedised construction which are demanded by these rigorous conditions.” The progress of the Trail by Fire expedition can be followed on: www.trailbyfire.org For further information please contact: Crowcon Detection Instruments Abingdon, Oxon. Tel: +44 1235 557700 Email: fiona.macrae@crowcon.com Web: www.crowcon.com

Brammer’s Mobile Centre of Excellence has reached a milestone number of visits to customer sites after a visit to British Sugar’s Bury St Edmunds site. In its third year on the road, the Brammer Mobile Centre of Excellence clocked up its 600th visit at British Sugar, welcoming 35 engineers aboard. The custom-built education and awareness training vehicle showcases a range of industrial maintenance products through hands-on product demonstrations, of particular interest to British Sugar engineers was the drive train best practice rig which highlights the improved production efficiency and energy consumption reductions that can be achieved through optimising mechanical power transmission. Brammer and British Sugar have enjoyed a 19-year relationship and as a result of this visit, a number of new value-adding projects have been identified which the two teams are now exploring . Ian Ritchie, Managing Director of Brammer, explained: “When we commissioned our Mobile Centre of Excellence, our aim was to engage engineers with hands-on displays that showcase the latest innovations that can add value to their production operations and maintenance. This visit shows how successful this has been.’’ At British Sugar, the Mobile Centre of Excellence was accompanied by one of a fleet of specialist tool demonstration vehicles, which showcase top-of-the-range hand and power tools from suppliers including Roebuck, a comprehensive range of quality tools and specialist equipment available exclusively through Brammer and Buck & Hickman. The Mobile Centre of Excellence can be booked for a visit to your plant by emailing marketing.uk@brammer.biz

BRAMMER ANNOUNCES NEW PARTNERSHIP Brammer UK, the UK’s leading distributor of industrial maintenance, repair and overhaul (MRO) products and services, is delighted to announce a new partnership with CEJN UK, a leading global quick connect specialist, which is dedicated to reducing energy consumption and boosting productivity across the automotive, aerospace and transportation sectors. The partnership forms part of an overarching strategy to support key customers within the three sectors and help them to achieve competitive advantage through cost savings. As part of the collaboration, Brammer will exclusively stock CEJN’new groundbreaking eSafe, which has been specifically developed to provide users with a cost-effective, durable and high-performing safety coupling, with a number of innovative features. With its unique patented design, the new eSafe combines a range of advanced elements which not only ensure the safety of the operator, but help to increase profitability and improve efficiency. ISO 9000 and ISO 14001 certified, the eSafe has been designed with the ever-changing needs of the end-operator in mind, and includes a series of user-friendly features such as a compact design and one-hand operation for ease of use. Additionlly the component complies with OSHA 1910.95 Grant Chaplain, Head of Business Development at CEJN, said: “We’re delighted to partner with Brammer UK and offer the innovative eSafe to the market. The collaboration forms part of a wider strategic partnership in which both organisations have a mutual interest in supporting customers.” Terry Davis, Head of Brammer’s Fluid Power team, explained: “As the leading global quick connect specialist, CEJN is dedicated to developing innovative engineering solutions and holds its customers at the heart of all that it does, which is a concept we advocate.’’ For further information visit www.brammeruk.com

FEMALE ENGINEERS TRIUMPH ON U.N DAY Women ‘Clean Up’ on Red Carpet

Women engineers are celebrating being the very best of British – after a glittering red-carpet ceremony in London. As United Nations Women & Girls in Science Day dawned, (February 11th) – British women were ‘cleaning up’ at the Semta Skills Awards held at The Hilton Park Lane – industry’s most prestigious awards ceremony. More women than ever before had been nominated for an award and one, Emma England, was judged to be the very ‘Best of British’. Emma, aged 26, from Exmoor, a Loads and Aeroelastics engineer at aerospace and defence giants Airbus Operations Ltd, Filton, Bristol, beat off strong opposition to win the most coveted award. Emma gained a degree in Aeronautical Engineering MEng at Bristol University Ann Watson, CEO of Semta, the employer-led organisation tasked with skilling Britain, said: “Not long ago women cleaning up at an engineering awards ceremony – would have had different connotations. “Maybe there are glimmers of a new dawn of diversity on the horizon. Semta will continue to work tirelessly to help make this happen.’’ ‘‘Congratulations to Emma – she is a very worthy winner – and an icon for other young women to follow.”

PROCESS INDUSTRY INFORMER January - February 2016

APPLICATIONS BREDEL HOSE PUMPS TACKLE TOUGHEST JOBS FOR SILTBUSTER

Siltbuster Ltd, a nationwide specialist in the supply of water treatment solutions for the construction, municipal and industrial sectors, reports that a number of recent tough applications have seen its preferred Bredel hose pumps tested to the full. Pumping kieselguhr and transferring crude oil are among the extreme tasks that Siltbuster has recently encountered, highlighting that there really is virtually no limit for these robust and reliable hose pumps. Since the launch of the original Siltbuster unit in May 2003, this forward-thinking company has become the UK’s leading authority on water treatment, wet waste and the prevention of waterborne pollution from construction and industrial sites. Among the 40-employee company’s solutions is a range of equipment for silt management and the prevention, control and treatment of water contamination. “We’ve been using Bredel pumps in our solutions for a number of years and have amassed quite a number,” explains Project Engineer Alex Spyropoulos. “Sludge transfer on DAF (dissolved air flotation) units is a good example of an application where we have extensive numbers of Bredel pumps in action. Here, we use Bredel 25, 40 and 50 heavy duty hose pumps to help manage sludge production. Bredel pumps produce much higher pressure on the discharge side, which also makes them favourable over electric diaphragm pumps in applications where there is a steep gradient or deep tank. The fact that they are self-priming offers additional process benefits over some alternative pump technologies.” PUSHED TO THE LIMIT Mr Spyropoulos can also recall a couple of recent applications where the product being pumped tested Bredel’s hose pump technology to its limits. “One of

the applications I have witnessed involved a switch from a progressive cavity pump to Bredel hose pump at a brewery which had keiselguhr (diatomaceous earth) amongst other difficult media in the sludge. It proved to be highly abrasive on the PC pump but the Bredel managed very well. This, in addition to the fact the Bredel units are able to handle a considerable volume of sludge means we consider this technology to be ‘tough’ and fit for purpose.” Elsewhere, Mr Spyropoulos recounts an application at a refinery, where Bredel 50 pumps were deployed to pump crude oil. “Pumping crude oil is a very aggressive application so we used Bredel CSM hose elements to ensure chemical compatibility and good hose life,” he says. In applications such as these, the selection of hose elements is critical to ensure pump performance and durability. Bredel CSM composite reinforced hoses are constructed from high quality compounded rubbers reinforced with four individual layers of braided nylon, and finished by high precision machining. For more information contact Watson-Marlow Fluid Technology Group, Falmouth, Cornwall Tel: 01326 370370 Email: info@wmftg.com Web: www.wmftg.com

VERDERFLEX PERISTALTIC PUMPS FOR RELIABLE WASTEWATER PERFORMANCE A leading international wastewater instrumentation manufacturer is now using peristaltic pumps from Verderflex as part of the wastewater sampler systems it manufactures. The pumps provide reliable and accurate performance which helps the Hydrocell sampler systems produced by Halifax-based Smart Storm to measure the volume and toxicity of wastewater effluent. As a leading provider of water and wastewater equipment, Smart Storm needed a pumping solution which offered reliability, accuracy and the ability to lift trade effluent up to 7 metres, prior to it being measured and analysed, without a secondary pump being required. The company chose Verderflex R3DC OEM peristaltic pumps to fit the bill, as these compact, easy-tomaintain pumps combine the required performance with a proven track record gained in a wide variety of industrial waste applications. In 2013 Smart Storm embarked on a design exercise to replace their existing waste water sampler with a new state of the art product that would meet the harsh demands of industrial waste water sampling. The new product, known as the Hydrocell sampler, included the Universal Smart Instrument (USI) as its instrument controller which offers the only waste water sampler on the market with a graphical user friendly interface and Windows CE programming. “To ensure that the new product exceeded the specification of the existing product and that of our competitors we also required the pump to perform to a higher standard than that of the old sampler pump’’ said Smart Storms Managing Director, Dr John Duffy. ‘‘After exhaustive tests on numerous pumps the Verderflex R3DC OEM pump was chosen. We choose the Verderflex pump because its vertical lift capacity of 9m far exceeded that of other manufacturers pumps, its reliability was very impressive and it was extremely robust everything we required’’ said Dr Duffy. Often the pump is the weakest part of a waste water sampler so reliability is paramount. Sending engineers to site to repair pumps is extremely costly and time consuming. ‘‘We have now been using Verderflex pumps on our samplers for two years and we have not had a single failure. We use the pump across our complete sampler range from single bottle samplers to multibottle refrigerated samplers. The Verderflex pump along with the advanced USI controller made this Hydrocell range of waste water samplers the most advanced on the market. Our R3DC pump is ideal for this type of demanding application,” adds Neil Thomas of Verderflex. “It features a robust design with thickwall tubing, and in addition to its high lift capability and a DC motor which can accommodate speed and flow-rate variations, it can handle flow rates up to 3.4 l/min.” For more information contact Verderflex Ltd, Castleford, West Yorkshire. Tel: +44 (0) 1924 221020 E-Mail: info@verderflex.com Web: www.verderflex.com

COOL SAVINGS ON MRO SPARES CONSUMPTION FOR FAN MANUFACTURER In a drive to source only a high quality engineering component and consumables service, one of the UK’s leading manufacturers of industrial fans was struggling to find a single-source supplier to meet their needs. As the UK’s leading distributor of industrial

maintenance, repair and overhaul (MRO) products, Brammer was ideally placed to lead a vendor consolidation project and one value-adding project in particular has achieved significant cost savings for Woodcock & Wilson – the implementation of Brammer’s Invend™ industrial vending service. As well as difficulties surrounding multiple consumable suppliers, specialist fan manufacturer Woodcock & Wilson had no traceability of which employee was using which products and, due to stock being kept in different areas of the factory and ordered from a variety of suppliers, the fan manufacturer also experienced frequent stock-out issues and high inventory costs. A particular challenge lay in the procurement of grinding discs, as they were using a higher than expected volume.. Brammer identified that its Invend™ service was the ideal solution. Having demonstrated the benefits of the industrial vending service, a profile of which employees needed access to which products for their role was established. Each vend is logged to each specific user through a password-protected system, providing management with visibility of product consumption levels by user and cost centre. Four Invend™ machines were installed at optimal locations to dispense PPE and workshop tools, with an additional benefit being a significant reduction in the amount of time each person spends obtaining the items. To solve Woodcock & Wilson’s issues with grinding discs, Brammer consulted with leading manufacturer 3M whose Abrasives division recommended several product styles should be trialled across the different applications. Through this process it was identified that one versatile grinding disc would suit the majority of tasks, rather than providing several varied finishes. This has cut down on the number of discs being ordered and, as they are now all stored within Invend™ machines, are instantly locatable. Woodcock & Wilson has reported an increased cash flow since the installation of its Invend™ machines, as all stock inside is owned by Brammer until it is dispensed meaning no cash is tied up in stores. For further information visit www.brammer.co.uk/invend

PROCESS INDUSTRY INFORMER January - February 2016

APPLICATIONS

MAINTENANCE

BABCOCK WANSON BOILER HELPS CONVERT FOOD WASTE INTO RENEWABLE ELECTRICITY

NEW FLUKE CONNECT® ASSETS MAKES PREVENTIVE MAINTENANCE PRACTICES POSSIBLE FOR ALL MAINTENANCE MANAGERS

Viridor, one of the UK’s leading recycling, renewable energy and waste management companies, has installed a Babcock Wanson HEB 1050 Hot Water Boiler into its anaerobic digestion plant at Walpole near Bridgwater, Somerset. Each year, Viridor transforms over two million tonnes of materials into high quality recyclate, and yet more into over 760 gigawatt hours of renewable energy. It operates several Anaerobic Digestion (AD) facilities across the UK, which uses renewable energy technology to capture methane expelled by digesting unwanted food within enclosed tanks. The gas is then used as a source of energy for heat and electricity, which is fed into the National Grid. To aid the production of methane, the digestors are warmed by circulating hot water around them. The new Walpole site has one boiler, a Babcock Wanson HEB 1050 Hot Water Boiler which has been used to start the initial AD process and will acts as a standby, should the Combined Heat and Power (CHP) system require maintenance or supplementary heat. Gas Oil fired, the boiler has been supplied by Babcock Wanson as a fully containerised solution for ease of installation and operation. The Walpole AD plant will be able to process up to 30,000 tonnes of food waste per year and is expected to save Somerset council tax payers £200,000 a year. Gas from the plant will be used initially to generate electricity - about 9,500 MWh a year - with nearly four-fifths exported to the Grid, which is enough to power more than 1,700 homes. For more information please contact Babcock Wanson on Tel: 020 8953 7111 or Email: info@babcock-wanson.co.uk / Web: www.babcock-wanson.co.uk

QATAR EXPORT SUCCESS FOR HADEN FREEMAN Design and management work on the infrastructure for a $4m Chemical Storage facility in the Ras Laffan Industrial City of Qatar, is the latest export success for Manchester and Redcar-based process engineering design consultants, Haden Freeman Ltd (HFL). The 11,000 sq. m facility for US oil services firm, Baker Hughes, is for the storage of chemical ingredients used in the preparation of drilling fluids used both onshore and offshore in the Oil and Gas industry.

Ian Dunkley, Project Director for HFL, commented, “We enjoy a good relationship with

Baker Hughes and have worked for them in several locations over the years. At Ras Laffan, the challenge was adapting our working practices to meet the cultural differences, as well as designing the facility to meet the extreme weather requirements due to heat and occasional heavy rain falls which often create heavy localised flooding. The facility had to be designed to enable it to remain operational under all conditions.” This latest export success follows hard on the heels of Haden Freeman’s work for the Qatar Vinyl Company (QVC), Qatar’s first downstream petrochemical project which produces caustic soda, ethylene dichloride, vinyl chloride monomer in addition to other products. The latest project has been for the design, installation and commissioning of new incinerator unit which would increase production by over one third. Haden Freeman provided all civil, structural, piping, electrical, instrumentation and project management services from their Doha office with support from Head Office in the UK, with the Madina Group, HFL’s Qatari partner, providing construction services. Adnan Abdullah Shaikh Al-Yafei, Head of Projects for QVC, commented, “The Incinerator project was completed on time and to budget and is now producing to the required quality in record quantities. We hadn’t used Haden Freeman prior to them undertaking this project. They proved to be extremely capable and I’m sure we’ll go on to form a lasting relationship.” Haden Freeman Ltd is a major process engineering consultancy and multi-disciplinary resource for the chemical industry. Established in Manchester since 1984, the company now has offices in Southampton, Qatar and Redcar, which enables them to provide a local service to clients in these areas with a number of their engineers based at client sites, supported from headquarters by a fully integrated digital infrastructure. For further details, please contact Duncan Cammack, Sales and Marketing Director by email, dcammack@hadenfreeman.com.

Unplanned downtime due to equipment failure can cost manufacturers up to three per cent of their revenue, according to the U.S. Federal Energy Management Program. Manual methods of tracking equipment health to predict failures are time consuming and prone to errors and incomplete data, while existing computerised maintenance management systems can be costly and complex and often require significant IT resources to implement. Fluke Connect® Assets changes the way equipment maintenance is documented, reported, and managed. Fluke Connect® Assets is a cloud-based wireless system of software and test tools that gives maintenance managers a comprehensive view of all critical equipment — including baseline, historical, and current test tool measurement data, current status, and past inspection data — enabling them to set up and sustain a preventive maintenance (PM) or condition-based maintenance (CBM) system easily with minimal investment. It features the industry’s only wireless one-step measurement transfer from more than 30 Fluke Connect wireless test tools. For more information contact: Fluke (U.K.) Ltd., 52 Hurricane Way, Norwich, Norfolk Tel: 0207 942 0700. E-mail: industrial@uk.fluke.nl Web: www.flukeconnect.co.uk

POWDER TESTING FREEMAN TECHNOLOGY LAUNCHES NEW POWDER TESTER AT POWTECH 2016 Freeman Technology, the powder characterisation specialists, will launch the Uniaxial Powder Tester (UPT) at Powtech 2016 (19 April – 21 April, Nüremberg, Germany). The new powder tester provides an accurate and repeatable measure of the unconfined yield strength (UYS) of a powder to assess and rank flowability. It is quick, reliable and easy to use, delivering value to scientists, process engineers and QC analysts working in a diverse range of bulk solids handling industries. Available in manual and advanced versions, the UPT offers a low cost, powder testing solution. For more information please visit www.freemantech.co.uk/upt. Alongside the UPT, the company continues to provide a comprehensive powder characterisation solution in the FT4 Powder Rheometer®, a unique universal powder tester, which uses patented dynamic methodology, automated shear cells and bulk property tests to quantify the flow properties of powders. See both instruments on stand #4-547 where representatives from Freeman Technology will be on hand throughout the event to discuss all aspects of material characterisation. There will also be an opportunity to hear about the company’s latest research during Partec, the conference running alongside Powtech. Specialists will present on the development of the automated uniaxial tester, predicting the performance of powder feeders using multivariate modelling and the influence of roller compaction processing variables on the rheological properties of granules. The team looks forward to welcoming you on the stand and discussing the challenges associated with powder handling and processing. *Please see article in SHAPA News -pages 37/51 For more information contact Freeman Technology Ltd, Tel: +44 (0)1684 851 551 E-mail: info@freemantech.co.uk Web: www.freemantech.co.uk

PROCESS INDUSTRY INFORMER January - February 2016

INFRARED CAMERAS FLUKE INTRODUCES A HIGHER RESOLUTION, HIGH-END MODEL TO IT’S TiS PERFORMANCE SERIES OF INFRARED CAMERAS Fluke has introduced a high-end, higher resolution model to its latest TiS Performance Series of infrared cameras. The new TiS75 offers manual focusing, capturing professional quality images on its 320 x 240 pixel, 3.5 inch screen. The rugged infrared camera can be used to upload images to Fluke Cloud™ via a wireless connection to securely store and manage images and potentially reduce administrative time back in the office. Reports can be created and emailed from the jobsite via Fluke Connect®, eliminating the need to return to the office to process reports. IR-Fusion® technology offers fast analysis with picture-inpicture mode and AutoBlend™ of visible and infra-red light at five pre-set levels. The Fluke TiS75 is ideal for applications in the process industries. It offers one touch image access, which eliminates the need to scroll through a menu to view images. Thousands of images can be stored on its 4GB of internal memory and 4GB removable SD card. Within your provider’s wireless service area and subject to your plan’s pricing and other terms. Fluke Connect is not available in all countries. 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

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TEST & MEASUREMENT NEW U10 SENSOR FROM HBM IS A FORCE TO BE RECKONED WITH!

HBM – a market leader in the field of test and measurement – is pleased to announce the launch of its new U10 force transducer, which can be used to measure static and dynamic tensile and compressive forces. The new U10 sensor, which is rotationally symmetrical and low profile, features an impressive precision with a linearity deviation as low as 0.2 in the entire measuring range, which in turn extends tolerance limits in production processes. With the ability to adapt to over 4000 configuration possibilities, the U10 force sensor provides users with a flexible solution to a wide range of measurement tasks. Featuring outstanding characteristic values for hysteresis, linearity and reproducibility and repeatability errors, the latest offering from the HBM force transducer range is particularly suitable for use on test benches, material testing machines and challenging tasks in production. Housed in a welded casing and hermetically encapsulated, the robust U10 force transducer is available in different ratings up to IP68, making it particularly suitable for use outdoors and in applications under adverse weather conditions. In addition to the new U10, HBM also provide a full range of force sensors and transducers to measure static and dynamic tensile and compressive loads – with virtually no displacement. For more information, please contact HBM on Tel: +44 (0) 208 515 6000 or visit Web: www.hbm.com

SHORT CUTTING FRONT END ENGINEERING & DESIGN (FEED) By Peter Laing – Operations Manager responsible for Projects & Engineering at ABB Consulting In the current economic climate operating companies have fewer resources, less money and time to commit in developing front end designs for a project without knowing that the business case for the investment is viable. This makes it important to have a rapid and effective way of generating reliable project cost estimates as quickly and cost effectively as possible. Combining modern software packages with experienced project development engineers now allows reliable estimates to be produced for around a fifth of the cost of traditional approaches. This article will explain how. CONVENTIONAL FEEDS Generally speaking conventional projects can be broken down into four, distinct stages; Conceptual Study, Front End Engineering and Design, Engineering Procurement and Construction (EPC) and Commissioning and Start-up. Front End Engineering and Design, or FEED as it is better known, is the phase during which a percentage of the overall engineering required for a project is completed, with the purpose of developing a Sanction Estimate. Capital cost has a major bearing on return on investment, so the Sanction Estimate is an important part of the investment decision. Conventional FEEDs are often referred to in terms of ‘shallow’ or ‘deep’, which relates to the quantity of engineering performed. Shallow FEEDs can be as little as 10% of overall engineering whilst deep FEEDs approach 25%. FEEDs are also associated with different Sanction Estimate accuracies (e.g. ±10%, ±20%) the convention being estimate accuracy is proportional to the level of definition available; in effect the quantity of engineering completed. It’s difficult to generate an estimate for scope which hasn’t been quantified. We know there will be a lot of piping on the new plant but how many lines will there be, what size are they, how long are the routes, what are the materials of construction, how will they be supported? All these criteria impact on cost but are difficult to quantify without at least a preliminary design in place. How much do FEEDs cost? Projects in the process industries vary enormously but generally engineering costs somewhere between 10% and 20% of the Total Installed Cost (TIC). Given shallow FEEDs start at 10% of engineering with deep FEEDs

approaching 25%, then taking the midpoints of these ranges expect a conventional FEED to cost in the region of 2%-3% of TIC. Not an insubstantial sum but the operator gets a return on its investment. Progress on the project is made in terms of the engineering, but more importantly greater certainty on the cost of the project is provided.

UK FEED MARKET Arguably the UK market for FEED has changed over the last decade. Previously new builds weren’t solely the preserve of Blue Chip operators but they were responsible for the majority of large capital projects. Blue Chip operators are still present in the market but increasingly new builds in the UK are by smaller operating companies; indeed these can constitute little more than a group of individuals with an innovative idea and the potential for venture capital backing. What’s the difference? Blue Chip operators had deep pockets and were prepared to invest in FEED in the knowledge that it was likely they would go on and build the plant. The new client base however tends to be more entrepreneurial with limited access to funds. Consequently spending 2%-3% of TIC on a ‘no’ investment decision often isn’t an option. So what alternative to conventional FEED is there for the new client base?

THE MARKET RESPONSE The market response to this question has been to develop more powerful, software based estimating tools which make use of

the primary data contained within commonly used, engineering tools in order to generate further definition through the use of algorithms and data sets. Process simulation software packages are now used globally throughout the process industries. Their purpose is to find the optimal conditions for a given process through the creation and manipulation of a heat and mass balance. The latest generation of estimating tools take advantage of the fact that most simulators contain algorithms which provide initial estimates of equipment size. Primary data is extracted from the process simulators and used as the basis from which to build a TIC estimate. The data extracted includes equipment types, equipment sizes, equipment connectivity, piping sizes and electrical loads. Equipment connectivity relates to the process lines connecting main plant items.

GENERATION OF FURTHER DEFINITION The primary data imported from a process simulation is at a relatively high level, typically corresponding to the detail found on Process Flow Diagrams. It is therefore necessary to develop further definition to support the estimate. This is achieved using techniques which are collectively referred to as ‘volumetric modelling’. Volumetric modelling starts with the allocation of a predetermined template of ancillary piping and instrumentation for each of the main plant items. For example, if we take a distillation column fitted with a thermal reboiler, then information concerning the feed, bottoms liquid, overhead

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vapour and reboiler lines, as well as the equipment items themselves, is extracted from the simulation. The predetermined template adds relief, blowdown and purge lines plus commensurate numbers of temperature, level and pressure instruments. Manual isolation valves, check valves, control valve bypasses, vents and drains plus allowances for tertiary steelwork and lighting are also included in the template. This operation is performed for each main plant item. The process simulation exists only in a 2 dimensional world and therefore it is still necessary for the user to define the plot size and number of levels required for the new plant. Based upon typical process plant configurations and densities, the estimating software can then approximate piping and cabling meterage and the primary and secondary steelwork required for the main structures. The cost of foundations for the main structures and equipment items are selected from look up tables on the basis of equipment type, size and an assumed soil density. The requirement to pile foundations is optional. The costs for process control, emergency shutdown and power distribution systems are estimated from the instrumentation count and number of electrical drives. Line temperatures are assessed and where necessary, an allowance for thermal insulation is calculated. Using the above process the estimating software generates

PROCESS

Basis of Design Relief Philosophy Fire Protection Philosophy Control Philosophy Process Flow Diagrams Heat and mass balance Operating Philosophy Materials Selection Diagram Design Pressure and Temperature Diagram Utility Consumption Schedule Utility Flow Diagrams Piping and Instrumentation Diagrams Cause and Effect Charts Catalyst Specification Process Equipment List Process Line List Equipment Process Data Sheets Instrument Process Data Sheets Effluent and Emissions Schedule Relief and Blowdown Summary Relief Calculations Prelim Hydraulic Calculations Dispersion Calculations Environmental Impact Assessment

layout can be entered into the estimating model when known thereby improving the accuracy of calculated steelwork, piping and cabling quantities. Also, the estimated costs of main plant items can be replaced with manufacturer quotations. Various other, in built options to improve accuracy are offered by the estimating packages including specific labour rates for different geographic locations, adjustments for local climatic and seismic conditions, various design codes, productivity rates and an annual update of the cost databases to reflect latest inflation. A verification of the final estimate output by experienced, functional personnel is strongly recommended to ensure there are no significant shortcomings with the software algorithms applied.

HOW ACCURATE ARE THE NEW SOFTWARE ESTIMATING TOOLS? Clearly ‘volumetric modelling’ represents no more than an approximation of quantities, nevertheless estimates generated using this technique have over time proved to be reasonably accurate. An underestimate in one area of the plant is often counteracted by an overestimate in another and so on.

DESIGN SAFETY

Safety Design Policy Design Safety Philosophy HAZID HAZOP LOPA SIL Assessment Area Classification Review LEAC Sheets

EQUIPMENT

Vessel Data Sheets Heat Exchanger Data Sheets Pump Data Sheets Compressor Data Sheets Fired Heater Data Sheets Packaged Equipment Data Sheets Enquiry Requisitions for Equipment Technical Bid Analysis for Equipment

calculated quantities for equipment and bulk materials. Engineering and construction manhours are factored on the basis of these quantities. Costs for these services are then generated using rates contained within look up tables which are periodically updated. All of this information is captured in standard document sets which includes PFDs, P&IDs, Data Sheets, Schedules, Bulk Material Take Offs and an estimate breakdown.

IMPROVING ACCURACY Changes to the estimating model can progressively be made by the estimator to improve accuracy, for instance in order to take advantage of further engineering definition. The actual plant

CIVIL AND STRUCTURAL

Topographic Specification Ground Investigation Specification Civil Philosophy Structural Philosophy Outline Design of Buildings Outline Design of Major Foundations Outline Design of Underground Services Outline Design of Key Structures Building Services Requirements HVAC Specification Site Preparation Specification

PIPING

3D Model Plot Plan General Arrangement Drawings Preliminary Stress Analysis Piping Specifications Valve Data Sheets Bulk Material Take Off Valve Schedule Tie-In Schedule

Equipment Process Data Sheets Utilities Schedule Equipment List Plot Plan and Elevations Outline Building Specifications

As opposed to the documentation required for a deep FEED: As a consequence, instead of spending 2%-3% of TIC expect to spend around 0.5% using the streamlined approach. Given the much reduced engineering required for the streamlined approach, this clearly offers a quicker route to sanction than the conventional approach, though ultimately the balance of engineering that makes up a FEED must be completed post sanction. A less obvious benefit to the streamlined approach is the flexibility for optioneering. The costs for differing capacities, configurations, technologies or locations can be relatively quickly evaluated without substantial rework. This allows value engineering studies to be completed in order to improve the overall business return for the project. No need to worry about the detailed definition, the software algorithms do all the hard work!

CONTROL & INSTRUMENTATION

Instrument Philosophy Complex Loop Descriptions Functional Spec for Process Control System Functional Spec for Emergency Shutdown System Functional Spec for Fire and Gas System Instrument List Instrument Equipment Room Layout Control Valve Data Sheets ESD Valve Data Sheets Analyser Data Sheets Flow Instrument Data Sheets Pressure Instrument Data Sheets Temperature Instrument Data Sheets Level Instrument Data Sheets Cable Block Diagram Preliminary Cable Routing Drawing Cable Schedule Bulk Material Take Off

ELECTRICAL

Electrical Philosophy Electrical Load Schedule Single Line Diagram Electrical Distribution Drawing Transformer Specification Emergency Generator Specification UPS Specification Motor Control Centre Specification Electrical Equipment Room Layout Preliminary Power Studies

Experience indicates TIC estimates generated straight from a process simulator without any additional data or refinements made by the operator are 40% accurate or better. The input of the actual unit layout, vendor quotations for main equipment items, electrical distribution details, ground conditions, etc. will progressively improve the accuracy to 30% and better. Benefits of the Streamlined Approach The primary benefit of the streamlined approach is it provides the information required for an investment decision at a fraction of the cost of conventional FEED. The required engineering documentation for the streamlined approach would typically be: • Heat and mass balance • Process Flow Diagrams • Material Selection Diagram • Design Pressure and Temperature Diagram

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• • • • •

DRAWBACKS APPROACH

STREAMLINED

The new estimating tools have a number of shortcomings. Infrastructure, offsites and utilities cannot be generated from the process simulation and as such allowances for these items must be added by the estimator. Nor do the new tools cater well for specialised items such as packaged equipment, fired heaters or large rotating machines. Clearly there are limits to the library of standard equipment that can be provided within the software. As previously noted, the estimating algorithms are driven solely by the equipment items contained within the process simulation and as such the costs for the instrumentation and electrical systems and distribution are based on scaled factors rather than installed base. As a consequence the costs generated for these items merit further scrutiny. Finally much of the documentation generated by the packages is generic, the Piping and Instrument Diagrams (P&IDs) in particular are of little value beyond project sanction.

SUMMARY

The current generation of software based estimating tools offer operators a relatively cheap and quick way of assessing the viability of a project in terms of return on investment. The estimate accuracy can be relatively high where the key issues that most influence the TIC are understood and focussed on. They do not however provide a short cut for the engineering required for a project should it obtain sanction. Peter Laing joined ABB Consulting in 2014 as the Operations Manager responsible for the Projects and Engineering functions. He has over twenty five years’ experience of delivering projects in the refining, chemicals and power sectors. Peter previously worked for a number of EPC contractors including Foster Wheeler, Amec and Costain where he was involved with projects ranging from small brownfield modifications to greenfield refinery. His last two positions were General Manager Costain Teesside Operations and Engineering Manager Foster Wheeler Teesside Operations.

NEW YEAR’S RESOLUTIONS

WORTH STICKING TO Mark Whitmore, General Manager at BOGE Compressors, outlines the New Year’s resolutions that users of industrial compressed air systems should consider adopting to ensure superior air compressor - and business - performance in 2016.

ith 2015 well and truly over, it’s time to think about resolutions for 2016. This year, let’s agree to avoid the types of resolutions that are usually broken by the end of the first month and, as an alternative, set realistic and achievable resolutions that have truly transformative effects on business efficiency, performance and, most importantly, the bottom line. One area where this can be achieved is in the operation of industrial compressed air systems. There are significant cost and efficiency savings to be made, and these are possible with just a few changes to the way these assets are operated, monitored and maintained.

CHECK SUPPLY AND DEMAND

performance of compressed air systems can now be monitored quickly and easily in real-time remotely from anywhere in the world, allowing action to be taken in the event a problem is detected. By implementing remote monitoring, manufacturers can increase plant efficiency and reduce unplanned downtime and maintenance costs. However, this can only be achieved if those responsible for monitoring do so regularly, analyse relevant data and make informed decisions. Failing to do so and failing to act appropriately based on what the data shows makes the use of remote monitoring systems redundant.

RECOVER HEAT

In many cases, air compressors produce considerably more compressed air than the process that they are feeding requires. Because of the high volume of energy used to produce compressed air, this means that businesses are consuming and paying for significantly more energy than is actually necessary. This doesn’t have to be the case. Variable speed air compressors work strictly in accordance with the air demand of a process and produce the exact volume of compressed air at the precise pressure required. As a result, the total energy required to produce compressed air is reduced, making the whole process more energy efficient and less costly.

With rising electricity prices to contend with, the need for businesses to improve energy efficiency and cut energy consumption is growing in importance. Air compressors demand high volumes of energy, and of this a high percentage of the energy used is turned to heat and wasted to the atmosphere – 90% in fact, according to The Carbon Trust. However, by installing an intelligent heat recovery system a high volume of the generated heat that is emitted can be recovered - 94% in the case of systems such as our DUOTHERM. This recovered heat can then be reused for another purpose elsewhere in the plant, such as for ambient heating, water heating or for other production duties.

MOVE TO STATUS BASED MAINTENANCE

COMPLY WITH PRESSURE SYSTEMS REGULATION

While the planned or routine maintenance approach is still widely used by manufacturers, it has a number of limitations. In the event that parts wear faster than predicted and deteriorate before the time maintenance is scheduled for, the quality of compressed air produced is likely to be reduced and the likelihood of machine failure increases. The knock on effect of this can be disastrous for manufacturers, which may experience negative impact on reputations, safety and productivity. An alternative to this approach is to implement status based maintenance, whereby the condition of parts within a compressed air system are routinely monitored and replaced only when deterioration has occurred. This option creates a cost saving opportunity since parts are only changed when they need to be, and long term expenses can be reduced by avoiding unanticipated issues and unplanned downtime.

In the event that pressure systems fail in use, they can cause serious injury or death to people nearby and cause severe damage to property. This can be extremely detrimental to businesses, with potential lawsuits, fines by regulators and reputations being damaged just a few examples of the possible impact that results from such an occurrence. To prevent this, a number of regulations and directives are in place to minimise the risks associated with systems or equipment that contain a liquid or gas under pressure. Compliance with these regulations and directives on an ongoing basis is essential if manufacturers are to successfully protect people, property, and the health of the business. Further information on these regulations and directives is available from the Health & Safety Executive (HSE).

TAKE ADVANTAGE OF REMOTE MONITORING The advancing of technology has brought about many positives for manufacturers, of which remote monitoring capability should be considered one of the most beneficial. The status and

UPGRADE DRYERS THAT USE BANNED R22 GAS In 2015, it became illegal to maintain and service compressed air dryers that use R22 gas. While manufacturers can still operate these dryers for now, at some point they will fail and production and output will be affected.

There’s no benefit to waiting for the dryer to breakdown when it’s going to be replaced anyway, so the best option is to be proactive and upgrade prior to failure. This presents the opportunity to specify a system that suits the specific needs of the business, instead of a system that may have an attractive purchase price but is expensive to operate in the long term.

GENERATE SPECIALIST GASES ONSITE Many businesses in industry, from medical to mining, opt to purchase specialist gasses such as nitrogen and oxygen from external suppliers. While this may be viewed as the easiest option, it is often not as cost-effective, reliable or safe as producing specialist gases onsite using generators. By having the generator onsite and permanently at hand, users of specialist gasses are in total control of purity. This means there is the flexibility to generate gas to a level of purity based on the application and what is actually required, instead of investing in optimal purity when it’s not needed. Additionally, safety risks posed by storing pressurised storage tanks onsite and the potential for late deliveries by an external gas supplier are removed, so users can have peace of mind that employees are safe and gas is always available for use when needed.

ASK THE EXPERTS With so much going on in such busy environments, manufacturers don’t need to worry about not having the time or knowledge required to implement changes to their compressed air systems. Instead, compressed air systems experts, whether that’s a local distributor or a systems manufacturer such as us, can help specify and install the right system and technology for any environment or application, allowing manufacturers to focus on their normal day-today duties. Compressed air systems offer an excellent opportunity for energy and cost savings as manufacturers look to boost profitability and gain an edge over the competition. By starting the new year with a new approach that incorporates the resolutions outlined above, manufacturers can benefit from enhanced efficiency and performance – much to the delight of those concerned with the bottom line.

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THE GREAT

OBSOLESCENCE DEBATE

When a part breaks in a car, you only really have two choices: find a like-for-like replacement or buy a new car. Fortunately, in a factory there’s freedom to be more creative; it’s a systems integrator job to be the artist in the process. The control system in a factory is what a motor is to a car, and when something is amiss, the systems integrator will analyse, design, fit and test, to make sure the system is better than ever and raring to go. However, there’s a topic that we’re finding crops up time and again.

Here Nick Boughton, sales manager at Boulting Technology, discusses best practice for obsolescence management from a systems integrator point of view.

he debate between upgrade vs. repair is by no means a new one, but it has become prevalent as most industries look to squeeze margins. Certain sectors have long had to carefully manage obsolescence due to their delicate nature. For example, pharmaceuticals manufacturing is well known for being heavily regulated and so sourcing spare parts instead of committing to a systems upgrade generally means saving time, money and a whole lot of paperwork. However, other sectors with critical systems and infrastructure often demand a combination of legacy systems and the latest technologies. Just think of aerospace and defence, for example. In almost all cases it’s a matter of planning and forward thinking, while implementing a healthy mix of upgrade and obsolescence management. The question you really need to be asking yourself is ‘what’s the best thing for the system overall?’

EVERYONE IS DIFFERENT... As a systems integrator, we’re called in when there needs to be a serious change. We’re there to analyse and advise on the options as best we can, but the decision is the customer’s alone and there are many factors that come into play when it’s time to commit. For a start, not everyone has the luxury of being able to afford a complete upgrade. On the flip side of the coin, not everyone has the choice of relying on spares. No matter what the client chooses, the role of a systems integrator is to complete the job to the highest standard using the tools available to us. Every job is different and usually comes with its own unique challenges that determine whether an upgrade is even possible. For example, Boulting Technology was recently called out to a factory manufacturing glass bottles to update the control system for its production process. The interesting thing about this job was that in the process, a kiln was automatically fed broken glass every five hours to keep it alive and to keep the production line moving. If the conveyor feeding glass into the kiln stopped and the oven cooled, the kiln would no longer be in a working condition. It was imperative for us to work around the issue. If we return to the car metaphor, we had to remove the old engine and replace it with a new one, but keep the wheels

turning at all times. We achieved this by implementing the new control system in phases and ensuring that a motor was running the conveyor at all times. In this case a complete upgrade was not plausible due to the nature of continuous production, which just goes to show that sometimes the choice is taken out of the hands of the client altogether.

ANALYSE, PLAN AND STAY ONE STEP AHEAD Regardless of whether a client is implementing an upgrade or using spare parts to maintain production, organisation and planning are crucial. Take the water industry for example. A plant that turns river water into drinking water is a critical application. If anything was to go wrong with the process, it could put lives at risk. It’s common for computerised maintenance management systems (CMMS) to be used in these types of plants. These systems help companies manage infrastructure. For example, they enable alerts for new software updates, manage records of where spare parts are located or calculate the cost of breakdown repair versus preventive maintenance for each machine. When relying on spares to keep production up and running, there are several questions that arise from a systems integrator’s perspective. First of all, does it contain obsolete components? If so, you have to accept there will only be a finite number of replacements out there, which means sooner or later you’re going to have to upgrade.

The big risk when it comes to managing obsolescence is reliability. If a system is brought to a halt because an obsolete component has broken down and needs replacing, how long have you got before the same thing happens again? Maybe there are bigger faults in the systems causing the part to fail? This would make replacing a false economy. You may think that in most scenarios facilities managers are faced with an easy decision – to replace the entire system. However, it might not be that straight forward. If this is a critical application then yes, an upgrade would be advisable, but if it’s not and replacement parts are cheap and plentiful, the company might be happy to carry on as it is. The analysis that most businesses use is called overall equipment effectiveness (OEE). This is a series of metrics developed to establish how effectively a manufacturing process is operating. Companies use OEE as a benchmark for how well they’re doing in terms of efficiency and we’re often called in as the result of the metrics pointing to improvements that can be implemented.

WHAT’S THE RISK? Downtime is the dreaded risk when companies decide either to upgrade or make do and source spares. In an automotive manufacturing plant, one minute of downtime costs on average $30,000. If production goes down for a couple of hours, the company loses just over $3.5 million. The correct answer for whether upgrading is better than likefor-like replacing really varies from job to job and in most cases the two solutions need to be used in parallel. The more planning, surveying, risk analysis done by a company, the easier it is to cope with a problem when it inevitably occurs. It should be noted there is an extent to both methods. Upgrading every time a more efficient system is identified would mean bankruptcy, based on the innovations in automation at the moment, whereas solely relying on legacy systems risks large failures and prolonged periods of downtime. Ultimately, the end goal is to find a harmony between the two, in order for factories to run like a dream.

PROCESS INDUSTRY INFORMER January - February 2016

HEALTH & SAFETY

INDUSTRY FIRST WirelessHART™ BURST DETECTION SYSTEM

ESAB OFFERS WELDING HELMET & AIR UNIT SELECTION GUIDE

- 2 industry experts helping to cut the cost of wiring in safety critical environments -

ESAB Welding & Cutting Products introduces a new Welding Helmet and Air Unit Selection Guide poster now available free of charge. The selection guide is designed to help welders identify the proper ESAB welding helmet and associated air unit for the specific welding process or project at hand. The poster format makes the guide a convenient and easy-to-use resource. ESAB offers a broad portfolio of welding helmets for all levels of users from beginner and recreational welders to professional welders and those requiring a high specification, multi-process head shield. The new Welding Helmet and Air Unit Selection Guide takes the guesswork out of helmet selection. Users can easily navigate the product range and select the headshield and available options in line with their application, personal preference, and health and safety requirements. All ESAB Personnel Protection Equipment (PPE) incorporates the latest in safety-related technology. The newest addition to ESAB’s PPE line is the Aristo® Tech HD auto darkening helmet, which provides best-in-class optical performance with a large 100 x 60 mm viewing area and new X-TIG mode for exceptional performance during low amp welding. The helmet is also offered with a Powered Air Purifying Respirator (PAPR) unit. For more detailed information on this and other ESAB PPE products, visit www.esab.com. In addition to this selection guide, ESAB also offers a range of training/educational posters specific to welding processes (GMAW, GTAW, MMA, plasma, oxy-fuel cutting and oxy-fuel welding). Check with your local ESAB representative for details. For more information contact ESAB Group (UK) Ltd. Tel: 0800 389 3152 E-mail: info@esab.co.uk / Web: www.esab.com.

Elfab Limited, global manufacturer of pressure relief systems, has recently launched its first wireless burst detection system. Elfab’s noninvasive, reusable, ATEX-approved burst detector; Flo-Tel™ ; has been offering customers, a fail safe way of notifying a disc has burst in safety critical conditions for over a decade. Uniquely, Elfab’s Flo-Tel actuator is installed on the vent side of the disc and is activated by the operation of the disc itself. Emerson Process Management recognise the benefits and advantages of Flo-Tel and are working closely with Elfab, helping to bring to the market the first WirelessHART rupture disc burst detector. Wireless technology offers a cost effective solution when monitoring rupture discs and explosion vents and can easily be implemented on both new and existing sites. Customers can expect to eliminate the costs and complexity of additional wiring by saving an estimated 50% of the cost and 90% of the time required to install a conventional wired system. Both new and existing customers can benefit from upgrading to this technology by obtaining immediate process alerts from an intelligent, real-time process monitoring equipment. Compatible with its non-invasive, fail safe burst detection systems, Flo-Tel™+ and Flo-Tel XD; Elfab’s wireless detection can be integrated and upgraded easily with Emerson’s WirelessHART™ Gateways. This allows for even further cost savings by eliminating the need for wiring on both new builds and on plant upgrades. For more information contact Elfab Ltd, North Shields, Tyne & Wear Tel: +44 (0)191 293 1234 / E-mail: sales@elfab.com / Web: www.elfab.com

PROCESS INDUSTRY INFORMER January - February 2016

MATERIALS HANDLING NEW DEMAG V-TYPE DOUBLE GIRDER CRANE • V-type range expanded to include double girder model • Easily adapted to existing building structures • Reduced deadweight for increased load capacities Following the launch of the innovative Demag V-type single girder crane, Terex Material Handling has extended the range to include V-type double girder overhead travelling models. V-type double girder cranes are available with load capacities of up to 50 tonnes and are offered with spans of up to 35 m as standard, with longer girder lengths available upon request. LOWER WEIGHT A significant feature of the V-type crane is the reduced weight of the crane girder compared with cranes manufactured in box section girders. This facilitates the accommodation of a rope hoist that has a higher load capacity for the movement of heavier unit loads. The reduced crane deadweight produces less wheel pressure, minimising the forces transmitted to the crane runways and existing building structures. Consequently, the new Demag V-type crane provides architects with greater freedom in planning new factory buildings. PRECISE POSITIONING OF SENSITIVE GOODS Another advantage over conventional box section girder design is that the V-type’s mechanically connected girders are inherently more rigid, enabling faster material handling and the ability to transport and position sensitive loads gently and accurately. EASILY ADAPTED TO EXISTING BUILDING STRUCTURES The V-type double-girder crane is offered in four different designs, with the side connection of the end carriages to the girder a common feature to all models. PRECISE CRAB RUNWAYS AND TORSION-FREE CRANE GIRDERS The Demag V-type double girder crane offers improved precision for its crab runway. This ensures that the track gauge of the crab runway is maintained precisely. MORE LIGHT FOR IMPROVED WORKPLACE SAFETY This improves line of sight within the building and creates a brighter and more pleasing workplace for a safer working environment.

Andreas Hambrock, Senior Director of the Universal and Modular Cranes’ Business Line at Terex Material Handling, stated:“Following the positive response from the market for our V-type single girder

crane, we have taken the next logical step with the introduction of the double girder design.” For more information contact Demag Cranes & Components Ltd, Banbury, Oxfordshire Tel: 01295 676100 Email: bnb-help@terex.com / Web: www.demagcranes.co.uk

NEW DEMAG CRANE RADIO CONTROL SYSTEM WITH MINI JOYSTICKS • Ergonomic concept for single handed control • High transmission reliability • Multi-transmitter operation for flexibility Terex Material Handling has added new models to its range of D3 generation new radio controls. The compact DRC-MJ hand held transmitter facilitates ergonomic joystick control of crane systems using just one hand. Previously, operators had a choice of two systems for the radio control of cranes; either a compact unit with pushbuttons or a large control unit with joysticks. The Demag DRC-MJ controller combines the convenience of joystick control of all motions with the ergonomics of a compact hand held unit. The housing of the new control unit is based on the proven design of the Demag DRC DC hand held transmitter. The impact resistant housing material has a smooth surface and is resilient to mechanical loads. Rubber coated end caps ensure durability, making it suitable for operation in arduous environments. The batteries may be used for uninterrupted operation for up to five days without recharging. CONTROL OF CRANE AND TRAVEL FUNCTIONS BY MINI JOYSTICK The innovative design replaces the conventional keypad panel of a compact controller with two integrated mini joysticks and four buttons. The lifting and lowering motions of a rope hoist may be controlled accurately using the top joystick. The lower joystick may be used for the variable control of two motion axes, such as two crane and travel functions. Simultaneous motions, including diagonal long and cross travel motions, can be controlled with just one hand. The lifting and travel motions may be limited, at the press of a button, to 30, 50 or 70% of the maximum speed for each motion axis. A distinct and illuminated bi-colour display shows the weight of the load. A vibration alarm indicates an overload and other status messages, relevant for safety and service purposes, may also be provided. Four user friendly buttons complete the control concept of the DRC-MJ units. UP TO THREE RADIO CONTROL UNITS PER CRANE For all Demag D3 radio control systems, the operator can pair each crane with up to three transmitters of various types; conventional pushbutton transmitters, classic joystick transmitters or mini joystick transmitters, with the ability to switch from one to another at the press of a button. The new D3 generation of radio controls is equipped with state-of-the-art radio transmission functions, including frequency hopping and “listen before talk”. For more information contact Demag Cranes & Components Ltd, Banbury, Oxon. Tel: 01295 676100 / Email: bnb-help@terex.com / Web: www.demagcranes.co.uk

SEALS & SEALING THREE DECADES OF PROBLEM SOLVING FOR PROCESS INDUSTRIES DuPont™ Kalrez® perfluoroelastomer parts (FFKM) were developed some three decades ago and have delivered outstanding sealing reliability throughout, even in the most aggressive production and processing environments. These high performance products are available in the UK from authorised distributor Dichtomatik Ltd. The Kalrez® parts improve sealing reliability particularly in conditions where high heat, aggressive chemicals and plasma are utilised. Aerospace and downhole oil and gas applications were some of the first successful applications of Kalrez® products where seal failure was unacceptable. An outstanding resistance to fuels, additives, lubricating oils and corrosive chemicals has ensured the high durability expected and achieved with Kalrez® products. They also provide a broad chemical and high temperature resistance to acids, amines, ultrapure de-ionised water and strong bases etc. This ensures that chemical/hydrocarbon processing plants can run hotter, longer and with a wider range of chemical products while also providing substantially increased MTBR times and improved operating safety. With a combination of thermal and chemical performance as well as rubber-like sealing ability Kalrez® FDA compliant seals offer the pharmaceutical, food and beverage industries the highest level of protection against product contamination and seal failure. Within electronics manufacturing operations, unplanned maintenance due to incompatible sealing materials can also be dramatically reduced. A typical example for the application of the Kalrez® products is their use as replacements for metal ‘O’ rings in a gear pump application, operating at temperatures up to 327°C and 100 bar pressures within the chemical process industry. The installation involved exposure to highly aggressive media, as well as fluctuating internal sealing forces within asymmetric pump housings when pumps were situated within reactor environments. Long-term reliability and stringent performance were an absolute necessity, and operating times in excess of 10 years have been achieved without the occurrence of production problems through the loss of sealing performance. The changeover to Kalrez® seals was so successful that they are now fitted as standard equipment to the manufacturer’s extensive range of gear pumps. Further information is available from: Dichtomatik Ltd, Derby, Derbyshire. Tel: 01332 524401 / E-mail:kalrez@dichtomatik.co.uk / Web: www.dichtomatik-kalrez.co.uk

PROCESS INDUSTRY INFORMER January - February 2016

DISASTER RESILIENCE:

ONE-SIZE FITS ALL WON’T DO By Tony Mannion, Business Unit Leader Industrial IT of SolutionsPT A disaster resilience strategy ensures that an organisation or facility will be able to function based on an event or failure. However, this strategy is often formed at corporate IT level, leaving organisations with manufacturing facilities extremely vulnerable. We look at the specific challenges facing plant environments and examine how a ‘standard’ solution created to serve a commercial office environment could have a disastrous commercial implications for manufacturers.

he terms disaster recovery and disaster resilience are often mistakenly interchanged, but ultimately, in the midst of chaos surrounding lost data and facility down time, very few people will care about the definition of the terms. However, it is vital organisations develop an understanding of both before such issues arise. A recent study by IBM announced that 43% of companies that suffer a major loss of business data never reopen, with a staggering 51% closing within two years and just 6% surviving in the long-term.

These worrying stats can be attributed to manufacturers being focused on developing, marketing and selling their products, and, as such, disaster resilience is often something that slips down the list of priorities – usually until something goes wrong. We’ve heard directly from engineering, operations and IT departments that there is a clear requirement for a reliable, secure and cost-effective IT solution to replace their existing systems. The plant floor provides a very different set of challenges to an office environment when considering the implications of

SO WHAT IS THE DIFFERENCE BETWEEN THE TWO? Disaster recovery relates to the process of restoring the data and applications your business runs on in the event of data centres, servers or other key infrastructure being severely damaged or destroyed. Conversely, disaster resilience refers to the process whereby businesses that suffer such issues are able to continue to operate with little or no downtime or outage, maintaining business continuity. On a basic level, one is picking yourself up after a fall, taking stock and continuing whilst the other is planning to not fall at all. Deciding between the two can be a difficult choice, especially when considering the grave consequences of selecting the wrong option. For disaster recovery, businesses need to first assess the cost of downtime whilst data is recovered, who and what is required for the recovery process and how long the process will take from disaster to recovery. For disaster resilience, businesses must assess the likely causes of the disaster, what the minimum components are for systems to still operate and how these will still be available during the disaster. Disaster resilience plans are commonplace in corporate IT, however there is often an assumption that a solution that fits an office environment will also protect a plant environment. A recent piece of research we conducted identified that manufacturing organisations often inherit IT infrastructures specified at corporate level that are not robust enough for the plant environment. The survey also revealed that 40% of manufacturing businesses were less than confident in their organisation’s ability to get up and running again after a critical IT failure.

unplanned system downtime. This can be attributed to the high costs associated with a production facility grinding to a halt. Manufacturers will not only face the cost of productivity loss, but they may also face fines for missing contracted production quotas and shipments. Likewise, the associated cost of a workforce unable to do their jobs and the knock-on effect this will have down the supply chain can also hit manufacturers. Quality loss and production variability from before or after the downtime can also mean that energy, materials and manhours are wasted manufacturing sub-substandard products. It is therefore vital that manufacturers consider a number of key questions when assessing their plant-specific disaster resilience plan, including: what is the maximum allowable downtime, how and where should data be stored, how quickly must data be retrieved and mounted or restored and how do you ensure your plan actually works? The process of developing and answering these questions will help you define the solution you require.

PROCESS INDUSTRY INFORMER January - February 2016

SYSTEM PROTECTION IMPERITIVE... At a time where manufacturers are becoming increasingly reliant on the reliability, availability and performance of their industrial IT systems, leaving themselves so exposed should be their primary cause for concern. System performance, whether that is the SCADA application, underlying technology or infrastructure, defines an organisation’s reputation, especially where downtime is no longer an option. A unified management approach is essential in maintaining and protecting a system’s health and security. Often though, this sort of approach requires a large investment of both time and money for manufacturers to rollout internally. However, it is becoming increasingly popular for organisations to utilise third parties to remotely monitor and backup systems. These services, such as SolutionPT’s Managed Platform service, offer a combination of encrypted local back-up virtualisation, off site replication and bare metal restore. Offering a complete IT system infrastructure combined with SCADA performance management and disaster resilience enables manufacturers to combine reduce downtime, lower capital and operating costs and increase competitiveness. In this instance the service is delivered and monitored by an expert team, who monitor and manage both the performance management and the disaster resilience. Key features of the system include the provision of a complete back-up and recovery solution for control infrastructures, which includes bare metal recovery, instant visualisation for rapid recovery and complete server recovery to any physical or virtual environment. The platform takes performance monitoring to the next level as the experienced team conduct deep network monitoring down to SCADA and application level and immediately alert production sites to any potential issues before a failure can occur. Tailored solutions such as this mean that disaster resilience plans need not be a luxury for companies but are instead a necessity, providing a solution to critical business risks and IT challenges at an affordable cost - allowing companies to focus their time, resources and energy on developing and marketing their products.

STEAM versus THERMAL FLUID Steam has been a valuable servant to the human race, from a means of powering engines to a method of cooking food. However, there’s one area where steam has been outdone in recent years – heat transfer using thermal fluid. Here Clive Jones, CEO of Global Heat Transfer outlines the benefits of using thermal fluids instead of steam in a heat transfer process.

istorically, if heat transfer was needed in a chemical process and heating via naked flame wasn’t feasible, steam was the preferred method. This was mainly due to the ease of sourcing water, the minimal cost of the resource and the perceived absence of environmental issues. However, using steam in a heat transfer system comes with numerous drawbacks.

SAFETY Steam requires a high operating pressure to achieve temperatures necessary for operating heat transfer systems. For example, to reach 300 degrees Celsius, steam would require a pressure of 85 bars. This is roughly 14 times the pressure inside your average bottle of bubbly. Picture what happens to Champagne when pressure in the bottle builds up and is given a means of release through the weakest point – the cork. Now times this by 14. Needless to say, the presence of high pressure brings with it the When steam reaches critical pressure and has no way of venting, the system can burst a pipe, seam or valve. This can result in an explosion of extremely hot steam and shrapnel from pipes. In contrast, most thermal fluid systems are vented and operate at atmospheric pressure, which means the risk to life and infrastructure from pressure is minimal. The widely held view that heat transfer fluids and systems present an operational fire and explosion hazard is a misconception. This can largely be explained by the use of inappropriately designed systems or the use of inappropriate heat transfer products and their mismanagement in a system.

EFFICIENCY Steam heat transfer systems rely on the generation of steam to drive pressure and ultimately, temperature. Due to this dependence on a delicate pressure balance, accuracy is generally limited to swings of ±6 degrees Celsius. This value is likely to increase as the system ages and corrosion takes its toll. In addition, condensate removal in steam heat transfer systems also affects the uniformity of heating. In comparison, thermal fluid systems can have an average temperature control of ±0.8 degrees Celsius. That’s a whopping precision of 99.8 per cent at a temperature of 550 degrees. This precision is accomplished by efficient metering and mixing of cooler return fluid with warmer fluid from the supply line.

MAINTENANCE Steam heat transfer systems require constant maintenance. In fact, in some countries such as the US - it’s a legal requirement that a qualified person must continuously monitor and maintain operations. This creates an additional maintenance and cost burden that isn’t present with thermal fluid systems. Furthermore, steam system infrastructure is far more intricate compared to thermal fluid applications. Safety valves, condensate return pumps, expansion joints, blow downs,

chemical additions and drains all need to be correctly managed for the steam systems to run efficiently. Thermal fluid systems, on the other hand, only require a pump, an expansion and storage tank and heat exchangers. The maintenance problems don’t stop there. Common issues with water and steam systems include corrosion and freezing. Despite steam systems depending on the use of demineralised water, the combination of water vapour and hot air alone is enough for corrosion and scaling to take place inside the pipes. To combat this, you could use stainless steel for piping, but this brings with it an added cost. Water in steam heat transfer systems is also prone to freezing if left unused in cold conditions – for example, if a facility closes for winter or the Christmas period. If the water in the system freezes there’s a significant potential for pipes to burst, causing harm to the system and water damage to surrounding infrastructure. In comparison, thermal fluids are extensively used in systems designed to work at low temperatures. Specific types of fluid such as Globaltherm EDT or Globaltherm ECO containing anti-freeze are specially formulated to pump at sub-zero temperatures and must be used in these cases. Although thermal fluids don’t require constant assessment, maintenance should be frequent and comprehensive. Annual sampling of heat transfer fluids is a minimal requirement to demonstrate compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). However, quarterly sampling is necessary to detect any short-term changes in the status of the fluid. This acts as a means of predicting future degradation and allows companies time to take appropriate action to avoid unnecessary downtime and high costs. A strategic maintenance plan is imperative for healthy and efficient heat transfer systems.

DISPOSAL Engineers must treat water in steam heat transfer systems to minimise corrosion to pipes and protect from freezing. These chemicals mean that the water cannot be disposed of into drains because they are harmful to the environment. In addition, some countries regulate the temperature of wastewater upon disposal. Again, this is in order to protect the environment. The disposal of water and thermal fluids that have been used in heat transfer systems, has to be carried out by qualified professionals in accordance with environmental regulations. This can be extremely expensive if unplanned, hence the need to have a comprehensive maintenance contract in place.

CONCLUSION Increased safety and flexibility combined with better efficiency and more manageable maintenance has meant thermal fluid systems have definitely come out on top in recent years. Steam may have once reigned supreme in heat transfer, but thanks to increasingly sophisticated products and maintenance practices, thermal fluids now dominate industries from pharmaceutical to food and beverage manufacturing.

PROCESS INDUSTRY INFORMER January - February 2016

COMPRESSORS

WELDING & CUTTING PRODUCTS

BOGE LAUNCHES NEW WHISPER QUIET & ULTRALOW VIBRATION OIL-FREE COMPRESSOR SERIES

NEW VERSION OF ESAB CUTTING SOFTWARE FEATURES POWERFUL JOB WIZARD, OPTIMISED USER INTERFACE

New series of whisper quiet and ultra-low vibration air compressors from BOGE delivers oil-free compressed air for use in clean and sensitive environments BOGE Compressors, a leading supplier of industrial compressed air systems, has launched an extremely quiet and ultra-low vibration series of air compressors. The BOGE EO series features compact, integrated compressed air treatment and reliably supplies Class 0 oil-free compressed air, ideal for clean and sensitive environments such as laboratories and hospitals. Each of the new BOGE scroll compressors in the series operates with two spirals – one of which is fixed while the other rotates eccentrically – which intertwine without touching and therefore don’t require oil lubricant. Intake air is continuously compressed into an increasingly narrower interior space, which quietly produces high quality compressed air that is completely oil-free with minimal vibration. The EO 22 D with integrated refrigeration dryer and focus control 2.0, for example, delivers oil-free compressed air at 8 bar and delivers 2,520 litres per minute at a sound level of 64 dB, which is 5dB lower than a silenced BOGE screw compressor. The EO series is designed to match compressed air output with demand to enable improved energy efficiency. Where higher quantities of compressed air is required then up to four compressors can be accommodated in a single housing. Mark Whitmore, General Manager at BOGE Compressors, commented: “The noise emitted by most air compressors is such that normally they must be housed a fair distance away from work areas. The new EO series, however, is so quiet and pulsation-free that it can be installed in close proximity to people and work stations. Additionally, because it is absolutely oil-free it is fit for use in sensitive and clean environments.” For further information contact: BOGE Compressors Ltd. Brighouse, West Yorkshire, E-mail: m.heeley@boge.com Tel: +44 14 84-719921 Web: www.boge.co.uk

PROCESS INDUSTRY INFORMER January - February 2016

ESAB Welding & Cutting Products announces the release of Columbus® CAD/CAM Nesting Software version 1.3, a powerful CAD/CAM programming and nesting software optimised for plasma, oxy-fuel, laser and waterjet cutting. This latest version of Columbus offers many new features and updates to make programming easier and more efficient, improve material utilisation, increase productivity, and streamline workflow. The most powerful function is the new Job Wizard, which automatically creates NC programs from customer orders. For the parts and plates within a customer’s library that are marked for automatic process, Job Wizard can automatically nest all parts on the correct plates, as well as assign the best machine to cut the part based on strategy settings. For job shops, Job Wizard can perform these functions automatically within minutes after a customer releases the order, saving hours of time. Influenced by customer requests, Columbus version 1.3 now features a simpler, optimised User Interface (UI). The menu-driven user interface complements the screen icons to help keep the workspace organised and keep important functions at the user’s fingertips. The workspace can be customised by hiding or showing all features in each section and organising the different menus with dockable windows over more than one monitor. Other enhancements include a zoom overlay window that shows details without zooming the complete layout, visual control for users to detect parts on a table grid which will tilt after cut, commands that improve cut quality and production time when beveling by optimising the cutting path and eight more improvements that simplify programming and cutting. ESAB offers total online support for Columbus software. All support is done on-line, which allows questions to be answered as quickly as possible to get customers up and running faster. For more information contact ESAB Group (UK) Ltd. Tel: 0800 389 3152 E-mail: info@esab.co.uk / Web: www.esab.com

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves

AXFLOW EXTENDS ITS ATURIA PUMP PORTFOLIO AxFlow has extended its portfolio of Aturia high pressure centrifugal pumps with the introduction of the TKK model. The TKK is a multistage, horizontal between bearing mounted pump and is available in several sizes. Delivering flows up to 500m³/ hr and with a suction flow of 25bar and delivery pressure of 100bar, the TKK comes with a maximum head of 880m and can accommodate fluids up to +160°C. The pump design incorporates PN25 suction flanges and PN100 delivery flanges, with suction and delivery nozzles being capable of 90° rotation in easy stages. Axial balance thrust created by the single impeller is balanced by a hydraulic throttle bush, with residual thrust being absorbed by the axial bearing. The seal chamber has been designed to accommodate API628 mechanical seals, and pumps are supplied with balanced cartridge seals. AxFlow reports that the Aturia TKK has been developed for applications including boiler feed water, condensate supply, pressure boosting and osmosis and ultra-filtration. For more information contact AxFlow Ltd, Ealing, London. Tel: 020 8579 2111 Email: info@axflow.co.uk / Web: www.axflow.co.uk

NEW HIGH-PRESSURE SEAL-LESS DIAPHRAGM PUMP Wanner has launched the Hydra-Cell T8030, a Triplex diaphragm pump that it claims eliminates leaks, hazards and the expense associated with replacing seals and packing. Pumping up to 98 l/min at pressures up to 345 bar, the Hydra-Cell T8030 boasts a unique diaphragm design that handles more abrasives with less wear than gear, screw or plunger pumps. It can operate with a closed or blocked suction line and can run dry indefinitely without damage, eliminating downtime and repair costs. With three hydraulically balanced diaphragms in a single pump head, designed to handle high pressures with low stress, the Hydra-Cell T8030 is energy efficient and has a lower energy requirement that similarly rated centrifugal pumps. Designed for long life with minimal maintenance, the compact design and double ended shaft provide a variety of installation options. The design also enables maintenance of valves and diaphragms to be undertaken easily in the field, without the need for heavy lifting capabilities. The Hydra-Cell T8030 is available with a choice of Nickel Aluminium Bronze or 316L Stainless steel pump head materials and the pump can also be configured to meet the requirements of API 674 if required. For more information contact: Wanner International, Tel +44 (0)1252 816847 Email: NHerrington@wannerint. com Web: www.hydra-cell.eu

THE IDEAL COMPANION To help you to select the right pump for your needs, the Grundfos Installer Companion App is proving to be a worthwhile and valuable download. This App is the latest reincarnation of the Grundfos Pump Installer Handbook that was so popular a few years ago but that grew too large to be a practical aide. Once uploaded, no matter where you are if you need additional information or some extra assistance, the App will be right there to support you. It will give you access to: product information, application know-how, easy sizing and selection, a handy replacement aid, pump selection guide; plus a really useful set of calculators that you can reference for a range of system parameters and trouble-shooting options. To find out more visit the website uk.grundfos.com/installer-app.html or download the App from Google play or the App store. We think you will find it this App to be an invaluable support tool; it will always be there ready to answer any pump query you may have. For more information contact Grundfos Pumps Ltd, Leighton Buzzard,Beds. Tel: 01525 850000 Email: grundfosuk@grundfos.com Web: www.grundfos.co.uk

PROCESS INDUSTRY INFORMER January - February 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves

316L STAINLESS STEEL FILTERS – CUSTOM-BUILT, HIGH SPECIFICATION, SIMPLE & EASY TO MAINTAIN Axium Process, filtration specialists, manufacture a comprehensive range of 316L stainless steel filters which are renowned for their robust construction, versatility, reliability and their ease and simplicity to maintain. The filters, which are manufactured to hygienic standards in accordance with ASME-BPE principles, are available with full materials certification, wedge-wire or sintered mesh elements and are designed for filtration levels from 5 micron up to 6000 micron as standard. Widely used across a broad range of industries for a diverse range of duties, Axium’s Standard range of filters include a 90º, in-line and straight through options as well as a Compact filter version designed for use in confined areas or where flow rates are low. Axium’s engineers specialise in customised hygienic stainless steel fabrication and filters are routinely manufactured to suit customer requirements. Engineers work closely with customers to fully understand their processing requirements so that the optimum filter is supplied for a given application. Customised options include stand-alone, duplex, triplex, multiplex, large capacity and jacketed filters. Sample valves, drain or vent valves can be integrated into any of the options as can isolation or back flush valves if required. For more information contact: Axium Process Ltd, Hendy, Swansea Tel: +44 (0) 1792 883 882 Email: info@axiumprocess.com / Web: www.axiumprocess.com

PROCESS INDUSTRY INFORMER January - February 2016

HYGIENIC CENTRIFUGAL PUMPS FOR FOOD & PHARMA PROCESSES When pumping applications require high levels of hygiene, resistance to chemical agents and gentle handling of delicate ingredients, the new range of Inoxpa PROLAC HCP hygienic centrifugal pumps are the ideal solution. Available through pumping specialists MICHAEL SMITH ENGINEERS, the PROLAC HCP range of compact, close-coupled centrifugal pumps are designed to provide flow rates up to 220 m3/ hour, maximum differential pressure (heads) up to 140 metres and maximum system pressures of 16 bar. HCP PROLAC pumps are available in 316L stainless steel, are EHEDG certified, and will be particularly suitable for main process pumping duties in the dairy, beverage, pharmaceutical and cosmetic industries. They feature as standard a single internal hygienic mechanical seal, a stationary face of carbon, a rotating face of silicon carbide and gaskets in EPDM. Also, CIP (clean-in-place) and SIP (steam-in-place) is possible without the need to dismantle the pumps. Higher specification options are also available to ensure suitability for a wide range of specific application requirements. These include double mechanical seals for additional security, gaskets and seals to FDA standards for optimum hygiene levels, different types of connection options for positioning flexibility, heating jackets for temperature sensitive products and ATEX rated versions which allow flammable liquids to be handled safely. Hardened face seal options are available for mildly abrasive liquids, and there are a variety of elastomer choices to ensure product compatibility. Special models for handling liquids with up to 60% solids are also available within the Inoxpa range. Further details available at: Michael Smith Engineers Ltd, Woking, Surrey Tel: FREEPHONE: 0800 316 7891 Email: Info@michael-smith-engineers.co.uk / Web: http://goo.gl/5k9v8g

FUELLING OPTIMISED SYNGAS PRODUCTION USING PROCESS ANALYTICS

Andy Eady, Product Manager – Analytical Products, Siemens UK & Ireland, says production of syngas - increasingly used to produce diverse synthetic products such as clothes, solvents and fuels – needs fully optimised process analytics functionality to drive production objectives and deliver an operationally efficient and safe manufacturing environment. ynthesis gas – more commonly referred to as syngas – is a renewable fuel source that is increasingly being used across a number of process industries, including ammonia and hydrogen manufacture, ammonium nitrate/nitric acid, urea and methanol plants, refineries and

coking plants. Synthetic gas is a mixture comprising carbon monoxide, carbon dioxide and hydrogen and is produced via the conversion of a carbon containing fuel to a gaseous product that has some heating value. Typical examples of syngas production include the gasification of coal products and the gasification of industrial and municipal waste. Syngas has 50% of the energy density of natural gas and though it cannot be burnt directly, it can be used as a valuable fuel source. It can be produced from any carbon bearing fuel, gas, liquid or solid, and its general raw material basis includes coal and petroleum-based materials, as well as other materials that would otherwise be considered as waste products.

FUELLING ENERGY FROM WASTE To assist the generation of syngas, waste material from municipal, industrial or other sources is being used as a feed/fuel stock for the gasification process. The feed stock is heated in a reducing atmosphere (with very limited or no oxygen content) and the resulting gases can be used for combustion purposes immediately, or thermally treated to improve their properties. This latter stage is referred to as advanced gasification or pyrolysis.As a renewable energy source, the conventional and advanced gasification processes are eligible for support under the Government’s Renewable Obligation Certificate (ROCs) programme, based upon a minimum calorific fuel value production. This is part of the multi-billion pound UK renewable electricity subsidy platform. Likewise, the advent of a strong waste product stream to supply the growing gasification industry is in part driven by the wish of suppliers to avoid the financial penalties associated with landfill

taxation. It is also fair to say that a number of competing technologies, processes and options are available for syngas manufacture.

CREATING SYNGAS – A CHALLENGE The gasification process for the production of syngas whatever its original origins is not without its challenges and is driving the need for accurate, reliable and safe process analysis functionality. Some of the measurement requirements include the need to assess the minimum calorific value of the syngas, a desire to optimise the collection of compositional data throughout the syngas production process, awareness of safety issues around the oxygen content, potential emissions monitoring and ongoing support as research or new start-up syngas production phases require enhancement. As operational requirements drive the need for accurate and reliable process analytics, this need is further reinforced by some of the production operating conditions associated with Syngas. Production typically takes place at extreme temperatures of up to 1200°C and pressures up to 6 bar, as well as having to deal with highly variable composition that is heavily affected by the original feedstock. This could, for instance, contain quantities of tars, solids, salts, moisture and other impurities. The challenges of syngas production can be addressed by a number of processes that can include reforming, filtration, cooling and catalytic conversion. Most of these methods aim to improve the hydrogen, CO and CO2 content of the gasification process, and, in turn, remove the tars, sulphurs and other impurities. At the advanced gasification or pyrolysis stage, efforts can be made to reduce the formation of undesirable compounds to lessen additional cost and resource requirements at later downstream treatment phases.

PROCESS ANALYTICS – SAFE & RELIABLE TECHNOLOGY SOLUTIONS TO HAND With the importance of process analytics recognised across

syngas production, both simple and more complex measurement applications exist within gasification plants. Challenging measurement applications are often linked to the raw syngas stage; these involve significant sample preparation and, by association, high initial costs and substantial plant maintenance resourcing. However:, if sample conditioning is handled correctly, utilising the latest flexible process analytic technologies now found within refinery and coke oven applications, such systems can become standard applications. Typical examples include hydrogen, nitrogen, water, methane, ethane, carbon monoxide, carbon dioxide, hydrogen sulphide and benzene measurement capability. Low risk downstream analytic technology solutions are also contributing to operational efficiency objectives, using technology such as the Siemens Calomat 62 for hydrogen, Ultramat 23 for carbon monoxide, carbon dioxide and methane, and MicroSAM GC for H2,

CO, CO2 & CH4 MEASUREMENT Safety is of paramount importance on all applications where a combustible gas is present. In-situ, fast acting oxygen safety standard solutions ,such as the Siemens Sitrans SL Single Channel Oxygen Laser and the LDS6 Multi-Channel Oxygen Laser, can offer protection at the hot, dirty end of the process.

THE FUTURE In the not-too-distant future, up-scaled syngas production in large quantities will not require burning within an engine or turbine to produce electricity. It will be increasingly common for syngas to be further upgraded for use as a liquid fuel, within a fuel cell, as a chemical feedstock, or for use within the gas grid. Syngas production is here to stay as a renewable and sustainable fuel source that is helping to alleviate significant volumes of waste going to landfill. Its production can be truly optimised through essential process analytic technology to provide the correct level of accurate measurement to ensure syngas production takes place within a highly efficient and safe operating environment.

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves

COMPACT PUMPS FOR GENTLE PUMPING OF SENSITIVE INGREDIENTS When you need to transfer products and ingredients with suspended solids and particles such as those occurring in the food, brewing, beverage and pharmaceutical industries, the CSF range of progressive cavity pumps is the ideal solution. Available in the UK through liquids handling specialists PUMP ENGINEERING, the CSF range includes the eccentric screw, positive displacement MAE series of pumps. CSF MAE progressive cavity self-priming pumps are extremely versatile and ideally suited to transferring low viscosity products like soups or sauces, high viscosity products such as jams, creams, pastes and pie filling or delicate ingredients such as fruits and vegetables, with a gentle pumping action which does not damage sensitive ingredients. The positive displacement pumping action from the rotor and stator arrangement deliversa consistent flow, without the need for pulsation dampeners or non-return valves. The MAE Series is designed as a more compact option with the pump directly coupled to the drive which results in a smaller footprint. When used in conjunction with a variable speed drive MAE pumps can be used for dosing or proportioning applications and where applications involve high viscosity products the pumps can be fitted with a hopper or wide throat inlet. All wetted parts are manufactured from polished or satin AISI 316L stainless steel and the pump’s tie-rod construction allows for quick and simple inspection, cleaning and maintenance. Stators are available in white rubber for food use or other elastomers to suit the application. MAE Series pumps are available with a single mechanical seal as standard, with double seals or packed glands if required. For more information contact Pump Engineering, Tel: 01903 730900 / E-mail: sales@pumpeng.co.uk / Web: www.pumpeng.co.uk

WEIGHING HBM LIGHTENS THE LOAD WITH NEW DYNAMIC TECHNOLOGY! Introducing the very latest in weighing technology, HBM – market leader in the field of test and measurement – is pleased to announce the arrival of its new PAD series of digital transducer electronics. Designed to meet the demands placed on weighing components involved in dynamic filling and metering applications, the new digital PAD series from HBM accurately digitalises signals of analogue load cells or force transducers, even under the harshest of conditions. The PAD series offers integrated measurement signal conditioning, including a selectable or automatic filter and two integrated digital I/O interfaces. Depending on the need, the new PAD series from HBM can also be configured via RS485 or CANOpen interfaces, which allows for analysis and remote access in networks. Depending on individual customer requirements, variants are also available with a prewired sensor connection cable (optionally as an aseptic version) or a plug/ plug variant, ensuring the greatest possible flexibility for load cells or force transducers. Housed in a welded casing and hermetically encapsulated, the robust PAD series reaches an IP rating of up to IP68/IP69K, making it suitable for a wide range of demanding process applications with sensors based on strain gauge technology. The new PAD series from HBM is OIML (International Organisation of Legal Metrology) approved and has been tested and evaluated to ensure that it meets all relevant standards and requirements required for weighing equipment, making it suitable for use in legal for trade applications. For more information, please contact HBM on Tel: +44 (0) 208 515 6000 or visit www.hbm.com

PROCESS INDUSTRY INFORMER January - February 2016

TANK CLEANING AUTOMATED STORM TANK CLEANING SYSTEM HELPS MEET THE CHALLENGE OF INCREASING FLOOD EVENTS

Evidence seems to be confirming that climate change is increasing the frequency of storm events along with higher levels of rainfall, as seen in recent months in the UK. As a consequence of this overfill storm tanks have been under severe pressure to cope with higher volumes of water and therefore it is has become increasingly important to keep these tanks free from debris, especially when significant rainfall exacerbates the problem. Poorly cleaned tanks can increase the risk of pump failure which can result in flooding. Typically, storm overfill tanks are cleaned manually where someone with a pressure washer enters the tank to perform regular cleaning as part of an ongoing maintenance regime. However, this is a labour intensive process and also raises issues regarding health and safety. A few years ago Spray Nozzle specialists BETE Ltd developed an automated storm tank and screen cleaning system incorporating theirHydroWhirl Storm Blaster which has been successfully deployed at multiple sites with 3 of the UK’s major water companies. The Storm Blaster is helping these companies meet their Environment Agency targets for clean tanks and reducing odour pollution. The Storm Tank Blaster can be configured to deliver high-impact cleaning to between 80º and 180º downward spray pattern. This, and the combination of its twin head, 8 nozzle design, results in powerful cleaning to storm tanks up to 20 metres in diameter with a cleaning cycle of under 10 minutes. The 4 nozzle variant can clean tanks up to 30 metres in diameter with cycle times as low as 15 minutes while the standard 2 nozzle model can clean even larger tanks, all be it with an increased cleaning time of about 30 minutes. Over time the system has been improved and enhanced which means that the standard product features have been increased providing users with important additional benefits. For example, a modification now deflects all drive water downwards into the tank to prevent any up spray. This improvement allays any concerns regarding open tank cleaning applications where some fluids may become aerosolised bringing the potential of pathogen risks. There is also a new 170º down option, again an improvement for open tank cleaning as the original 180º down models were sometimes found to skim some fluid over the top of the tank at the high point of their cycle. Sealed gear boxes are now fitted as standard which eliminates the potential for them becoming clogged, even though supposedly potable water was used. Non-sealed machines will run fine with a clean water supply but practical experience has revealed that in the reality of the storm tank environment, even potable water supplies may become contaminated with debris or silt which can result in machines becoming jammed. Therefore the solution is to only fit a sealed gearbox which provides users with the assurance that the system is designed to handle a high particle content. Further details on the HydroWhirl Storm Blaster are available from: Ivan Zytynski, The Spray Nozzle People (BETE Ltd), Tel: +44 (0) 1273 400 092 Email: Ivan@bete.co.uk

NEWS

JAN / FEB 2016

BPMA CELEBRATES 75TH ANNIVERSARY WITH GALA DINNER

his year the BPMA achieves an impressive milestone – three quarters of a century serving the British pump industry. From its humble beginnings back in 1941, whilst the UK toiled with the inherent difficulties of the second Word War, through the numerous economic peaks and troughs that have inevitably followed, and against an ever changing legislative landscape, the BPMA has been a constant source of support, guidance and information. To celebrate 75 years of unbroken service to both its members and the wider pump industry, the BPMA will be staging a special 75th Anniversary Gala Dinner. Held at the impressive De Vere Heythrop Park Resort in Oxfordshire, on

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Thursday 6th October, the event promises to be the highlight of its year-long celebratory activities. Heythrop Park boasts a unique and luxurious venue set in 440 acres of stunning Oxfordshire Countryside. Dating back to 1710 this quintessential English country estate seamlessly combines elegance with style. Located on the edge of the Cotswolds, with Oxford on the doorstep, it is also close to Blenheim Palace and the picturesque Cotswold villages of Burford & Chipping Norton. The Resort also offers a championship 18-hole golf course, superb health club facilities, and exceptional dining. A glittering champagne reception, held in the main hall and accompanied by live music, will be followed by a stunning 4-course dinner with fine wine, and further musical entertainment direct from London’s West End. More music and dancing courtesy of the Swinging Little Big Band, will ensure a great time is had by all. BPMA President, and MD at Grundfos Pumps, Peter Reynolds, said of this

anniversary year: “Being elected as President of the BPMA is a great honour and one which has been heightened by the added good fortune of my term in office coinciding with its 75th Anniversary. We have a number of activities planned throughout the year, all of which will highlight this impressive milestone, but the culmination will surely be our special 75th Anniversary Dinner Dance. I very much look forward to hosting the event and to welcoming friends and colleagues, old and new, to what we believe will be a fitting tribute to the past endeavours of our industry Association. It will also serve to herald the next 75 years of BPMA service”. BPMA members, along with their clients, partners, friends and colleagues are all invited to attend this wonderful night of celebration. Further information and booking details will be available shortly, but in the meantime, and with just 250 tickets available, be sure to reserve your place soon, by emailing hannah@ touchwavemedia.co.uk.

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UTILITY WEEK LIVE ARE DELIGHTED TO ANNOUNCE THE BRITISH PUMP MANUFACTURERS’ ASSOCIATION AS AN ODDICIAL UTILITY WEEK LIVE 2016 SHOW PARTNER & THE OFFICIAL TRADE ASSOCIATION PARTNER FOR UTILITY WEEK LIVE’S INNOVATIVE THE PUMP STATION SHOW FEATURE

2016 is a big year in the world of pumps as water companies take responsibility for thousands of pumping station across the UK and the industry continues to prepare for the opening up of the non-domestic water market – the biggest change to our industry since privatisation. So it’s the perfect time to launch The Pumping Station in association with the BPMA, bringing clarity to the industry, and giving Britain’s water companies a clear understanding of the latest innovations and solutions currently out there or about to launch’ Ellen Bennett, Content Director, Water & WastewaterTreatment, WET News, Utility Week, and Utility Week Live 2016. Having enjoyed a good relationship with IWEX in the past, the BPMA is delighted to be extending its support and participation to the new Utility Week Live, and specifically its Pumping Station feature. This event coincides with our 75th Anniversary, and as part of the year-long celebrations, our attendance provides an excellent opportunity to showcase our many endeavours on behalf of the UK pump industry’ Steve Schofield, British Pump Manufacturers’ AssociationThe Pumping Station 2016, in association with the British Pump Manufacturers’ Association.

BPMA LAUNCHES NEW WEBSITE British Pump Manufacturers Association is delighted to announce the launch of its new website - www.bpma.org.uk Designed ‘from the ground up’, the new site has undergone much more than a cosmetic facelift, it has been configured to be more user-friendly with many new features being added, as well as a major overhaul of existing features. Members will enjoy easier access to detailed technical information via the site, and through the new Members List, which now includes company logos, they will have greater brand promotion and improved access to their own websites. The ‘pump search’ facility, which from an end-users’ perspective has always been a significant and acutely useful feature, is now far easier to navigate. The adoption of a simple drop down menu enables an end user to readily find who, within the BPMA membership, makes a certain type of product. A unique service offering, this feature which will continue to help engineers across industry undertake their pump selection tasks, in a quick and easy fashion. Steve Schofield, Director and CEO at BPMA commented, “Having been one of the first trade associations in the country to have a dedicated website, we have been mindful for some time that an update of our online presence was overdue. But we have been careful to ensure that not only does the new site utilise some of the very latest website protocols, it remains true to its core objectives, which is to provide useful, relevant and accurate information for our Members, their customers and other interested parties. We hope you will enjoy visiting and using our new site and if you have any questions or ideas for improvement we would welcome your feedback”.

THE PUMPING STATION 2016, IN ASSOCIATION WITH THE BRITISH PUMP MANUFACTURERS’ ASSOCIATION, INCLUDES:

• The Pumping Station workshops and product showcases at Utility Week Live 2016 (17-18 May) • Branded content in the three supporting media brands (Utility Week, Water & Wastewater Treatment, and WET News) • A special 16-page (approx) pumps and valves supplement distributed across the industry BPMA members can claim a number of exclusive discounts, designed to help you cost-effectively market your pump and valve solutions to Britain’s water and sewerage companies.

SAVE ON YOUR EXHIBITION STAND

Featuring technical pitches, product demonstrations, and live content on pumps and pumping, this is a chance to place yourself centre stage as the industry gathers to discuss all things pumping and source new suppliers. Utility Week Live 2016 takes place May 17-18 at the NEC Birmingham. All BMPA members qualify for an exclusive £20 per square metre discount when exhibiting in The Pumping Station at Utility Week Live 2016.

THE PUMPING STATION’S PUMPS AND VALVES SUPPLEMENT SPECIAL OFFERS

A comprehensive guide to pumps and valves, aimed at purchasers, specifiers and operators. Containing project case studies, issues-led features and industry opinion plus Water and Wastewater Treatment’s popular annual Pump File compendium. Publishing April 2016, and distributed industry-wide through Utility Week Magazine, Water & Wastewater Treatment Magazine, and WET News Magazine. All BMPA members will qualify for exclusive Pumps and Valves Supplement discounts (tbc).

To claim your reduced rate exhibition stand, please contact: Rachael Lyon, Sales Director, Utility Week Live 2016 17-18 May, NEC Birmingham Tel: +44 (0)1342 332097 Mobile: +44 (0)7968 301370 E-mail: rachael.lyon@fav-house.com Faversham House Ltd | Windsor Court | Wood Street | East Grinstead | West Sussex | RH19 1UZ | 2

THE 2016 BPMA GOLF DAY WILL BE HELD AT THE WORLD CLASS Vale Resort Vale of Glamorgan on Thursday 19th May 2016

Tea, Coffee & Bacon Rolls at Reception 18 Hole Team Competition Wales National Course - Buggies Individual Prizes Prize Giving Dinner Overnight Accommodation Breakfast on Departure

Only £199 Per Player + VAT Contact s.smith@bpma.org.uk for a booking form

BUY WITH CONFIDENCE FROM A BPMA MEMBER

PMA has recently adopted a “BUY WITH CONFIDENCE FROM A BPMA MEMBER” ethos based on the BPMA Code of Conduct for members below ----BPMA seeks to represent Members that demonstrate the highest degree of professionalism, expertise and ethical standards in every aspect of their operations, including the safety, reliability, quality and support of their products and the competence of their employees and representatives. BPMA therefore expects each of its Members to abide by the BPMA Code of Conduct which is designed to assure users, specifiers and purchasers of pumping equipment that they can “BUY WITH CONFIDENCE” from a BPMA Member.

Equipment supplied by Members will be manufactured to comply with regulations and restrictions affecting the use of certain materials in its construction therefore minimising the environmental effect.

Members will make relevant operating manuals available. Copies of manuals will be held for the expected lifetime of the equipment.

INTELLECTUAL PROPERTY

Members shall respect the basic human rights of their employees and take responsibility for their health and safety in accordance with current UK requirements.

Members shall recognise and respect ownership of intellectual property and refrain from plagiarism or other abuse of the intellectual property of others. Where a Member has not contributed directly to the origination of design, system or process that it subsequently offers for sale, it shall seek assurance that the intellectual property belongs to the supplier or that the supplier is licensed to re-sell the design, system or process.

INSTALLATION

SUPPORTING BPMA ARTICLES OF ASSOCIATION AND Members will, to be best of their ability and within the limit of their control, ensure that the equipment they POLICIES Each Member commits to respect the requirements of the BPMA Articles of Association and Policies that are agreed from time to time. In particular each Member agrees to respect in Association meetings and other activities the requirements of Competition Law and limit discussions and actions so as to comply with all such laws and regulations.

PRODUCTS AND TECHNICAL STANDARDS

Each Member shall ensure that the products it offers for sale globally are supplied, manufactured or manufactured under licence to conform to any statutory requirements and standards as may be mandated by local law.

CE MARKING

All equipment manufactured or supplied by Members of the Association that is being placed onto the European market will be CE marked as required to confirm that it complies with EU law and that is ‘fit for purpose’ and safe. Members should be able to produce technical files to support the CE marking within 10 days of being requested

PRODUCT PERFORMANCE

A Member shall be able to demonstrate the published features of any product that it supplies and substantiate any benchmarks, performance characteristics, serviceability levels or other criteria to which it lays claim.

QUALITY ASSURANCE

Members will be certified to or aspiring to ISO 9001/2 or will demonstrate an adequate in-house quality assurance scheme exists.

ENERGY & ENVIRONMENT

Members shall act in accordance with the relevant standards on environmental protection and seek to continually reduce their impact on the environment.

supply is installed to the standards currently in force.

AFTER SALES SUPPORT

Members will be able to advise operators on training, maintenance and support, for all their products whether the support is supplied direct or via a third party.

SERVICE AND MAINTENANCE

Each Member will ensure that sales service, repair and maintenance is available through:•Their own network of service engineers •Nominated service agents •Providing details of other agents

SPARE PARTS

Members will ensure that replacement parts are available for the anticipated working life of the equipment supplied.

REPRESENTATIVES

A Member shall ensure that its employees, contractors and/or agents are adequately trained, qualified and exercise their responsibilities with appropriate skill, care and professionalism.

SALES ASSURANCE

All claimed performance criteria relating to a product, whether orally or in writing, shall accurately reflect the product’s features and performance characteristics. Members will, where required and practicable, provide pre-sales support and services to ensure the appropriate specification of the equipment for the required purpose. The level of associated support will be evaluated and in line with customer needs. Member’s sales staff and technical advisers will receive full training.

OPERATING INSTRUCTIONS

EMPLOYEES

CUSTOMER COMPLAINTS

Any business purchasing from a BPMA Member or their nominated supplier who subsequently has a grievance or complaint should, in the first instance, make representation to the Member in writing. The Member shall respond promptly in writing to all complaints lodged by a customer. The Member will use its best efforts to resolve all such complaints in an equitable and timely manner. The Member will maintain a record of such complaints. Should the customer not receive a satisfactory response BPMA will provide a complaint resolution service as follows, so long as the Association Director has received a written letter, which details the following:-

SUPPLIER INFORMATION

•Date equipment purchased and from whom •Name of sales contact •Installation date and details of installer

PRODUCT INFORMATION

•Manufacturer and brand of the equipment •Model Number •Serial Number

NATURE OF COMPLAINT

•Full details of the problem BPMA will pass these details to a senior manager of the Member and will request a written response within 14 days of receipt. BPMA will actively seek to find a satisfactory resolution and will respond to the complaint with the outcome of its involvement. BPMA will not be liable for any redress over any failure to resolve the issue and the offer of this service does not affect the statutory rights of the customer.

ACTION ON MEMBERS FAILING TO ADHERE TO THE CODE OF CONDUCT

Members found to be flagrantly ignoring this Code of Conduct or convicted of any offences relating to its content may have their membership rescinded at the discretion of the BPMA Council A Member which has been suspended or excluded from membership by a BPMA Council decision has the right to appeal against the decision and make a direct representation to the Council.

NEW COURSE FROM BPMA

City & Guilds BPMA Competency Electrical Course (3 Day) 15-17 March 2016 COSTS: £420.00 PLUS VAT PER PERSON, WHICH INCLUDES REFRESHMENTS AND CITY & GUILDS CERTIFICATE (PLACES ARE LIMITED - BOOKING NOW)

BPMA CERTIFIED PUMP SYSTEM AUDITOR RESIDENTIAL COURSE 25-28 APRIL 2016

Venue: Rezidor Park Inn Hotel West Bromwich, West Midlands (J1, M5)

It is usual in many industries to find that companies have radically streamlined their maintenance and technical workforce departments. This puts pressure on company managers to use nonelectrical personnel for routine electrical duties. This three day course is specifically designed to assist non-electrical employees to prepare themselves for cross trade working, and to help companies comply with the requirements of current legislation regarding the use of such people for minor electrical tasks.

COURSE OBJECTIVES:

After completing the course, students should be able to: • Recognise safe working practices (related to electricity in the workplace) • Work within the requirements of current electrical legislation (relating to topics covered) • Understand the fundamental principles of electrical energy • Perform routine electrical tasks at a basic level • Perform safe isolation of electrical circuits • Enhance their workplace skills • Relate to electrical circuit diagrams

WHO SHOULD ATTEND:

The course is primarily aimed at mechanical or un-skilled tradespersons that are preparing themselves for work upon electrical systems. The course may be of great benefit to companies that intend to employ non-electrical personnel to perform routine electrical duties, such as, lamp replacement or portable appliance testing etc.

TOPICS COVERED:

• Health and Safety legislation (related to electricity in the workplace) • Basic electrical principles • Electrical power and units of measurement • Safe isolation of electrical circuits • Safe working practices • Electrical test instrumentation • Conventional circuit layout • Basic first aid (related to electrical hazards) • Electrical diagrams • Cable and wiring system

PREREQUISITES:

Basic numerical and literacy skills are required.

IF YOU WOULD LIKE TO BOOK PLACES, PLEASE E-MAIL S.SMITH@BPMA.ORG.UK

JOIN BPMA To submit a membership application for consideration by BPMA Council please ensure you have read the BPMA Memorandum and Articles of Association and then download the relevant application form. There are two categories of BPMA membership: MEMBERS Membership of the Association is available to manufacturers, contractors, distributors, importers, repairers of industrial pumps including wholly owned subsidiaries of foreign companies providing they have an investment in buildings and plant in the UK and Republic of Ireland. Membership is also available to suppliers to pump companies such as manufacturers of bearings, seals, couplings, motors, components, software (pump specific) etc. To download a Member Application Form please type the link below into your browser: http://goo.gl/z9VCkb ASSOCIATE MEMBERS Associate Membership is available to companies and individuals who work with or supply services to BPMA Members. Eg. Industry Journals, Technology Centres or Consultants. Please type the link below to download a Associate Member Application Form http://goo.gl/H402ax NOTE: Please don’t forget to complete the form, not forgetting to sign it and then return it by post to :Mr Steve Smith, BPMA, National Metalforming Centre, 47 Birmingham Road,West Bromwich, West Midlands B70 6PY or e-mail s.smith@bpma.org.uk

BPMA - REPRESENTING THE INTERESTS OF THE UK PUMPS & SYSTEMS MARKET, WORLDWIDE 4

The Energy Savings Opportunity Scheme (ESOS) Regulations 2014 came into force on 17 July 2014 and are a mandatory energy assessment and energy saving identification scheme for large undertakings (and their corporate groups). The scheme applies throughout the UK. ESOS Energy Audits have the potential to increase businesses profitability and competitiveness by identifying costeffective savings which, if implemented, will improve energy efficiency. The scheme is estimated to lead to £1.6bn net benefits to the UK, with the majority of these being directly felt by businesses as a result of energy savings. ESOS is the UK Government’s approach to transposition of Article 8(4) of the EU Energy Efficiency Directive, which requires all large (non-SME) enterprises to undertake energy audits by 5 December 2015 and every 4 years thereafter. Guidance has also been published to help potential participants in the scheme understand their obligations and on page 43 of the full ESOS guidance document you will see that the ISO/14414-Pump System Energy Assessment standard is referenced as an auditing methodology that can be accepted by “Lead Assessors” approved by the Environment Agency. Accordingly it is hoped BPMA CPSA accredited persons (who are trained according to the IS0 14414 standard) will be recommended by Lead Assessors to undertake the pumping system elements of company energy audits. The BPMA Certified Pump System Auditor Scheme (www.bpma-cpsa.co.uk) has established BPMA as THE body to train and certify personnel who undertake “Pumping System Assessments” as referenced in UK Government Energy Strategy documents BPMA are now offering the opportunity to attend a four day residential course culminating in certification and eventual personal ID “Certified Pump System Auditor” status following approved audits.

Our next scheduled course will take place on 25-28 April 2016 Register now by calling 0121 601 6691 or email s.smith@bpma.org.uk Delegate fees £1,500 + VAT (BPMA Members) £1,750 + VAT non-members (incl. 3 nights accommodation (b&b) at the Rezidor Park Inn Hotel)

KSB ANNOUNCE THE APPOINTMENT OF THEIR NEW UK MD DALE CROKER, MANAGING DIRECTOR, KSB LTD Dale Croker has joined pump manufacturer KSB Ltd as managing director. Dale has taken over from Andy Ratcliffe, who held the responsibility for eight years. Mr Croker has been employed within the KSB group for 28 years and has relocated from South Africa to the UK. Dale has over 30 years experience in the pumping industry.

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

i-ALERT2 EQUIPMENT HEALTH MONITOR The i- ALERT2 Equipment Health Monitor is a Bluetooth Smart-enabled machine health monitor that allows customers to identify potential equipment problems before they become costly failures. ITT’s i-ALERT2 Equipment Health Monitor is an inexpensive Bluetooth Smart-enabled equipment health monitor that allows customers to identify potential problems before the machines become costly failures. It tracks vibration, temperature and run-time hours and wirelessly syncs the data with a smartphone or tablet through the i-ALERT2 mobile app. The i-ALERT2 condition monitor combines the latest in Bluetooth low-energy and sensor technologies commonly used in the newest consumer health and fitness trackers and smart watches. The i-ALERT2 device is the first condition monitor to successfully integrate these technologies into an industrial package in a small footprint [2.24 in. (L) by 1.54 in. (W) by 1.04 in. (H)] which is half the size of a credit card. It is engineered and rated for use in a wide range of industrial environments. It is chemical resistant, rated for extreme temperatures (-40 to 183 F) and is rated to operate in environments with explosive gases, dust and fibers. With 24/7 monitoring, a wireless range of up to 100 ft and the ability to scan multiple i-ALERT2 devices at once with a mobile device, customers will be able to quickly and safely inspect multiple pieces of equipment and be alerted of potential problems before they become critical failures. Through the i-ALERT2 mobile app, customers can now provides them with the data necessary to make informed decisions. Customers can now spend less time collecting data and more time solving problems. Buy a Goulds ANSI and ISO process pump and these are supplied with i-Alert fitted as standard and a 5 year warranty - you’d have to ask yourself, why not? For more information contact ITT Goulds Pumps, Tel: 01297 630473 Email: www.gouldspumps.com/Contact-Us Web: www.gouldspumps.com Web: www.ittproservices.com

WATER INDUSTRY RECOGNISES THE POTENTIAL OF FLOMATE FROM STUART TURNER Stuart Turner were rewarded at the 2015 Water Innovation Awards when the industry recognised the ingenuity behind their Flomate range agreeing that ‘Flomate Mains Boost Pumps can improve water pressure in problematic areas’. The compact Flomate Mains Boost pump can be connected directly to the incoming mains supply, eliminating the need for a cold water break tank and at times of low mains water pressure, Flomate will provide an additional 1.5 bar to any existing mains pressure at a maximum flow rate of 12 litres/minute, meeting the requirements of most combination boilers. Flomate will start automatically when a flow of 0.6 litres or more exists and features a built in bypass, which means should mains pressure exceed 1.5 bar the performance will not be restricted. Flomate Mains Boost Extra pumps are designed with an additional pressurised water vessel. By supplementing the water pressure boosting performance of the original Flomate pump with the supply from the pressurised water vessel, ‘Flomate mains boost extra’ pumps can deliver up to 30 litres/minute at 3.0 bar pressure to provide a consistent flow of water and increased water pressure, boosting multiple outlets simultaneously such as taps and showers. Flomate provides a patented and simple solution to the problem of low or intermittent mains water pressure and are suitable for a variety of applications. The range is WRAS approved, complies with UK water regulations and has been used by water authorities in meeting the requirements of DG2: Inadequate pressure indicators set by OFWAT. Supplied with a 3 year guarantee, they provide a fully assembled and tested solution for any sized property. For further information, visit www.stuart-turner.co.uk or contact: info@stpumps.co.uk

The path to a greener future... Efficiency l Strength l Reliability Since January 2015, EU MEPS have stipulated that any new motors on the market ranging from 7.5 kW to 375 kW power output have to meet the IE3 efficiency standard or IE2 efficiency standard if used with an inverter drive. Our inverter drives will work with new and existing motors to help you reduce energy consumption and meet legislation when used with an IE2 motor.

For a greener future www.weg.net Visit us at the Pump Centre Conference 12th May

WEG also offer a complete range of IE3 and IE4 energy efficient motors both for safe area and hazardous area applications. Watt Drive high performance gearboxes are built to withstand the toughest industrial applications meeting the demands for operation across different industries. Individually, our gearboxes, drives and motors are amongst the most energy efficient available. Together they give you unbeatable levels of reliability and performance.

MOBILE APP POINTS TO POTENTIAL ENERGY SAVINGS OF PUMPS Dipl.-Ing. Christoph P. Pauly - KSB Aktiengesellschaft, Frankenthal, Germany In many process engineering applications, pump systems form the backbone of production (Figure 1) and greatly impact the economic efficiency of the entire system. Pumps consume a large amount of the electrical energy used in industry. Depending on the scope of analysis, the potential savings on energy in current industrial systems range between 30 percent and 40 percent. In concrete terms, the German Energy Agency (dena) has calculated that pump system operators in Germany could save as much as 14 billion kWh per year. That would translate into annual savings of 1.12 billion Euros for the operators themselves and a drop of 7.7 million tonnes in CO2 emissions.

Figure 1: It is particularly in existing plants that much potential for reducing pump operating costs can still be identified.

There are many reasons why much too much energy is still being wasted in connection with pump operation. In refineries and process engineering plants, maximum priority is attached to productivity and fast restarting following repairs. Frequently, when piping systems have been modified for production-related reasons, the installed pump sizes are not subsequently adjusted to match. The reason why far too much energy than necessary is sometimes used has to do with choosing the wrong valves or valves that are not dimensioned correctly, installing inadequate pipe radii or undersized pipe cross-sections. Aggravating the situation is the fact that many pumps are selected with a 10 or 15 percent “safety margin” – just to be sure. Another widespread problem is that pumps are often left to run far off of their originally envisaged operating point. It is relatively easy to select a hydraulically optimal pump for new installations. As long as the requirements to be met by the pump are known, a very energy-efficient pump set can be chosen with great accuracy by way of pump selection programs like those that most manufacturers have on hand for their customers. It is, of course, essential that a large number of closely spaced pump sizes be available to the user, and that the impeller diameters be trimmed to match the required operating point. Safety margins should be avoided. Even efficient pumps cannot run economically if they are used in the wrong operating mode.

INTRODUCTION OF APTITUDE... The first step in identifying energy saving potential is to ascertain the pump’s present operating point and mode of

operation. In the past, this was almost impossible without using additional measuring equipment. Pump manufacturer KSB has developed the Sonolyzer app to help plant operators. This is a free app for smart phones or tablets that can analyse potential savings in a fast and simple measurement process and can even be used in potentially explosive atmospheres if the smart phone or tablet PC has appropriate protection. The advantage is that it can determine within 20 seconds whether or not a pump is working under part load. Use of the app is not restricted to KSB’s products – it works just as well on products of other makes. The app is designed to save valuable time by calculating operating points very simply and its operation is intuitive. After downloading the app, the user selects the relevant pump type and enters the name plate data of the pump and connected asynchronous motor. It is also possible to enter a designation for the measurement and save it with a photograph of the pump in the data record. The measurement is then started and the smart phone is held next to the fan hood of the motor for 20 seconds (Figure 2). The motor fan’s noise is recorded and the noise spectrum is transferred to the KSB Cloud for analysis via a secure connection. Based on the maximum amplitude of the recorded spectrum, the algorithm now calculates the number of blades of the fan impeller and the blade passing frequency and derives from this information the shaft speed of the machine. Using the nominal data of the asynchronous motor entered by the user and a slip model, the algorithm then calculates the input power on the basis of the shaft speed. It can estimate the pump flow rate from the input power calculation. By correlating the performance data entered by the user with the hydraulic systems database developed by the manufacturer, the app can conclude whether the pump is operating at part load. The applied algorithm is patented and has already been in use for a number of years in thousands of practical applications as part of the PumpMeter product.

Figure 2: The KSB Sonolyzer mobile app allows users to analyse the efficiency of fixed speed pumps with asynchronous motors in just 20 seconds.

The analysis result is displayed on the mobile phone or tablet (Figure 3). If it is established that the pump is working under part load, then there is potential for energy efficiency optimisation. Using this app, it is possible to identify pumps with optimisation potential simply and efficiently during a site survey or plant walkdown by service staff. Identification of potential on the basis of the pump’s age, an inconvenient paper-

based process that does not provide meaningful results, is no longer necessary, while checks using the new app can be included in the daily work schedule. Furthermore, by repeating the analysis of a pump at different times, it is possible to eliminate the risk that the operating conditions prevailing during one particular measurement have falsified results. Identification of potential, however, is only the first step in analysing pumps for the purpose of optimising energy efficiency and reducing Figure 3: Screenshot of the KSB operating costs. It is Sonolyzer measuring a pump not only important to operating under part load. assess the individual machine, but to evaluate the system as a whole. In the case of pumps, this means that valves and piping must also be taken into account. Although an assessment of individual components can identify potential savings of up to 10 percent, an evaluation of the whole system can achieve savings of up to 60 percent. While identification of potential savings is important, it is also vital to focus on the cost effectiveness of optimisation measures. Finding ways to reduce the operating costs of pumps and other rotating equipment has been made simple with KSB Sonolyzer. For the actual implementation of energy saving measures, KSB is offering the FluidFuture energy efficiency concept, a structured system of suitable products, equipment and services.

The following options are available, depending on the load profile: • Operate based on actual demand (variable speed operation) • Reduce the impeller diameter • Use smaller pump sizes • Install high-efficiency motors • Optimise piping FluidFuture allows operators and service staff to access the wealth of experience garnered by the pump manufacturer over many decades. Modern centrifugal pumps have already achieved a level of efficiency that could hardly be further improved. When they appear to be consuming more energy than necessary, it is very probably due to the fact that people pay too little attention to pumps that just keep running. No pump can operate more economically than its surrounding system allows.

IAN MAVERS JOINS SPP PUMPS TO HEAD UP ENGINEERING SERVICES DIVISION IN SCOTLAND SPP Pumps has appointed Ian Mavers as its new Business Development Manager, Engineering Services Division for Scotland. Ian brings his extensive experience, built up through over 40 years of working in the industry, to the role. “SPP Pumps is a growing company and I am joining it at an exciting time for its Engineering Services Division,” he said. “I’m looking forward to working with the team - there is such a deep pool of knowledge and expertise to share between us and that can only be good for our target sectors in Scotland. It’s also significant that as a company SPP is expanding at a time when many others are cancelling projects.” SPP Pumps Engineering Services has a network of service centres strategically located across the UK and 24/7 response for its field service team. All service centres are ISO9001 approved and the company deals with maintenance, refurbishment and repair of all kinds of rotating equipment as well as valve repair and refurbishment. Under Ian Mavers, the Engineering Services Division in Scotland will continue to focus on the key market sectors of Oil & Gas, Power and Water. He concludes: “I think the SPP Pumps Engineering team is acknowledged as the best in the industry - and who doesn’t want to join the best? It is most certainly an exciting step in my career.” More information about SPP Pumps can be found by visiting the company’s website at www.spppumps.com.

GRUNDFOS MAKES THE SHORTLIST Grundfos Pumps are proud that they have been nominated in multiple categories in two separate prestigious industry awards – the H&V Awards and PIA (pump industry awards). The Grundfos TPE2/TPE3 families of vertical in-line pumps are shortlisted within both awards. In the PIA awards, they have an opportunity to win the Technical Innovation of the Year – in the products category. The new Alder Hey in the Park hospital features as a finalist in the Technical Innovation of the Year that relates to projects and one of our employees Ryan Pearson, is a finalist in the Engineer of the Year category. All the winners will be announced at the PIA awards ceremony on 10th March. In the H&V News Awards Grundfos have achieved shortlisted finalist status in two categories – Training Initiative of the Year for the Grundfos Ecademy – a free digital training tool and in the M&E Building Services Product of the Year with the Grundfos TPE2/TPE3. The winners are due to be announced at the awards dinner that is being held on 21st April. Awards are an important measurement as they allow you to view yourself against peer organisations as well as being an important way to showcase interesting products, projects and solutions to a wide audience. We will publish the results on www.grundfos. co.uk For more information contact Grundfos Pumps Ltd, Leighton Buzzard,Beds. Tel: 01525 850000 Email: grundfosuk@grundfos.com / Web: www.grundfos.co.uk

AN OVERVIEW OF

DOSING, METERING & INJECTING PUMPS by Richard Charlton and Malcolm Walker, AxFlow - London The task of carrying out an overview of dosing and metering pump technology is one that is not straightforward due to the vast number of applications and the resultant diversity of pump types employed for such purposes. Even the definition of what’s being discussed is confused between industries - one man’s dosing is another’s injecting and someone’s metering is another’s dosing. This diversity isn’t surprising when one considers the number of industries involved including toiletries, detergents, pharmaceuticals, water and waste treatment, food and beverages, power generation, chemical processing, petrochemicals and oil and gas recovery. Liquids can be anything from fragrances and colours for toiletries and food, acids and alkaline solutions for chemical processes and water treatment, hydrocarbon condensate from crude oil extraction to liquid CO2 in cryogenic duties.

CONSIDERATIONS

The starting point, as with any pump application, is to identify the flow rate, the differential pressure and, as it’s a dosing application, the level of accuracy. Having established these basic facts the fluid’s characteristics, such as viscosity, solids content, abrasiveness, corrosiveness and toxicity are required. This information will tell you the scale of the job and in which general pump direction you are heading. Higher pressures, levels of accuracy and lower flows and viscous liquids will veer towards gear, piston, plunger and diaphragm metering pumps while lower pressures, levels of accuracy and higher flows will lead you towards peristaltic, air operated diaphragm (AOD), vane or even centrifugal pumps. Next are the specific requirements of the operating environment and industry specific considerations such as ATEX, API or the various levels of hygienic and sanitary design required by the food and pharmaceutical industries. These standards can have quite an impact on the choice of pump particularly if you don’t have access to a large product range. Engineers often settle for second best as their options are limited by what’s offered to them with ATEX certification, EHEDG approval or conformity to API 675 etc. Lastly, there is the method by which the pump will be controlled – will it be a simple manual adjustment, timer, variable speed drive, 4-20 mA signal or a process control system such as PROFIBUS.

chemical processing for “injecting” and the food industry for adding colouring and cleaning agents. When it comes to light, non-lubricating fluids such as alcohols and solvents then vane pumps are very often the best solution as they are self-lubricating and can (with the correct design) cope with low NPSH. At AxFlow we have had particular success with vane pumps in biodiesel processes for blending methanol and introducing scale and corrosion inhibitors inhibitors. Gear pumps can be used where space, a smooth flow, or noise is an issue such as medical and pharmaceutical applications. They can be accurately controlled and made from chemically resistant materials to deliver up to 10 m3/hr at pressures of 20 bar. But, as their gears wear their performance alters and changes in pressure and fluid viscosity will affect the volume they deliver. Thick liquids and those that need a gentle pumping action as found in the food industry are often best dosed with external circumferential piston (ECP) pumps. Not to be confused with their less accurate cousin the rotary lobe pump, ECP pumps offer a low

TYPES OF PUMPS

Dosing and injecting So what makes a pump a dosing pump and not a metering pump? At AxFlow our definition is quite simple – a metering pump is one that always delivers a controlled volume irrespective of the fluid’s properties and the pressure it’s pumping against. So, let’s start with pumps that don’t do this - which is most of them including many that are regularly described as “metering” pumps. If the flow is over 1 m3/hr, at relatively low delivery pressures and with a liquid that’s not too viscous or heavy, then a centrifugal pump can be considered. With a VSD and a bit of effort, a predictable, controllable flow can be achieved with a centrifugal pump, and with flows measured in cubic meters they often represent the most cost effective solution. A big advantage is that with so many to choose from, considerations such as chemical compatibility, ATEX and hygienic requirements can be catered for. At flows of below 10 m3/hr, and where an accuracy of 3% is acceptable, then Air Operated Double Diaphragm (AODD) pumps are commonly used. They can be easily adjusted, cope with viscous and corrosive liquids, will suck out of a barrel/IBC, can be hygienic, ATEX complaint, are moveable and not excessively expensive. AODD pumps are a popular choice in the water industry for water treatment additives,

shear pumping action and due to the long sealing path, a highly controlled delivery volume to almost that of a true metering pump. They can also handle extremely viscous fluids to over 500,000 cP and offer the very highest of hygienic designs. Another low shear option is that of eccentric rotating disc pumps as they too can be can be hygienic, are self-priming and will run dry. Most importantly eccentric rotating disc pumps will completely clear a line, a particularly useful trait when dosing a finite quantity of liquid, and one that also negates the need for air blasting or pigging to empty a line of unwanted fluid. For high pressure “injection” dosing duties piston pumps are the traditional solution as they are simple, use a well understood principle and can be constructed into multiple chamber designs to suit different requirements. But, despite their precise sounding description of “injection” pumps, like all of the other dosing pump types, their delivery volume will vary as components wear and

when operating against differing back pressures. Lastly, we come to peristaltic pumps, a very common solution for dosing applications as they are simple, easy to regulate, chemically resistant, relatively inexpensive and versatile. They are popular from laboratories and cleaning equipment to medium sized chemical processes that require a range of different chemicals and also for the introduction of thick slurry type additives such as lime dosing in the water industry. Despite the fact that peristaltic pumps are commonly described as metering pumps they fail AxFlow’s definition of a metering pump. Unless the delivery flow is closely monitored and the tubes replaced on a regular basis, peristaltic pumps will display quite high variations in delivery volume because of the elongation and hardening of the tube material. Furthermore, like all of the previous pump types, their output too will be affected by the pressure they are working against.

METERING

There are only two common pump types that guarantee a fixed delivery volume over time and against varying back pressures, these being reciprocating diaphragm pumps (that come in two varieties) and plunger pumps. For mild and less-corrosive liquids, the first reciprocating diaphragm pump variant with mechanical diaphragms is favoured by most for metering pressures up to approximately 10 bar and flows of 1,000 l/ hour. They are popular as the flow can be modified by either shortening the stroke or by its frequency, plus they can be arranged in multiple banks of units, can be controlled by all manner of command signal and will clear a line. For higher pressures (up to 400 bar in the case of API models) and higher flow applications, plunger pumps are used. The standard plunger pump head, consisting of a housing, displacement plunger, seal arrangement, pump valves and suction/discharge side connections, is commonly used where high pressures and high flow rates are encountered. The simple design and small number of components allows a low dead volume and high volumetric efficiency. However, plunger pumps don’t offer the containment of a diaphragm pump nor their efficiencies. Consequently hydraulically actuated diaphragm pumps have emerged over the past couple of decades which offer both the containment of the mechanical diaphragm and the pressure capabilities of plunger pump. Hydraulically actuated, double diaphragm pumps will reach pressures of up to 1000 bar with a leak-free operation, can provide a smooth product flow across a wide operating range, including low speeds and will accommodate the widest possible range of duties for all critical pressure processes. They can be constructed from a range of chemically resistant materials and offer excellent containment due to the pressurised hydraulic fluid.

SUMMARY

Do you care if the dosing volume changes over time or as a result of system and environmental factors? If the answer is yes, then you are limited to a very select ban of true metering pumps. If on the other hand your application isn’t so demanding and you are able to periodically monitor the delivery flow to make sure it’s what you want, then possibly a much wider range of options is available to you than is often imagined.

Xylem Water Solutions UK is the name of the newly integrated company and is comprised of many of Xylem’s well-known and trusted brands including Lowara, Flygt, Wedeco, Jabsco and Sanitaire. In addition, Xylem’s service capability for these brands has been enhanced by the acquisition of PIMS earlier this year. Xylem Water Solutions UK is dedicated and focused on superior products, application expertise and aftersales support for customers, across all of our core markets. Contact Xylem Water Solutions UK;Nottingham Head Office: Tel 0115 940 0111 | Email: sales@flygt.co.uk | Website: www.xylemwatersolutions.com/uk Axminster (Lowara): Tel: 01297 630 230 |lowaraukenquiries@xyleminc.com Rental & Service (24/7): Tel: 0845 707 8012|fgb.rental@xyleminc.com

CONDENSATE SORTED WITH GRUNDFOS CONLIFT

You are invited to cast your vote! Launched 16 years ago, the Pump Industry Awards is now widely regarded as THE industry event. Whether it's recognising companies and individuals who go the extra mile or acting as a motivator to encourage more companies to fulﬁll their potential, the core values of the awards have not changed over the years. The judging panel have now announced the 2016 ﬁnalists... to submit your vote visit -

www.pumpindustryawards.com

BOOK YOUR PLACE TODAY!

Gala Aw ards Cerem ony hosted

Mary R y hodes

After D Enterta inner inment with

www.pumpindustryawards.com hannah@touchwavemedia.co.uk ORGANISED BY:

Domin ic Holla nd

Condensate can be a real problem in certain situations, for example in applications that include dehumidifiers, air conditioning systems as well as in terms of modern condensing boilers. At Grundfos we have provided a solution to these issues for many years with our range of Grundfos CONLIFT pre-assembled lifting stations. This family offers 3 models, an entry level CONLIFT1 LS, the CONLIFT1 and CONLIFT2. The CONLIFT1 LS has a few less features, but still offers a range of benefits including easy installation, low noise operation and superior reliability. A big plus for these units is that they are also suitable for connecting to a domestic boiler PRV. This means they are able to handle high temperature (≤90°C) inflows for up to 5 minutes. All models in the CONLIFT range have been tested and confirmed suitable for connection to the discharge from a domestic (<40kW) condensing boiler Pressure Relief Valve (PRV). The motor/pump unit can turn 180o on the tank which increases the flexibility of the installation process, a situation which is enhanced by the four symmetric well-sized inlets that means the unit can be connected from any direction. In addition this compact range can be installed either as floor standing or as wall mounted units. Find out more about the CONLIFT family as well as other exciting new developments from Grundfos by visiting www.grundfos.co.uk the information you need is only a click away.

NEW SERIES OF USER-FRIENDLY & COMPACT VARIABLE SPEED DRIVES FOR LOW-POWER MOTORS WEG, a leading global manufacturer of motor and drive technology, has launched a new cost-effective, reliable and easy-to-use series of compact variable speed drives (VSDs) to enhance energy efficiency across a wide range of applications requiring low motor power. Designed to drive motors with power from 180 W to 4 kW, the CFW300 series is ideal for relatively small machinery such as centrifugal and metering pumps, fans and ventilators, stirrers and mixers, extruders, roller conveyors, cutting machines and rotary filters. “WEG is committed to boosting energy efficiency across a broad range of industrial applications and has launched the CFW300 to meet the needs of those sections of the market where the demand for inverters is growing, even when it comes to relatively small industrial applications,” says Johannes Schwenger, Head of Product Management Low- and Medium-Voltage Drive Systems Europe at WEG. “With the addition of the CFW300 series to our existing range of drives, which include the CFW100 Mini Drives and the CFW500 VSD series,WEG now boasts a comprehensive VSD offering for industrial requirements.” Easy to use and maintain, the CFW300 features an integrated micro PLC and a user-friendly control panel with LCD display. Installation is also easy and quick thanks to plug-and-play extension modules and the drive unit’s fan can be easily removed for maintenance. The CFW300 will initially be available in frame size A for rated power from 180 W to 1.5 kW and frame size B for rated power from 2.2 to 4 kW. It will provide supply voltage flexibility with versions for single-phase and three-phase power. The single-phase version can also be powered directly from a DC supply connected to the DC link, in order to drive three-phase induction motors from a DC power source. For more information on WEG’s energy efficient drive solutions visit or contact Tel: +44 (0) 1527 513800 E-mail: wuk-sales@weg.net Web: www.weg.net

SPP PUMPS CHOSEN FOR WORLD’S BIGGEST REFINERY PROJECT November 2015: SPP Pumps, a leading designer and manufacturer of centrifugal pumps and systems is providing 24 pumps for the largest refinery in the world, under current construction in Jazan, Saudi Arabia. The pumps have been specified by Air Products, one of two joint owners of the giant complex that will supply 75,000 metric tons per day of oxygen and nitrogen to the Saudi Aramco refinery. The other joint owner company is Acwa Holdings. The 12km2 Jazan refinery site will eventually produce 80 million barrels per day of petroleum, 250 million barrels per day of diesel and over one million tonnes per year of other petrochemical products. SPP Pumps has a long relationship with Air Products, dating back to 2001 when the Reading-based pump manufacturer was selected as its preferred global supplier of general service water pumps.

Martin Bagg, Business Manager for Water at SPP is delighted with the contract win: “We’ve been working with Air Products for some years now and so winning this order for such

a highly visible project is testimony to the quality, performance and reliability of our products.” The 24 pumps comprise 12 split case and 12 end suction models, both well established products with an enviable track record for unbeatable performance and low life cost thanks to enhanced reliability and low power consumption. “Value for money is essential for any project,” continues Martin Bagg “but that needs to be married to other key factors such as minimised downtime, which our customer knows we can provide having partnered with us on many previous occasions. At SPP we have built our reputation on optimising efficiency to give our users the very best value in performance and operational energy usage. We prioritise lifetime running costs achieved through our unrivalled engineering expertise and our customers reap the benefits.” For further information on the SPP Pumps portfolio please visit www.spppumps.com or call Tel:0118 932 3123 or E-mail: enquiries@spppumps.com

ABB DELIVERS ITS 10 MILLIONTH VARIABLE SPEED DRIVE

The ten millionth ABB low voltage drive rolled off the production line at ABB’s Beijing factory in November. The tenth millionth drive is going to Wuhan Guide Electric Co., Ltd. in China, a system integrator manufacturing electric control systems for port cranes. “The outstanding direct torque control (DTC) motor control technology and built-in crane control software of ABB’s industrial drives help us to maximize crane performance. For our customers – the ports – ABB industrial drives mean improved safety, high availability, and high total efficiency, resulting in lower energy costs,” says Mr. Li Xiang, CTO of Wuhan Guide Electric Group Co., Ltd. Drive number 10 million is an ACS880 industrial drive, part of ABB’s all-compatible drives portfolio. Compatible with virtually all types of processes, motors, automation systems and users, they are designed to tackle any motor-driven application in any industry, whatever the power range. The innovation behind all-compatibility is the new drive architecture, which simplifies operation, optimizes energy efficiency and helps maximize process output. The ACS880 series consists of single drives, multidrives and drive modules. “We place high demands on our suppliers, especially concerning product quality, reliability and service. ABB drives live up to our requirements, and for ten years now we’ve had a strategic partnership with ABB,” says Mr. Li Xiang. ABB developed its first AC drive in the 1970s, and today they offer the most advanced range of variable speed drives in the world. ABB drives cover a wide power and voltage range, including voltages up to 13.8 kilovolts and power up to 100 megawatts. Using variable speed drives to intelligently control motors increases energy efficiency. Over the 40 years that ABB has been delivering millions of drives to all industries, a huge amount of energy has been saved. The installed base of ABB drives saved 445 terawatt-hours (TWh) in 2014 alone, equivalent to the consumption per year of more than 110 million households in the EU. If that 445 TWh would have been generated by fossil fuel-powered electricity plants, ABB drives reduced CO2 emissions in 2014 by about 370 million metric tons, corresponding to the yearly emissions of more than 90 million cars. For help with any technical terms in this release, please go to: www.abb.com/glossary. For more other information contact ABB Ltd, Warrington,Cheshire. Tel : 01925 741 111 | E-mail: energy@gb.abb.com / Web: www.abb.co.uk/energy

FLOTRONIC PUMPS NEW ‘E’ SERIES’ ACHIEVES THE EHEDG SEAL OF APPROVAL Flotronic Pumps Limited, the UK-based specialist manufacturer of air-operated double diaphragm pumps, having already secured 3-A Sanitary Standards, Inc (3-A SSI) approval for their ‘H’ series pump, have now achieved the European Hygienic Engineering & Design Group (EHEDG) accreditation for their new ‘E’ Series pump. Flotronic’s ‘E’ Series pump has been specifically designed for the Food and Beverage industry and other processes where product contamination must be avoided. The pump’s features include Flotronic’s established and unique ‘ONE-NUT’ pump design which allows swift diaphragm access without disconnecting process pipework. The internal surfaces of the ‘E’ Series pump can be effectively ‘cleaned in place’ or, alternatively, easy dismantling can be carried out for cleaning and inspection. Cleaning is aided by the provision of polished wetted surfaces to 0.8μm Ra maximum and an electro-polished overall finish. Cleanability is also assisted by the incorporation of a support stand whereby the pump can be inverted for full draining. “The ‘E’ series pump passed EHEDG’s tests with flying colours,” says Flotronic’s Chief Engineer, Peter Wheal, “confirming that the pump meets EHEDG standards for sanitary product transfer. Other features, including a diaphragm rupture detection system with instant pump shut-down alarm facility and BS, DIN and ISO hygienic connection options, all help to keep product contamination free and to ensure that hygienic standards are not compromised.” “A unique feature of the Flotronic ‘E’ Series pump is that the diaphragms are reinforced as standard,” Peter continues. “The reinforcing plates add support to the diaphragms and ensure that the pumps can withstand CIP pressures in the suction line of up to 5 Bar with no diaphragm damage. Other suction pressure challenges resulting from SIP systems, bulk tanks with head pressure of more than 0.5 Bar, re-circulation and thermal expansion can all be met by the ‘E’ Series.” Flotronic designed the ‘E’ Series for markets at home and abroad where independent hygiene accreditation is growing in importance. “While EHEDG accreditation is not necessarily a statutory requirement, our customers are increasingly seeking conformance with the high standards required,” says Flotronic’s Managing Director, Jane Waite. “Being authorised to display the EHEDG logo confirms the new ‘E’ series pump’s credibility and gives our customers peace of mind.” For more information contact Flotronic Pumps Tel: +44 (0) 1444 881871. E-mail: sales@flotronicpumps.co.uk / Web: www.flotronicpumps.co.uk

MULTIPLE ZEROLOSS BENEFITS Sundyne HMD Kontro Extends ZeroLoss™ Containment Shells to Frames l, ll & lll Pumps Due to increasing customer emphasis on reliable, safe and efficient pump operation, Sundyne HMD Kontro has extended the availability of its ZeroLoss™ containment shell to now encompass Frame l, ll and lll versions of its most popular sealless pump ranges. The robust qualities of ZeroLoss™ has been a significant factor in establishing the success of this optional containment shell which eliminates the eddy current losses in a pump, considerably increasing margin-to-flash safety as well as reducing energy consumption. Five times lighter than steel but just as strong, the ZeroLoss™ shell is engineered from a composite material of poly-ether-ether-ketone (PEEK) and carbon fibres. In addition to its higher specific strength, the material is tough and durable, essential for applications pumping volatile and heat sensitive liquids. Tests by Sundyne HMD Kontro have shown that installing a ZeroLoss™ containment shell in a sealless pump can result in a 20% reduction in power consumption, leading to major operational cost savings. The advantage increases in proportion with the magnetic coupling size and is particularly appropriate for larger pumps, making the magnetic drive option even more attractive because through life costs are reduced further. Lower power consumption not only results in reduced running costs but also potentially provides lower initial capital costs, as smaller motors can be specified. For further information about using ZeroLoss™ containment shells with Sundyne HMD Kontro sealless pumps, please see www.sundyne.com/hmdkontro. Alternatively, please call +44(0) 1323 452000 or send an email to vince.lee@sundyne.com for product literature detailing this unique robust, power saving technology.

PROCESS MEASUREMENT

& INSTRUMENTATION

REACTOR VESSEL PRESSURE CONTROL & 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 profile - 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. To illustrate the solution uniquely offered by Bronkhorst® please see the adjacent schematic. At the inlet of the reactor, a Mass Flow Controller (MFC) provides the process gas delivery, whilst an Electronic Pressure Transmitter (EPT) measures the reactor pressure. At the outlet of the system there is a flow restriction which could simply be a (needle) valve or, as shown in the illustration, a Mass Flow Regulator (MFR) with local display. The reactor pressure is controlled by giving a setpoint to the pressure transmitter. In the illustration this is achieved by a script programmed into a PC and delivered via RS232. The integrated PID-controller of this pressure meter (Master) controls the valve position of the MFC’s control valve (Slave). When building up the pressure in the reactor, the maximum inlet flow is restricted by the MFC, thus preventing a flow peak. By using the ‘slave factor’ option, the maximum flow can be adjusted. When the process pressure has reached the desired value, it is kept constant whilst the required amount of reaction gas is controlled with a constant flow. It is also possible to pre-set the total amount of reaction gas allowed into the system by using a batch control function Once the total amount is reached, the set-point for the MFC can be programmed to be reset to zero, thus switching off the gas supply, independent of the process pressure. 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, Tel: 01223 833222 | E-mail : sales@bronkhorst.co.uk

COMPACT FIELD MOUNTING 4/20 mA INDICATOR CAN BE INSTALLED IN LIMITED SPACE BEKA have added compact field mounting instruments to their range of 4/20mA loop powered indicators. The new ‘G’ models have a large easy to read display housed in a compact, IP66 impact resistant GRP enclosure which can be installed where space is limited. ‘G’ indicators offer a choice of four 34mm high digits, or five 29mm high digits with a 31 segment bargraph. All have an operating temperature of –40ºC to +70ºC and include a root extractor, lineariser, calibrator and slide-in scale card. Backlighting, dual alarms, and a pipe mounting kit are available as accessories. Indicators are available with ATEX and IECEx intrinsic safety gas and dust certification and, for applications in Zone 2 or 22, Ex nA and Ex tc approval permits installation without Zener barriers or galvanic isolators significantly reducing loop cost. General purpose models are also available. For further information including datasheets, certificates and application guides please visit Web: www.beka.co.uk/compact or phone the BEKA sales office on Tel: 01462 438301.

PROCESS INDUSTRY INFORMER January - February 2016

VIBRATION MONITORING

HEAT TRANSFER & ENERGY

EFFECTIVE MONITORING OF VIBRATION ON LOW SPEED MACHINES

ALFA LAVAL GASKETED PLATE HEAT EXCHANGERS -EVERYTHING YOU NEED

Slow speed rotating machinery (typically, less than 300 RPM) is commonplace in many industrial applications, for example; cooling towers, hydroelectric turbines and wind power generation. To ensure this type of machinery and plant is functioning at optimal levels it’s essential to measure vibration, as much as it is a critical requirement for standard speed machinery applications. Whilst the use of accelerometers is common place on standard speed machinery (i.e. 1500 RPM) this becomes problematic at lower speeds as the absolute accelerations measured are much smaller in value for similar vibration displacements. Condition monitoring specialists SENSONICS have recognised the need for a sensor which can meet these requirements and has developed the VEL/GLF, a new LOW FREQUENCY VELOCITY VIBRATION SENSOR. The VEL/GLF is an electro dynamic sensor which offers a superior performance compared to piezo-electric devices by combining high measurement sensitivity with a frequency response down to 0.5 Hz and is therefore ideally suited to measuring velocity vibration on equipment with speeds below 300 RPM. The sensor offers a standard IEPE type interface to enable easy integration with existing plant protection and monitoring equipment. Furthermore, the VEL/GLF provides advantages over traditional piezo-electric based velocity vibration sensors which are susceptible to many forms of interference in low frequency applications that can result in spurious readings and alarms. Thanks to its robust design, the VEL/GLF combats these effects, offering high noise immunity due to the low impedance electro dynamic nature of the sensor assembly. In addition to the filtering of high frequency events and since no electronic integration is required, the design is immune to the saturation problems that impair the reliability of piezoelectric devices. Typical applications for the VEL/GLF will be found in cooling towers, hydroelectric and wind power generation, slow speed pumps and also structural monitoring. Further details on VEL/GLF sensors are available from: Russell King, Sensonics Ltd, Tel: +44 (0) 1442 876833. / Email: sales@sensonics.co.uk / Web: www.sensonics.co.uk

Suitable for a wide range of applications in most industries, Alfa Laval’s gasketed plate heat exchangers are a compact and efficient heat transfer solution. Alfa Laval’s gasketed models are designed for exceptional control, which makes them ideal for heating and cooling duties in demanding hygienic processes. Not only do Alfas heat exchanger solve your heat transfer needs, they also improve process efficiency and reduce downtime during servicing. Frames- Holding the plates together are sturdy, pressure graded frames with hygienic and labour saving features. The simplicity of Alfa Laval’s frame design offers great flexibility for expansion and reduces downtime during servicing. Stainless steel versions are available for the more demanding hygienic standards. Plates- The plates have been uniquely designed to maximise productivity and ultimately reduce your running costs. Alfa Laval’s CurveFlowTM distribution area eliminates any stagnant zones and reduces any chance of fouling optimizing the heat transfer of your unit and improving efficiencyReducing your costs! Gaskets- The unique design of Alfa Laval’s Clip-on Gaskets allows for quick and easy removal and installation reducing servicing time and saving you money. The Gaskets are available in many elastomers types allowing you to select the perfect match for the application temperature and characteristics you require. Alfa Laval’s gasketed plate heat exchangers have been proven solutions in many industries saving customers money through improved efficiency and reduced servicing times. Please contact Industrial Trading Solutions, Alfa Laval’s official master distributor, if you have any queries or requests for an Alfa Laval Gasketed Plate Heat Exchanger. For more information contact Industrial Trading Solutions Ltd, / Tel: 01675 4675 465191 E-mail: sales@industrialtradingsolutions.com / Web: www.industrialtradingsolutions.com

PROCESS INDUSTRY INFORMER January - February 2016

ETHERNET IS MAKING INROADS INTO INDUSTRY

CAN IT COPE WITH THE HIGH DEMANDS?

Once considered a solution that was limited to corporate network environments, Ethernet is fast bringing the concept of future proof communications systems to the world of factory and process automation. But how suitable is Ethernet in the industrial sphere? Bernd Knöll, International Product Manager at HBM, explains the reasons behind this growth and looks at how appropriate it really is.

s manufacturers seek to improve processes, reduce expenses and improve productivity without negatively influencing the quality of the product, many are turning to Ethernet technology on the factory floor. Once considered a solution that was limited to corporate network environments, Ethernet technology has proven to be a robust alternative that can now meet the unique and often challenging needs of the manufacturing arena. Using IEEE standards-based equipment, organisations can now migrate all or part of their factory operations to an Ethernet environment at a pace they wish.

broad and this is where fast connection, as offered by Ethernet, is a significant advantage, particularly where very large data volumes occur during measurement tasks. Furthermore, if the measurement technology used needs to be integrated in a higher level control architecture, for example based on PLC, appropriate hardware can be utilised to provide the appropriate communications options. The PMX measuring amplifier system from HBM is equipped with an interface card (PX01EO) for EtherNet/IP, one of the most commonly used automation protocols in the world for programmable logic controllers.

REAL TIME REACTION

WEIGHING UP THE OPTIONS

In terms of communication, an industrial application poses real time requirements that do not play a role in other applications; for instance, an email which arrives with a half a second delay in a corporate environment is hardly an issue but such a delay when controlling machinery could lead to potential malfunctions, which could in turn lead to huge cost implications. With this in mind, a reaction must occur within a specified time frame and this is where Ethernet provides a solution!

CORPORATE vs. INDUSTRIAL Widely considered as a logical step, considering Ethernet is an open standard which enjoys a high level of acceptance worldwide, it is worth remembering that although state of the art networks are now standard in the office environment, it isn’t simply a case of applying it to another industry. Unlike conventional Ethernet, the various solutions for real time Ethernet use protocols, components and topologies which are significantly different. We also need to recognise the particular demands imposed by industrial working conditions that need to be taken into consideration. During production, dust, humidity, high temperature, shocks and vibrations must all be tolerated, so components must be able to work under significant stress and in a wide range of ambient conditions.

MEASUREMENT TECHNOLOGY Another factor to take into consideration is measurement technology. Frequently used in machines and plants during industrial production processes, the spectrum here is extremely diverse. Ranging from simple signals with low frequencies to more complex measurement data, the spectrum of tasks is

updated, without the need for comprehensive modifications to the hardware. However, as you would expect with the introduction of any new trend into the marketplace, there have been certain criticisms linked to Industrial Ethernet technology. Predominately, the biggest argument being that off-the-shelf commercial Ethernet and IP solutions lack the degree of determinism and predictability required for industrial control. However, in response to these perceived shortcomings, several Ethernet and Ethernet based systems have been developed specifically for industrial applications. EthernetIP, for instance, offers the flexibility of standard Ethernet, which takes advantage of today’s Ethernet technology without resorting to modified switches, silicons and stacks.

This makes it possible to use PMX in many areas of machine and factory automation as a slave module in EtherNet/IP networks.

A UNIVERSAL STEP BEYOND TRADITIONAL NETWORK INSTALLATIONS Compared to traditional network installations, Industrial Ethernet networks that use intelligent switching technology can offer a variety of advantages. Providing both plant control and office data capabilities, manufacturers are now starting to reap the benefits of Industrial Ethernet, which include easy integration of shop-floor to top-floor systems and the opportunity to use a single network infrastructure for several different functions, which in turn enhance performance. In addition to universal communication, Industrial Ethernet also offers the added advantage of a very high bandwidth that makes it possible to transmit even larger data volumes than ever before, at a very high speed. A universal system also offers notable advantages with regards to maintenance, back up and engineering. Laying the foundations for possible future enhancement, a system with open communication interfaces can also often be cost effectively

PROCESS INDUSTRY INFORMER January - February 2016

Despite the rapid migration to Industrial Ethernet technology, the decision to switch from a purpose built network should not be a decision which is taken lightly nor based on the simple fact that ‘we need to move with the times’. Instead, various factors need to be taken into consideration to understand the actual need and more importantly, the actual benefits of the system. Firstly, what exactly do you want to achieve? Is the installation actually suitable for instance, will it be under or over specified? Also, from a performance perspective, how much data will be carried over the network and how fast it will change will have a big impact on its architecture. Lastly, the actual system environment is something that needs to be fully understood; for instance, will the automation system be integrated, connected or isolated from the IP system? The migration to Ethernet in manufacturing environments has been growing steadily for years and according to a recent ARC Advisory Group study, this growth is expected to continue at a rate of 84% over the next five years. To reflect this, companies are quickly beginning to recognise the many benefits Industrial Ethernet can deliver. Whilst it may be argued that Ethernet within the industrial sector does not offer all of the features of a purpose built control network, it is arguably a versatile system which can open the door to a wealth of opportunities designed to increase productivity, reduce assembly and maintenance times and enhance the level of process transparency. In short, a well implemented Industrial Ethernet network can provide greater control and enable companies to more closely link their internal data networks with the factory floor to make the entire company’s operations more efficient. Industry standard in measurement technology, PMX supports current industrial Ethernet technology and integrates seamlessly into modern production plants and enables the measurement, calculation and automation of data in real time.

KEEPING YOUR SYSTEM SAFE

FIVE STEPS

TO BETTER INDUSTRIAL SECURITY

According to the Global State of Information Security Survey 2016, 38 per cent more security incidents were detected in 2015 than the previous year. As a result, industrial businesses across the world are implementing new strategies to improve security. Reassuringly, 91 per cent of survey respondents have a risk-based security framework in place, but the most cited source of compromise still lies with employees. Rather than jumping to the conclusion that these compromises are intentional, consider how much the usual employee actually knows about keeping your system safe. Here Reinhard Mayr, product manager of industrial automation software specialist, COPA-DATA discusses the five vital steps any manufacturer can take to improve the security of connected automated systems. ASSES EXISTING SYSTEMS TO IDENTIFY POTENTIAL THREATS For most automated systems, an integrated user administration service is used to protect information and stop unauthorised personnel from gaining access. However, for the added security necessary in today’s facilities, the best solution is encrypting all data that is transmitted over networks to other stations and companies. When the information reaches the receiving end, digital certificates can be implemented to assure the recipient that the information is legitimate and hasn’t been tampered with during transmission. However, for automated SCADA systems, encrypting data can be a disadvantage to productivity. Transmission of encrypted data can only be done over a high-performance network, lengthening the process for standard users. Also, for bigger facilities using more than one system, the level of encryption needs to be consistent. If one system is working at a lower level, then money and resources are being wasted encrypting more extensively across other networks. SCADA engineers need to identify the security risks in their application and pinpoint what data needs to be protected. For example, if employee training records were to be accessed, the

consequences wouldn’t be as drastic as, per say, if more private product specification documents were instead compromised. It’s logical to assume that many companies have confidential product information stored on their network. The last thing they would want is for this private data to be made available to competitors and the wider audience, or worse destroyed, as it could mean losing years of research and significant product advantages just because of one security flaw.

SET UP A SCADA SECURITY SYSTEM Trends like Industry 4.0, Smart Grids and Smart Factories are all opening systems up to security risks. Previously, manufacturing and IT departments had isolated systems, increased connectivity is bringing the two together. It is almost impossible to share information over a network and not risk unauthorised personnel gaining access. However, industrial automation SCADA/HMI software has the ability to encrypt data across the network and provides centralised user administration, so obstructions are in place to stop breaches. The ability to set parameters is a software feature that strengthens industrial security. Standard products, firewalls and interfaces that open communication ports are usually not configured, meaning intruders can see which doors are open.

PROVIDE ADDITIONAL INFORMATION

SECURITY

FOR

SENSITIVE

When implementing security measures, it’s important for the user to decide what information is considered sensitive to the company. In an ideal world, everything would be encrypted, but cost and transmission issues will usually impede this. A solution would be to identify the areas with a higher risk of a potential security breach and use your findings to design your counteractions. Making networks secure to external threats is not always enough. Potential threats from inside the facility still need to be considered. Although it’s something that most companies don’t like to think about, these situations are increasingly common. The easiest way to stop internal threats is to give only one or two users access to a security system’s project data. This way, security features can’t be shut down by unauthorised personnel and companies can rest assured their system is secure.

KEEP YOUR POLICY UPDATED When setting up your initial security policy, commitment from

CEOs and management is extremely important as the most challenging step is ensuring that the entire workforce has a common mindset. If there are breaches in one area of the company, protection measures elsewhere can become obsolete. Your security policy should include a regular risk assessment, carried out at least once every twelve months. This allows you to identify potential breaches and assess how vulnerable your system is to attacks. Staff members need to know that cyber attacks aren’t limited to standard office computers. Security is an issue throughout the increasingly connected production line and everyone needs to be familiar with the company cyber security policy.

TRAIN THE TEAM When new industrial automation software is implemented, the provider should ensure standard training on all of its features, from operating the user administration platform, to identifying encryption requirements. The current problem with internal security training is that the majority of industries aren’t aware of the risks. They may have heard of the term cyber security, but still associate it with office environments. The energy sector shows the most awareness because of recent smart grid breaches. However, in many other sectors that use industrial automation, there’s a low level of knowledge, which correlates to organisations’ levels of commitment to improving their cyber security. Over the past few years, the amount of security breaches has been rapidly increasing. To counteract this, companies should be prepared to increase their focus on the topic and employ the help of Chief Information Security Officers or external specialists. If your staff are aware of the consequences of a security breach, they may be more willing to make changes to current procedures. Not all internal security breaches happen intentionally, and it’s likely that your employees don’t consider them as they go about their day-to-day activities. Following these five simple steps can give you peace of mind, a workforce that is engaged and on board with security policies and a secure automated system. As a general rule for better industrial security, manufacturers should first make sure they assess their systems and identify potential threats. Companies should then address existing security risks by introducing a SCADA security system, encrypt information on different levels and finally, ensure the entire team is on board and understands that industrial security is just as important as locking the front door.

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Solids Handling & Processing Supplement

January - February 2016

MOVERS & SHAKERS By Gus Bishop AS OTHERS SEE US…

A recent industrial survey concluded that at least 80% of service providers questioned said they provided a good service. A similar survey of customers of the same providers concluded that only 8% provided a good service – something of a chasm between conflicting views. Who do we believe?

– suffice it to say that this did not involve participants in our industries, but it serves as an awful warning to avoid complacency. Of course, good communication between suppliers themselves and also between suppliers and customers can go a long way towards reducing such gaps in credibility and good partnerships

continue...

Strengthen your process

A BRIGHTER OUTLOOK?

Indeed, manufacturing output and profitability, albeit briefly, increased during the latter part of the year. In spite of a steadily increasing value of the Pound, especially against the Euro, exports have not suffered too badly. In fact UK manufacturing output has been trending upwards for some time now. Singlemindedness and dedication are key to this hard won success. Cooperation between supplying companies and partnership building with clients have contributed greatly to this success.

SNAKES AND LADDERS

Importers and exporters are affected by market fluctuations, great and small, around the world. Dips in the rate of growth in China and other erstwhile emerging powerhouse economies have checked the need for oil, with reduced manufacturing and shipping activity. Bad news at one level, but offsetting this is the consequent cost reduction for these activities here in UK, helping competitiveness in a nevertheless challenging market place. Low inflation, or even slight deflation here, but greater in countries such as Japan add to the task for exporters, as some countries endeavour to concentrate on “home grown” products and services. Cheap steel from China and India have hit domestic steel production hard, denting our opportunities to supply this industry. Conversely, cheaper steel itself may help to reduce product manufacturers’ costs, but then again, there are issues with poorer quality or inconsistent materials. Notwithstanding all of this, the solids and bulk handling equipment manufacturers and suppliers continue their key role in keeping a vast range of vital industries operating smoothly and efficiently.

AL wi with ith optional ventbox ntbox box and dropoutbox dropoutb

BTD BT TD Ball Type Diverter

When handling abrasive materials, the use of abrasion resistant rotary and diverter valves reduces the downtime for replacement or re-adjustment of worn parts, the refurbishment costs and thus the cost of ownership. Also the valves have a more predictable and reliable performance, making preventative maintenance schedules easier to establish. DMN-WESTINGHOUSE abrasion resistant ceramic coated or Ni-hard rotary valves and the specially designed, rugged BTD ball diverter can help you strengthen your process.

AIRLOCKS • BLOWINGS SEALS DIVERTER VALVES • SLIDE GATE VALVES MORRIS COUPLINGS

COMPONENTS FOR BULK SOLIDS HANDLING

015 may well be receding rapidly into the mists of, for many, best forgotten memory. The year threw up a bewildering barage of conflicting, disturbing, but occasionally encouraging events, data and information. Both politically and commercially it was a year that jerked upon the reins of sanity, spooked any ideas about steady progress and made us all think and reassess our hopes and aspirations. Inevitably the security of people, premises and data has come into sharper focus. Just as we become super-reliant on e-, i-, smart- and other internet driven functions for everything from material supply to marketing ( there’s even an app to tighten your shoes now!), we must make redoubled efforts to keep vital information, including customer data, secure. Nobody, particularly given the events around the world last year, would presume to be complacent – but life goes on and the wheels of business continue to revolve with gathering pace.

DMN UK Ltd. T +44 1249 818 400 dmn@dmnuk.com

www.dmnwestinghouse.uk

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

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today. There is always much work to be done, however, as new materials, finer blends and technologically precise and often delicate materials join the ingredients list across a range of applications. So, following the successful introduction last year of the SHAPA Industry Awards scheme, the Association has developed an enhanced set of prestigious awards this year – with five categories available. They will be hotly contested by companies who demonstrate knowledge, commitment, enthusiasm and success in their fields. Hurry and visit www.shapa. co.uk for details – time is getting short!

ENGINEERING THE FUTURE

Material analysis become essential to ensure that what we supply is really what the customer wants and actually needs.

The need for shrewd, skilled and highly motivated people for our industries has never been greater. SHAPA recognise this ongoing demand and actively encourage up and coming engineers and managers to become the movers and shakers of the future. Regular Engineering the Future seminars encompassing education, networking as well as some entertainment feature in the Association’s calendar. The body of knowledge held by SHAPA via committed member companies is huge and growing day by day. We all recognise the need to “stick together” and this is well illustrated by member companies who are suppliers to and customers of each other. Not only that, they frequently find themselves as complementary colleagues working side by side on large projects. Inter-member networking is clearly beneficial.

THE COMING OF GUILDS

Clearly an association of manufacturers and suppliers, run on an equitable basis to aid communication would have many benefits. But there is nothing new in this idea. As far back as the 12th century trade guilds were emerging with the aim of standardising quality amongst individual tradesmen, to enable customers to have confidence in the goods and services that they were purchasing. Today’s surviving Liveried Guilds, whilst serving as a reminder of past enterprise, operate solely as charities for worthy causes. It took the Industrial Revolution, during which time “cottage industries” gradually combined to become factory workplaces attracting along the way increasingly complicated and onerous regulation, to spawn the idea of engineering trades associations to share and spread the load. Several generations passed, however, before they became properly established.

A MODERN DAY “GUILD”

In 1982 such an association formed. The Solids Handling & Processing Association (SHAPA) is still in rude health with 110 key member companies, many of which are long standing members and some even founder members. The original aims, to reduce costs, to combine knowledge and improve customer experience, are as true now as when the original Guilds were formed. Membership of a modern engineering trades association offers so many advantages, so well documented that repitition here seems hardly necessary – just visit www. shapa.co.uk

REWARDING MOVERS & SHAKERS

In all senses of the words the solids handling industry makes movers and shakers, eg. conveyors, sieves and screens, elevators and a host of processing equipment and controls, but more particularly it is the human movers and shakers who down the years have provided the innovation and impetus to develop and succeed with novel and better ideas. The SHAPA Council is very keen to acknowledge these worthy inventors and industrialists and other enablers who have brought our industry to the finely tuned science-based condition we see

Process controls

REALLY USEFUL MEETINGS

This is not an oxymoron for SHAPA members! Apart from facilitating development of shared insight, technical, commercial and marketing intelligence, the quarterly General Meetings are essential forums for idea exchange and partnership building. Enjoy the following pages whist pondering the real value of membership, or alternatively of putting your trust in SHAPA member company expertise.

Seminar workshop

Storage Silo 2sp

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

FARLEYGREENE CELEBRATES 40 YEARS OF SIEVING TECHNOLOGY

Farleygreene Ltd, established in 1976, celebrate their 40th year with a 2016 Ruby Jubilee. From modest beginnings Farleygreene now provide one of the largest ranges of UK manufactured sieving machinery available across the Globe. Renowned for design and build quality they pride themselves with supplying some of the most prestigious names in the food, pharmaceutical, chemical and additive manufacture industries. Included within their ‘SIEVMASTER’ portfolio are the popular ‘Artisan & Bakery’ sifters, ‘Slimline’ check sieves, ‘Segregator’ linear feed screeners, ‘Rota’ centrifugal sifters, and the ‘Multiscreen’ vibratory grading separators. In addition, Farleygreene provide bespoke powder sieving stations designed to customers’ exact requirements including sack handling, conveying and transfer options. Not just satisfied with this success, Farleygreene have launched their new line of innovative high technology sieving equipment. Titled ‘SIEVGEN’, this new range represents the companies next generation of sieving equipment, and commitment to moving the technologies forward for the future. The first design, launched in late 2015, was the SIEVGEN SG400-US unit, which is aimed directly at the additive manufacturing sector. Other models and innovations will be launched during 2016, along with a special microsite dedicated to the new ‘SIEVGEN’ technologies. Since 2010 Farleygreene have grown substantially, this is due to a combination of moving to a new larger manufacturing site in December 2014 where they can now provide full test facilities; secondly, and most importantly they have experienced staff across all departments to provide their customers with a comprehensive service to support them during the life of the machine, starting from the initial enquiry right through to aftersales support. Farleygreene are delighted and proud to celebrate their first 40 years and look forward to taking this success through to their next anniversary. Farleygreene would like to celebrate their 40th Birthday in February with their customers by giving away a bottle of Champagne to 10 owners of the oldest operational Farleygreene sieving machine. Please notify them of your machine serial number to: hello@farleygreene.com. Also every entrant will receive a 10% off voucher for their next spares part order. This is only valid for the month of February, so do not hesitate to get your emails in!

ENERGY-SAVING WELDING FUME EXTRACTION IG Masonry Support Systems Ltd, a division of The Keystone Group – Europe’s largest steel lintel manufacturer – has recently invested in an energy-saving welding fume extraction system from specialist extraction engineers Cades Ltd part of the DCS group. A vent-to-atmosphere weld extraction system was designed, supplied and installed by Cades Ltd to effectively deal with welding smoke, fumes and grinding dust from a new 10-bay steel lintel welding line at IG’s fabrication facility in Swadlincote, South Derbyshire. Here, the company produces brick slip masonry support systems in stainless steel and galvanised steel. Each welding bay has a centrally located, 3m long fume extraction arm and captured welding smoke, fume and dust is removed via ductwork to a high-efficiency Gold Series® filter unit. The maintenance-friendly GS6 cartridge-type reverse jet filter contains six high-efficiency HemiPleat Gold Cone filter cartridges; providing optimum cleaning efficiencies, as well as increased filter life and reduced servicing requirements. Powering the system is a 15kW low-noise Moldow main extraction fan set, fitted with a variable speed drive. A key feature of the installation is the inclusion of ECOGATE® energy-saving technology which is designed to reduce power usage on the extraction system by as much as 57%. Each fume extraction hood is fitted with an automatic ECOGATE® motorised damper and a PIR movement sensor which signals an ECOGATE® greenBOX12 controller to open or close the damper as welding stations come on-line or shut down. The greenBOX12 detects changes in extraction load and adjusts the variable speed fan drive accordingly. The result is an extraction system that provides precise extraction volumes, only when required. For more information: Tel: 0845 838 6166 or visit www.cadesltd.co.uk

ROTAVAL – REFURBISHMENT & SERVICING OF ROTARY VALVES As well as supplying new rotary, diverter and special application valves, Rota Val is an experienced spares and refurbishment provider. With over 45 years of experience, their technical knowledge and expertise surpasses any third part service provider. Rota Val can supply a full range of spares and also offers off-site refurbishment, their team is backed by decades of experience and offers a highly competitive schedule of rates. Their factory features space to specifically carry out refurbishments and when finished any old valve will look brand new. Contact: T: 01249 651136 E: sales@rotaval.co.uk W: www.rotaval.co.uk

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

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KNOW YOUR DUST Mark Shannon from BS&B Safety Systems discusses the importance

of dust testing when taking protective measures against dust explosion risk WHY IS DUST DANGEROUS IN PROCESS INDUSTRIES? In any industry that handles or stores organic materials for processing, there is always a risk of dust explosions occurring. A myriad of powdered or ground organic materials ranging from carbon to milk powder are prime constituents for ignition and fuelling of ensuing primary explosions within process facilities. Taking every precaution to ensure that such explosions don’t happen is of paramount importance for the protection of personnel, equipment and facilities. Dust explosions occur when an ignition source ignites combustible organic material that is fuelled with oxygen in a closed atmosphere. This can take place inside a grain silo, process or storage enclosure, or even originate in pulverising or grinding process equipment. It takes only milliseconds for a violent explosion to occur after a rapid pressure rise in process equipment. Depending on the type of equipment or vessel that holds the materials, certain fail-safes are implemented to stop an explosion occurring. This is where a thorough understanding of dust characteristics becomes important. In the UK and Europe, there is a requirement to identify any potentially explosive substances in the workplace. In the UK this requirement is governed by the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). DSEAR classifies dangerous substances as those used or present at work that could, without adequate controls, cause harm as a result of a fire or explosion. In Europe, ATEX is the common name given to two European directives that specify what controls employers should use to prevent explosion risks, which are divided into danger ‘zones’.

BOTH DSEAR & ATEX RECOGNISE DUSTS AS EXPLOSIVE RISKS. As far as BS&B are concerned we offer various solutions to protect against dust explosions. Before we recommend the right ones to a client, the very first question we ask is “what type of materials are you handling in your facility?” Different types of dust have different particle sizes, properties, ignition temperatures, and ignition sources, from each other. Dusts are given explosion severity classifications; St1 to St3. ‘Not specified’, means the material is non-explosive and St3 is the most explosive type of material. Most people think that dust is, for the most part, the same. However, the range and qualities of dangerous dusts is expansive across the process industries and include organic materials that most of us would not even consider as an explosive risk. Nevertheless, for the purposes of manufacturing and processing, a closer analysis of dust characteristics is required to specify operational conditions and protection. For example, according to the Health & Safety Executive’s

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guidelines Safe Handling of Combustible Dusts, wheat has an average particle size of 80 µm; wood flour is 65µm, tissue paper is 54µm; magnesium at 28µm, which has a classification of St3 and is highly combustible. Dust testing is designed to identify two key performance characteristics of dust, which in turn influence explosion protection equipment design and their application as well. • The first measures maximum pressure of a dust explosion (Pmax in bar) • The second identifies the speed of the rise in explosive pressure (KSt in m/sec) Returning to the very fine and highly explosive magnesium powder as an example, the KSt value can be approximately 500 bar m/s. In comparison, wheat flour, only has a KSt value of around 110 bar m/s – a significantly slower rate of explosion pressure rise. Nonetheless, it could remain a danger.

“Of course there is no substitute for exercising good housekeeping in factory facilities. Regular removal of dust accumulations in the factory space is also a vital means of mitigating against dust explosions.” Testing under laboratory conditions will tell you what St class your dust is, based on its KSt value. It will also reveal the dust’s performance under specific equipment operations and processes; is it being milled, ground, poured or dried? What is its Minimum Ignition Temperature (MIT) while being subjected to these processes – in other words, what temperature will the dust withstand before it becomes an ignition risk? All aspects of the dust’s behaviour in relation to its process environment can be determined to inform the correct precautionary measures against a potential explosion.

MATCH THE PROTECTION TO THE TYPE OF DUST Because dusts have different explosive properties, these are often handled and stored in different ways and locations, the protective measures in each location will be tailored to meet the associated risk. Facilities can be protected from the risk of dust explosions by various means depending on your application. An explosion protection consultant will advise on the best solution for your facility: SPARK DETECTION DEVICES: sense hot particles, sparks and flame that could become the ignition source for a fire or

explosion. They can include automated shut-down systems to interrupt the feed of combustible material along the process equipment. All processes may be monitored by an operative via a control panel to assess any further risks. Spark detection is particularly useful to manage fire and explosion risks in process equipment such as dust collectors, bins and silos. CHEMICAL SUPPRESSION SYSTEMS: designed to detect the pressure wave at the very start of an explosion and deliver dry, inert chemical extinguishing agents into a developing internal deflagration. These suppression and isolation systems can be activated either by pressure, optical or vent sensors. Any deflagration travelling through interconnected equipment is quickly and efficiently extinguished, preventing any spreading explosion damage. FLAMELESS VENTS: the preferred passive method to relieve explosive pressure in a process or storage vessel containing combustible materials. It is not always practical or safe to vent the pressure and flame to a particular area, therefore these vents intercept, quench and retain all burning materials, preventing them from expelling into the atmosphere. They are particularly useful for dust collectors, bins and bucket elevators. ISOLATION: designed to prevent any kind of deflagration or explosion from spreading to other parts of process equipment. There are two methods of isolation used. The Passive method does not require detectors, or control and indicating equipment. These may be arrestor mesh, rotary valves, lock valves, rotary screws, flap valves or diversion valves. The Active method is activated by detectors and a control and indicating equipment, which are parts of the system, such as pinch valves, chemical Isolation or fast acting valves. Even though chemical suppression is used to reduce the initial building pressure in an enclosure, some hot gasses will attempt to exit to areas of lower pressure. This causes a flow through the inlets and outlets of the enclosure, hence the need for isolation.

SAFETY COMES FIRST Of course there is no substitute for exercising good housekeeping in factory facilities. Regular removal of dust accumulations in the factory space is also a vital means of mitigating against dust explosions. Dust that accumulates in eaves, ceilings spaces and beams are waiting fuel to propagate a secondary explosion. Up to one ton of accumulated dust has been recorded as the fuel for a devastating explosion in a pharmaceutical facility in 2003. Investigators of the disaster said it had collected in the ceiling spaces and workers were unaware that the risk was above their heads. Conducting a factory survey and dust testing service for clients as a matter of course is essential to achieve optimal dust explosion protection. It’s the first step in ensuring that they receive the appropriate explosion protection solutions for their business. When it comes to the safety of equipment and personnel in dust explosion risk zones, thorough identification of organic dusts is good business practice. IT PAYS TO KNOW YOUR DUSTS.

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

Guest Feature

CHOOSING A POWDER TESTER FOR PROCESS OPTIMISATION By Tim Freeman, Managing Director, Freeman Technology Ltd

owder processing presents widely recognised challenges. Equipment selection and design typically call for specific expert input and even then, over the long term, day-to-day problems with product variability, blockages and stoppages often erode profitability. Powders usually have a specification defined on the basis of composition and particle size, but successful powder handling and processing requires greater insight into the potential behaviour of the powder than these analyses afford. Powder flowability is a property that is often identified as being useful to measure and there are a wide range of options when it comes to test equipment. This raises the question of how to choose a powder tester that is well matched to a specific, process-related need. The commercial introduction of a new powder testing technique – uniaxial testing – makes it timely to review the most valuable testers for process support and compare their suitability for specific applications. Here we consider the advantages and limitations of uniaxial testing, biaxial shear cell analysis and dynamic powder testing within this context.

EXPLORING REQUIREMENTS FOR POWDER TESTING A robust assessment of the relative merits of alternative powder testing options relies, in the first instance, on understanding why testing is carried out within the process environment. Powder testers differ substantially in terms of the data they deliver. Matching the capability of each tester and the information they provide to defined process needs is the key to choosing an appropriately specified tester that will yield a good return on investment. Powder flowability measurements can improve manufacturing efficiency in a number of ways and are routinely implemented in:

• QA/QC – to assess the consistency of a raw material or finished product; to evaluate an alternative supplier; and/or to achieve value added product performance. • Routine plant operation – to optimise aspects of manufacturing practice, such as hopper fill level and shutdown protocols; to troubleshoot issues with product quality or plant performance. • Equipment design and specification – to determine

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whether existing plant can be re-used in the manufacture of a new product and/or to develop an optimal process design.

One of the first issues to consider when selecting a tester is relevance. To be relevant, and consequently useful, a tester must measure a property that correlates directly with performance in process. It is not unusual to test a powder in QA/QC against a defined specification and find it acceptable, but then encounter problems when the material is introduced into the plant or released to the customer. This situation results from a failure to define a relevant specification i.e. one that relates to how the powder will actually perform during a particular processing stage. The sensitivity of a powder tester is crucial to its ability to support process optimisation. Certain techniques are inherently more sensitive than others but repeatability and reproducibility are also critical. Where instruments utilise the same technique, the one with higher repeatability and reproducibility will more successfully differentiate samples and, therefore, offer greater insight to advance process understanding. Features which enhance repeatability and reproducibility include well-defined measurement protocols, precision engineering and a high level of automation. Such features also beneficially impact the third factor that influences the value of a tester, which is practicality. Ease of use and measurement time both affect the ability of a powder tester to provide efficient manufacturing support.

REVIEWING THE OPTIONS The limitations of simple powder testing methods, such as tapped density, flow through an orifice and angle of repose, have led many powder processors to seek alternative techniques to support in this area. Uniaxial testing, on the other hand, is a recently commercialised approach withconsiderable promise. Understanding what each of these techniques has to offer is crucial for their efficient application.

UNIAXIAL TESTING HOW DOES IT WORK AND WHAT DOES IT MEASURE? Uniaxial testing involves measuring the normal stress required to fracture a free-standing consolidated

powder column. It delivers values of unconfined yield strength (UYS) as a function of a preconsolidation or major principle stress, o1, the same terms that are generated less directly by translational/rotational (biaxial) shear testing.

Figure 1: Uniaxial testing involves the fracture of a consolidated powder column and directly measures UYS.

THE PRACTICALITIES OF APPLICATION Uniaxial testing is simple and fast, with measurement times in the order of just a few minutes. Furthermore, equipment costs are low - automated instruments are around £10,000, and manual versions around half this price. These are crucial advantages for the manufacturing environment. The primary challenge in implementing uniaxial testing is to construct a uniformly consolidated powder column, and this is especially difficult for more free-flowing powders. Recently commercialised instrumentation for uniaxial testing (Uniaxial Powder Tester, Freeman Technology) has features that directly address this challenge and enable highly repeatable measurement for a wide range of powders. However, the technique is somewhat limited in terms of the conditions applied during measurement, with relatively high consolidation stresses. It is also less suitable for very free-flowing materials.

AREAS OF APPLICATION Uniaxial testing is arguably the simplest, most inexpensive way of quantifying powder shear strength, with high repeatability. Shear strength relates to how a powder flows, making uniaxial testing a cost-effective choice for the measurement and comparison of powder flowability. It is likely to prove particularly useful to powder processors who currently rely on test methods

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

Guest Feature that are failing to provide sufficient differentiation, or who currently have no access to powder testing. Uniaxial testing is well-suited to QA/QC for rapid assessment of the consistency of a raw material or finished product, and is an accessible choice for process optimisation/ troubleshooting when exploring the causes of problems such as variable fill weight or erratic hopper discharge.

BIAXIAL SHEAR CELL TESTING UNDERSTANDING THE TECHNIQUE AND WHAT IT MEASURES Biaxial shear cell testing involves measuring the forces required to shear one consolidated powder plane relative to another. Shear stress is measured at a range of applied normal stresses and the resulting data are used to generate UYS values by a process of extrapolation. Analogous methods are applied to measure wall friction - the friction between a coupon of an actual or potential material of construction and the powder in question. Combining both sets of data enables the calculation of flow function (FF) and flow factor (ff), the two parameters routinely used in hopper design.

generate parameters for hopper design and this remains a primary application. By measuring powder properties under the moderate to high stress conditions that develop in small to large hoppers respectively, biaxial shear cell testing is useful not only for design, but also for determining whether existing storage is suitable for a new powder product and for troubleshooting erratic or sub-optimal discharge, a perennial problem. More broadly, shear testing enables the investigation and comparison of how consolidated powders transition from the static to dynamic state. Shear cell analysis is also used more widely to support process optimisation and can be effective within this context providing there is recognition of its limitations with regards to predicting the behaviour of free-flowing powders and performance in a low stress and/or dynamic environment.

DYNAMIC POWDER TESTING UNDERSTANDING THE TECHNIQUE AND WHAT IT MEASURES Dynamic powder testing involves measuring the axial and rotational forces acting on an impeller as it is precisely rotated through a powder sample. The properties measured include Basic Flowability Energy (BFE), which quantifies how easily a powder flows under forcing conditions, and Specific Energy (SE), which defines unconfined flow properties. Dynamic testing can be applied to consolidated, moderate stress, aerated or even fluidised samples, to comprehensively characterise flow behaviour across a complete range of process relevant conditions.

THE PRACTICALITIES OF APPLICATION Figure 2: All shear cell designs measure the forces required to shear one consolidated powder plane relative to another to quantify certain powder flow properties.

THE PRACTICALITIES OF MEASUREMENT Since shear cell testing was introduced more than 50 years ago, substantial effort has been expended in refining instrument design. Today’s shear cell testers vary in their level of automation and also in terms of cost, with the most precise instruments enabling effective control of the test conditions applied and highly repeatable measurement. However, even with the best systems measurement times remain in the order of 10 – 20 minutes and some expertise is required for effective application of the technique and processing of the resulting data. The fact that testing is carried out using consolidated samples means that the relevance of the data is limited for certain processes; however, this is also the case for uniaxial testing, which demands the application of higher consolidation stresses.

AREAS OF APPLICATION Biaxial shear cell testing was developed specifically to

fail to rationalise poor process or product performance. The ability to measure as many as 25 – 30 different powder properties makes dynamic powder testers unrivalled in terms of troubleshooting capability, while exceptional sensitivity allows advantage for the robust differentiation of raw materials and products. The ability to directly characterise the response of a powder to air, up to and beyond the point of fluidisation, is a unique benefit that offers enhanced support for the optimisation of, for example, fluidised bed and pneumatic conveying processes.

Dynamic test methodologies are well-defined and instrumentation is precision engineered and highly automated. As a result, dynamic powder testers, though relatively expensive, deliver unrivalled sensitivity and versatility. For example, using dynamic testing it is possible to clearly differentiate samples that would be classified as identical with shear cell testing but would go on to perform differently in a process. Measurement times are in the region of 5 – 10 minutes for a basic assessment of flowability, but the range of testing available means that longer, more in-depth investigations of the effect of variables - such as flow (or strain) rate, air and moisture content, storage time and electrostatic charge - are routinely implemented. Testers that offer dynamic powder characterisation also enable shear and bulk property measurement and can be productively used to build a database of powder properties to support the optimal processing of specific powders in a wide range of different unit operations.

Figure 3: Dynamic powder testing measures the powder in motion and can be applied to samples in a wide range of different states to simulate numerous process environments.

MAKING A CHOICE No one powder tester offers the best cost benefit ratio for every application. The introduction of a new powder tester, the Uniaxial Powder Tester from Freeman Technology, brings greater choice in powder tester selection, and crucially, reduces the price point at which robust and repeatable powder testing is accessible. However, over the long term, alternative testers can ultimately yield a greater return, providing that the information they produce is relevant to the process need, and therefore of practical and commercial value. Rigorously reviewing what a tester can deliver, against what is required, is the key to an optimal choice.

AREAS OF APPLICATION Dynamic powder testers provide detailed and valuable information from early product and process development through to QC, but most rapidly deliver an attractive return on investment when other techniques

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HOSOKAWA MICRON USE AIRFLOW DYNAMICS SIMULATION TO OPTIMISE DOWNFLOW BOOTH AND WORKSTATION DESIGN Leaders in containment technology, Hosokawa Micron Ltd, are now offering customers the opportunity, to accurately check, at design stage, how the placement of objects, equipment and operatives in their downflow booth may affect airflow patterns and containment all important to the achievement of critical OELs. This leading edge airflow dynamics modelling package complements Hosokawa Micron’s existing ergonomic modelling to combine to deliver the most appropriate downflow booth solution to meet the customer’s needs and working practices. Explains Carl Emsley, Hosokawa Micron Ltd, ‘Customers can see for themselves how airflow in the booth can be effected by protective screens, local extract ventilation, ancillary equipment, as well as the presence of an operative. The simulations represent conditions under normal established operations – starting with an empty booth demonstrating the down flow with primary ventilation system running. Further simulations can then be created to demonstrate how airflow would change when equipment or operatives are brought into the booth – this means Hosokawa Micron engineers can optimise positioning of

Advanced computer modelling provides a visual demonstration of local extract as part of a downflow system. equipment and operations within the booth; right at early design stage. Using the airflow simulation package allows Hosokawa engineers to produce a proven downflow booth design for both standard and non-standard units and is invaluable when designing for complex, multi-use operations. With this software not only can we see the clear airflow patterns but workers can also see for themselves how they will be protected when handling potentially hazardous materials, giving them confidence in the task they are required to undertake. We can also say that in installations where downflow booths are placed within cleanrooms, where sometimes the ventilation systems can conflict, this new software is proving invaluable.’ For more information contact Hosokawa Micron Ltd, Runcorn, Cheshire Tel: +44 (0) 1928 755100 Email: info@hmluk.hosokawa.com Web: www.hosokawa.co.uk

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BARTON FABRICATIONS HAS INSTALLED A 40 TONNE FLOUR SILO AT SPECIALITY BREADS’ NEW £3 MILLION BAKERY IN MARGATE The 12 metre high, 3.5 metre diameter ATEX compliant silo has been installed on the 3,000 square metre site, situated close to the bakery’s existing production facility. Speciality Breads, which is a Red Tractor-certified company, will use the new facility to produce around 20 handmade lines, while providing essential additional cold storage, work space and ovens for the team’s artisan bakers. Commenting on why Barton Fabrications was chosen for the installation Peter Millen, Managing Director at Speciality “Barton

Fabrications have a fantastic reputation not just in the UK but around the world for their expertise and service so it wasn’t too difficult a decision. Their professionalism was top notch and there was no problem or issue which they couldn’t counter or have a strategy to solve.’’ Barton silo being installed at Speciality “In any build, whether it’s for a new site or a site Breads’ new Margate site being redeveloped, there are always issues, delays and problems on a day to day basis. For this reason, it is essential that you have a team who can be pro-active, re-active, adaptable and flexible. The Barton team ticked all these boxes.” The new bakery was opened in 2015 by MP Sir Roger Gale who cut a giant ciabatta at the inaugural event. For more details on Barton Fabrications’ silo solutions, contact Mark Barton: Tel: +44 (0) 1275 845901 | E-mail: sales@bartonfabs.co.uk | Web: www.bartonfabs.co.uk

BRITISH REMA LAUNCHES INTERCHANGEABLE BLENDER British Rema Process Equipment has launched an Interchangeable Blender which enables the homogeneous blending of multiple granular products, dry powders, and liquids into powders, including fragile and abrasive products of varying densities and batch sizes, whilst meeting exacting process requirements in terms of blending

efficiency. Suitable for laboratory and small-scale production with a capacity of between 5 and 100 litres, the Interchangeable Blender comprises a base section with motor/gear box, support structure and cantilevered arm capable of holding a wide range of different blender body types and sizes which can be easily interchanged. As a result customers wishing to blend different products with different densities can do so without the capital expense of procuring multiple blenders or the resulting poor quality blending and longer blend times associated with process compromises such as over or under filling blenders. Further benefits are that cross contamination is eliminated as individual products can be dedicated to a single blender cone or section. The blender base can be fitted with V Cone, Double Cone, Ribbon, Octagonal and IBC blender bodies. Bodies of varying sizes, in a range of 5 to 100 litres, can be kept in storage on a dedicated trolley. When required, the trolley is presented to the blender base and, with a simple connection, the bodies changed in a matter of minutes. Also available as an optional feature is a RFID system which works with the controls package to ensure that only the correct body dedicated to a specific product or recipe can be used. The software will not allow the blend to run if the correct blender body is not installed. Founded in 1927, British Rema was an early pioneer in the field of particle size reduction and size control specialising in blending, milling, micronising and classification. Today the company is a leading supplier of powder processing equipment to the Pharmaceutical, Food, Plastics, Metal Powders and Chemical industries. For more information on the Interchangeable Blender please contact Debbi Marlow on +44 (0)1246 269955 or email info@britishrema.com For more about & other products contact British Rema Process Equipment Ltd, Chesterfield, Derbyshire go to www.britishrema.co.uk

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LOW POWER DUST TIGHT CONVEYING

Multiple Outlet Tube Chain Conveyor for Kaolin Many industrial processes need to move dusts and powders around the system. The holy-grail is to achieve this with low cost of ownership and consume low amounts of energy. The conveyor needs to take in all of the material and discharge all of it at the required outlet without damaging the material. The Schrage Tube Chain Conveyor meets these objectives. It enjoys the following benefits: • Low power consumption – the smallest conveyors can move 0.45m3/h and only consume 250W – less than an office computer! The upper limit to throughput is 60 m3/h with 11kW. • Gentle handling – your delicate product is discharged in exactly the same physical form as it entered the conveyor • Low wear rates – due to the slow speed of operation, the life of wear parts is measured in years. • Low maintenance – a simple check every month is all that is needed, just taking a few minutes. If required at all, major maintenance can normally be planned for an annual shutdown. • ATEX ratings available – conveyors can be supplied to Cutaway Section meet all ATEX levels; safe zone to ATEX 20. • Totally dust tight – the all steel construction means no leakages, all of the product you put into the conveyor comes out at the other end. As there is no pressure inside the conveyor, there is no internal force trying to push material out. • Range of steel types – from carbon steel right through to 318 stainless (corrosion and abrasion resistant) • Large conveying runs possible – 60m horizontally or 40m vertically. The conveyor can run at any angle from 0o to 90o.C Three dimensional configurations possible – this can reduce the machine count significantly, enhancing plant reliability. • Multiple inlets and outlets – feed and discharge your material in any combination.Characterised by long life time and excellent cost to performance ratio, the tube chain conveyor is the solution to many conveying problems. Totally dust tight, all product passes through the conveyor without losses, increasing process efficiency and having very low power requirements. We are always happy to discuss applications and create the optimal configuration for your process. For more information contact: Renby Limited - Tel: +44 (0)1829 740913 Email info@renby.co.uk |Web: www.renby.co.uk / www.schrage.de

FROM STAND-ALONE BULK HANDLING EQUIPMENT TO INTEGRATED SYSTEMS

Individual bulk handling equipment from Flexicon includes: Flexible Screw Conveyors, Tubular Cable Conveyors, Pneumatic Conveying Systems, Bulk Bag Dischargers, Bulk Bag Conditioners, Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Tippers, and Weigh Batching/ Blending Systems. Each of these product groups encompasses a broad range of models that can be custom engineered for specialized applications, and integrated with new or existing upstream and downstream processes and storage vessels. For large-scale bulk handling projects, Flexicon’s separate Project Engineering Division provides dedicated Project Managers and engineering teams on four continents to handle your project from concept to completion. Working with your engineering firm or directly with your team, Flexicon adheres strictly to your unique standards, documentation requirements and timelines through a single point-of-contact, eliminating the risk of coordinating multiple suppliers. All equipment is available to food, dairy, pharmaceutical and industrial standards and conforms to ATEX, UL, CSA, CE and other electrical standards. For more information contact Flexicon Europe Ltd Tel:+44 (0)1227 374710 E-mail: sales@flexicon.co.uk Web: www.flexicon.co.uk

VISIT THE VEGATRUCK ON ITS UK TOUR The VEGA TRAINING TRUCK has been specially designed to be a memorable experience for people involved with level and pressure measurement, and it tours the UK in February and early March 2016. An iconic American truck hauls an amazing ‘Formula One’ built trailer, which converts into an interactive training space for level and pressure instrumentation. Once inside, you will find working process displays of both solids and liquids applications, operational instruments to see and handle, along with a presentation area. Be assured, this is not just another mobile exhibition. It will be stopping at a number of venues where you can come along and visit, they include: Aberdeen; Grangemouth; Liverpool; Hull; Grimsby; Derby; Coventry; Peterborough; South Wales and Burgess Hill. This facility is specially designed to educate, inform and inspire engineers or stakeholders involved in processing and manufacturing at all levels. Come along, bring colleagues, and our experts will be there to help you get the best from it. Take away a great experience, some new ideas, a training certificate and memento of a visit you will be glad you took time to see. If you would like to come along for a session contact linda.macdonald@vega.com for further details, locations and timings.

Made in Britain

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ADDING & RETAINING VALUE IN BULK MATERIALS PROCESSES

By Dr Robert Berry, Consultant, The Wolfson Centre for Bulk Solids Handling Technology

ost manufacturing plants employ multiple processing steps to take raw materials or (pre-processed) materials and create a finished particulate product that is required to have consistent bulk properties and functional performance, e.g. taste, dissolution properties, chemical composition etc. These processing steps might include operations to; create particles (spray drying, centrifuging), modify the particle size (grinding and crushing or comminution and agglomeration), blend or separate different particulates (mixing, grading screening) remove moisture (band dryer), and finishing processes (coating, tableting or packing into big bags, sacks, sachets etc). In order to achieve these successive processing operations, the bulk particulates must be conveyed through the factory from one step to the next using; mechanical conveyors; screw, chain, vibratory, pneumatic conveyors, belt conveyors or manual handling. Since these processing operations require a continuous material feed for efficient operation, buffer storage in the form of a hopper, silo, bulk bag is required before each process. In many industries it is the performance of the storage and handling equipment that can limit the process throughput, due to the potential for material arching over the outlet of a silo or block in a conveyor due to cohesion i.e. particles sticks together when compressed. Cohesion is primarily a function of particle size, as this reduces inter-particulate forces (van der Waals) dominate over gravity forces. As typical values, most materials start to exhibit cohesion when the particle size reduces below 100microns and some become non-flowing when the particle size approaches 1micron. However, the forgoing assumes the absence of liquid; the surface tension of the liquid on wet material can generate cohesion when the particle size is of the order of several millimetres. Free flowing materials can also generate processing problems but presents different challenges. These are the: • Propensity for the material to segregate, i.e. particles separate by size, shape or density when poured to form a heap, as occurs when they are gravity loaded into a buffer silo or into some types of conveyor. • Separation of dust or fines (typically below 50microns) occurring when material is charged into an open space at high velocity, e.g. pneumatic loading of a silo or equipment fed by long gravity chutes (e.g. where processing steps feed from one floor down to the next). Thus process plant design and efficient operation is complicated by the interrelations between the numerous processing operations and the flow characteristic of the storage vessels and conveyors being used, which can also generate unintended changes in the particulate material. For example: • process steps that change the particle size, or drive of surface moisture will result in changes in the way the bulk material flows through the conveyors, most operating less efficiently as the particle size reduces, or surface moisture increases (below saturation). • Furthermore some conveyor types lead to particle attrition in operation. For example in a pneumatic conveyor the particles suffer an impact against each bend in the pipeline

leading to particle fracture, fines generation and an unwanted change in the size distribution of the product. • Another common challenge is that poorly designed silos can drive segregation of particles by size, which can undo preceding blending operations and result in a finished product that is out of specification. Segregated Bulk Materials

When troubleshooting a processing line or defining modifications to a plant it is critical that a holistic view of the interaction of the complete assembly of equipment. Failure to do so considerably increases the risk associated with such projects. Most of the above problems can be predicted and equipment can be designed to either eliminate or minimise the effects. However all these design methods require characterisation of the relevant flow properties of the material to generate relationships between particle and bulk scale, which requires testing on representative samples at process appropriate conditions of temperature, relative humidity and storage pressure.

INDEPENDENT EXPERTISE: PROVIDING COST-EFFECTIVE SOLUTIONS TO INDUSTRIAL PROBLEMS

Degraded Breadcrumbs

Biomass Caking Characterisation of Grain Samples

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

The Wolfson Centre for Bulk Solids Handling Technology is internationally recognised for its expertise in fields associated with bulk particulate handling and in the science and practical application of technologies to deliver improved process efficiencies. Our mission is to help industry to get powders and bulk materials to behave predictably through processes. Industry sectors benefiting from our services range widely and include power generation, chemicals, pharmaceuticals, foods, plastics, paper, minerals and cosmetics. Our clients are predominantly based in the UK, although many European and overseas companies take advantage of the independent and bespoke nature of our work. We have developed our portfolio of services over nearly four decades of interaction with industry, trade associations and professional bodies. We offer consultancy services to industry, conduct industrially focused research related to bulk solids handling issues and offer specialist short courses targeted at industry professionals. If you have a problem with your plant or process, we have the knowledge and experience to provide cost effective answers that you can rely on. The centre is situated at the University of Greenwich’s Medway Campus, where we are part of the School of Engineering. Our location offers excellent transport links within the UK and EU enabling us to provide a prompt and flexible response to site visit requests and client meetings. Our experts have between them over one hundred man-years of experience of solving problems in the flow and processing of powders, granules and lump materials, in all industries from pharmaceuticals and food to mining and chemicals; from biomass waste and recycling to household goods and pet foods. They concentrate on the needs of the industry and share their knowledge through the provision of technical research papers, articles and editorials through the media and at conference and exhibitions where they often present papers or hold workshops. Our industrial-scale pilot plant is available to test a processing step, or mock up a whole handling process or logistics chain, at full scale or near full scale. This can be used to find and solve the problems off-line, then when you transfer the same process or material to your own or your customers’ plant, you can be confident it will work! Contact us now on Tel: 020 8331 8648 E-mail: wolfson-enquiries@gre.ac.uk to find out how we can help you.

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DUST SUPPRESSION WITH FOG

– JUST ONE OF MANY USES FOR FOG By Robin C Travis, B.Eng MIET, Managing Director of Renby Limited

Fog; microscopic sized water droplets suspended in the air – often an alien tool for many - is finding favour in a broad range of applications. It may not be a panacea for everything but it is proving highly useful in numerous areas. The Renby MicronFogTM system objective was to use it for dust suppression. As experience with the technology has increased, a whole host of other uses have materialised in previously undreamt of applications.

WHAT IS FOG? At this time of year in The UK, you are often surrounded by it. That is; microscopic droplets of water suspended in the air. The Renby MicronFogTM system recreates this phenomenon demand from pure drinking water, there are no additives. To be a fog, mist or haze the water droplet size is the same, it is just the quantity or density of water droplets that varies. The Met Office defines fog or mist by visibility i.e. quantifying the distance that you can see through it: • Haze: Visibility over 2km • Mist: Visibility between 1km and 2km • Fog: Visibility less than 1km, With MicronFogTM we can produce anything from a fine haze to a thick fog with visibility falling to a few metres! The key to fogging or misting is to keep the water droplet size small and therefore light enough to be suspended by the air molecules. To achieve this, the droplet size needs to be in the range 5 to 20 microns. With droplets in this size range, the fog hangs in the air and dwells for some time after the system has been stopped. This effect cannot be achieved with a sprinkler system where the droplet size tends to be in the region 200 micron and droplets are heavy enough to fall straight to the ground. The small fog droplet size is important for several other reasons as well, more of which will come later.

HOW IS FOG GENERATED?

Rapid Assembly Fog Line appearing as a mist. For an industrial process, fog is required upon demand, so a controlled approach is required that can be switched on or off at will. There are in fact several ways to produce fog artificially. In an increasingly energy sensitive environment, it is important to opt for the lowest energy approach. The solution to this is to pressurise the water to significant pressures – 70 Bar / 1000 psi or more. The water is then fed through lengths of tubing to a network of nozzles and forced through a tiny orifice in the nozzle to produce a plume of fog. The quality of the orifice is essential to producing an even, fine spray of fog. There are many cheap nozzles available with rough edges around the opening. These tend to produce over-size droplets and are often identified by an irregularly shaped cone of fog emerging from the nozzle. Renby MicronFogTM nozzles use laser drilled ruby orifices to ensure a smooth, round opening every time. With openings as small as 85 microns, it is crucial that the water in the system is clean. A two stage water filtration system is used to remove particles and sediment from the water.

Poor Drilled Nozzle

Nature has developed a very effective way to produce fogs and mists naturally, by localised changes in temperature, resulting in air becoming saturated and the surplus moisture

Laser Drilled Ruby Nozzle

Without good filtration, the nozzles will block regularly and this extra stage pays dividends in longevity of the nozzles. Likewise, hard water can cause problems, so every system is supplied with an electronic descaler that ensures lime does not precipitate out before the water leaves the nozzle. The electronic descaler also means that there are no softening chemicals to be topped up.

FOG SAFETY Legionnaire’s Disease is another important consideration. If a system does not pay full attention to this then avoid it at all costs. It may be cheap in the short term, but who wants to be the one to explain to a family that they have lost a loved one as a result of saving a little bit of money? As the water droplet size is so small, it and whatever it contains can easily enter the body, therefore, it is essential that the water used in the fog is extra safe. To this end, we insist that mains potable water is used as a supply and then take the supplemental step of further disinfection using ultra violet light. This is interlocked with the system control which prevents the system from operating if the UV lamp is not functioning or has reached the end of its life.

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ENERGY USE By using high pressure water, the energy requirement is approximately 1/8th of alternative techniques and uses relatively small amounts of power. All systems come with motor inverters to further reduce power consumption. As an example, a major onion packer uses a system that consumes less than 1.25kW power to suppress dust in a building with an area of 1100m2 and uses 28 nozzles. At the other end of the scale, a biomass store with a floor area of 6000m2 uses 5.5kW low flow nozzles. In both cases, the systems must not wet the product in the building. This has been achieved through the use of careful nozzle placement and electronic controls on the system. Those familiar with dust collection systems will find these power figures remarkably low, making fog a cost effective solution for dust suppression in large warehouse type areas.

DUST SUPPRESSION WITH MICRONFOGTM This a major use for fog. Many industrial processes generate dust. Once airborne, this will hang in the air for hours and can be breathed in by operatives, pollute the process and clog equipment. Fog works as a dust suppressant due to the small droplet size. This is a similar size to the dust particle enabling the two to stick together when they collide. Typically, several dust particles adhere to the water droplet. As a result, the overall weight of the agglomerate becomes large enough to fall out of the air, removing the respirable airborne dust with it.

growth. MicronFogTM replaced a low pressure spray system that was humidifying a group of polytunnels used for mushroom growing. Not only was the result a more precise control of humidity levels but it also reduced water usage as the older technique was wasteful. When required, the system can be expanded to measure and control the humidity in each tunnel. This versatile function enables the system to provide precise humidity levels in each tunnel, responding to the crop requirements at each stage of the growth cycle.

Exotic Mushrooms Grown with MicronFogTM

LANDSCAPE AND ARCHITECTURAL Whilst not strictly an industrial process, the versatility of the system is such that it can produce great effects for art installations and sculptures. The ability to switch fog on and off at will facilitates the design of a whole new area of kinetic sculptures providing an immersive experience to visitors. The system has been used to provide effects ranging from banks of fog for visitors at a tropical rainforest attraction to atmospheric effects for film sets. The image shows a kinetic sculpture designed by a leading UK sculptress, renowned for some of Europeâ&#x20AC;&#x2122;s largest kinetic sculptures.

Dust Suppression of an Energy from Waste Fuel Intake

MicronFogTM nozzles can be placed around the source and in certain cases can drop the dust back into the process. In other applications, for instance warehousing, a more general arrangement can be configured at roof height. Any airborne dust is then captured and dropped to the floor. There is often concern about wetting the product but MicronFogTM has been usedsuccessfully on dry powder bagging lines, potato and onion packing. In each of these applications, it is essential that product remains dry. If not, the product becomes unsaleable. At present, there is a Government public education campaign about COPD (Chronic Obstructive Pulmonary Disease). Whilst smoking is a cause of this, breathing in workplace dust is another common cause. There are already regulations in place limiting exposure to silica dust to 0.1 mg/m3. There is discussion about reducing this further to 0.05 mg/m3. Fog has been used successfully to bring the levels below this tighter requirement and will be an essential tool to meet the stricter requirement.

Kinetic Sculpture with MicronFogTM

CONCLUSION The objective of this article has been to give an insight into the breadth of applications that can use fog. Fog offers a comprehensive range of options that can be tailored to address all manner of applications. When using fog in any application it is essential to ensure that due consideration is given to water safety. MicronFogTM has been proven to offer a practical,economical and low energy solution for all manner of uses.

HUMIDIFICATION AND COOLING Another effect that occurs with fog is flash evaporation. Once again, due to the small droplet size, the fog droplet can rapidly evaporate into the air. As the flash evaporation occurs, there is a corresponding drop in temperature. In a building, this can occur after a few minutes, but it has also been observed within seconds on a ducted system. For instance, when a fan is used to force air into a process, the compression can cause the air to increase in temperature. By introducing fog downstream of the fan, cooling will occur due to flash evaporation. We have observed temperature drops from 40oC to 25oC within seconds on process air. For food cultivation, the control of humidity is an essential ingredient for promoting crop

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

For more information contact Renby Limited Tel: +44 (0)1829 740913 E-mail: fog@renby.co.uk Web: www.micronfog.com 13sp

IS YOUR PLANT VULNERABLE TO CYBER-ATTACKS? Easy steps to closing the door

High profile cyber attacks on banks, charities, telecom companies etc have hit the headlines lately, but your plant is just as much at risk! Have you evaluated how secure your plant is? In a bid to help industrialists better prepare for possible infringement to their industrial control systems network security, experts at the Wolfson Centre for Bulk Solids Handling Technology have devised a one day short course that examines this topic from design through to installation. It will inform attendees of best practice in industry such as strategies, activities, or approaches, which have been shown to be effective through research, evaluation and implementation. The Chancellor has pledged to increase spending on cyber security to £1.9 billion by 2020. You are not being asked to spend a billion; just £490 will secure your place on this one day course on 9 March 2016 at the Centre’s premises in Chatham Maritime, Kent. Contact details: Wolfson-enquiries@gre.ac.uk 020 8331 8646 www.bulksolids.com

INTERNATIONAL SYMPOSIUM, FUNCTIONAL NANOMATERIALS IN INDUSTRIAL APPLICATIONS Hosokawa Micron Ltd announces their three year partnership and sponsorship of the International Symposium on Functional Nanomaterials in Industrial Applications organised by University of Central Lancashire (UCLan), Preston, UK. The academic-industry meet will take place at UCLan, Preston on 29th – 31st March 2016. Bringing together researchers from both academic and industrial organisations on a single platform, organisers believe that after 25 years of research in nanotechnology, the time is right for academic researchers to discuss with industrial organisations an exploitation plan and future strategy for the ultimate goal i.e. Benefit for society. The symposium aims to discuss three major thematic areas; (i) Nano-energy/environmental for a better society; (ii) Nano-medicine for health and diagnostics and (iii) Nano-catalysis for green technology. Eight keynote speakers who have made outstanding contributions to their field and four eminent and enthusiastic plenary speakers from Europe, USA and India, including Iain Crosley, MD, Hosokawa Micron Ltd, will deliver presentations to an international audience. The additional submission of over 130 abstract presentations, from every continent, means delegates will find the broadest representation on each of the three symposium themes. ‘After our many years of research and pioneering advancement in the developments of our technologies to create new functional nanopowders and a diverse application menu, Hosokawa Micron welcomes this opportunity to share ideas for a future, concerted andglobally beneficial nanomaterials strategy.’ Iain Crosley, MD, Hosokawa Micron Ltd For Symposium information: www.hosokawa.co.uk For further information/reader enquiries, please contact: Hosokawa Micron Ltd, Runcorn, Cheshire, WA7 3DS. Tel: +44 (0) 1928 755100 Email: info@hmluk.hosokawa.com www.hosokawa.co.uk

FAST, HIGH CAPACITY PRECISION MIXING The new Bella XN double shafted Fluidized Zone Mixer by Dynamic Air includes access doors which not only increase accessibility but also make it much easier to clean when necessary. The Bella mixer achieves fast, high capacity, low shear, precision mixing of either dry bulk solids or liquids with solids. Regardless of particle size, shape or density, materials are mixed with a fast, efficient, and gentle action - typical mixing times are 60 seconds or less. A weightless zone created by low-speed counter rotating shafts generates very low friction without shear. This makes it ideal for fragile products that cannot tolerate rough handling. Even flakes or spray-dried bodies remain intact. The Bella XN mixer includes twin bomb-bay door openings for fast, efficient discharging and to minimize segregation during discharge. The Bella mixer is available in stainless steel for sanitary applications. Custom sizes, finishes and materials of construction are available upon request. For more information contact Dynamic Air Ltd. Milton Keynes Tel: +44-1908-568155 E-mail: sales@dynamicair.co.uk Web: www.dynamicair.com

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WEIGHING UP CONVEYING OPTIONS FOR THE RIGHT MATERIAL SOLUTIONS By Dr Will Weston, Head of Materials Handling, Spiroflow Limited

. Conveying of bulk solid materials within a factory setting is a complex area. Manufacturers require dust-tight systems that can provide optimum performance, whether equipment is required for food ingredients such as flour, cereals and coffee granules, efficiently transporting waste for the nuclear power industry, or accurately controlling the flow of materials for the chemical and mineral sectors. Here Spiroflow, one of the world’s leading manufacturers of a full range of equipment for handling dry bulk solids and ingredients, takes you through the conveying options available depending on the customer’s materials, processes and the factory layout.

t Spiroflow’s well-equipped material characterisation laboratory within its UK technology centre in Clitheroe, Lancashire, scientists measure the fundamental physical characteristics of a customer’s material, determining how it will flow into and through conveying equipment to enable the design of the feed hopper and decide which, if any, mechanical flow aids are needed. The type and design of conveyor is matched to the nature of the ingredient. This knowledge enables customisation of machinery exactly to clients’ needs. Here is a list of questions that will need to be answered as a minimum before the choice of conveyor can begin: 1.The product(s)? 2. Its/their bulk density(ies)? 3. Its condition (moisture content, average particle size, temperature etc)? 4. Is the product likely to change in anyway in the future? 5. From what is the product being conveyed (silo, big bag, sack tip station)? 6. To what is the product being conveyed (mixer, sifter, mill, reactor)? 7. If it’s a reactor of any type, is there any steam, gas or solvent given off that might enter the conveyor? 8. The horizontal conveying distance? 9. The vertical height to which the product has to be conveyed?. 10.The route of the conveyor (inside, outside, number of bends required etc)? 11. The conveying rate in kg/hour or the batch size over a given time? 12. Is the conveyor to transfer a pre-weighed batch, is it transferring material to a receiver of a given size / on load cells or is it a continuous process? 13. How often / for how long will the conveyor run each day? 14. Is it important to deliver the material to the receiver in a homogenous manner - such as when flakes are added to a liquid to make a lump-free paste? 15. If the product is a mixture, is it essential that the integrity of the mix is maintained? 16. Is the material fragile and how important is it to minimise damage during conveying? 17. What accessories are required (sack tip station, bulk bag discharger, receiver hopper, etc)? 18. Is the conveyor to operate in a dusty or otherwise

hazardous area (i.e. do the Atex/Desear regulations apply)? 19. Is the conveyor manufacturer to supply the control panel, level sensors, etc? 20. Will the conveyor be readily accessible for maintenance purposes? 21. For how long is the conveyor expected to run between services

Cableflow™,Tubular Drag and Pneumatic conveyors – to meet the most testing conveying challenges. Each technology best suits different sub-sets of classes of material as explained below: Flexible screw conveyors are more than just flexible in the mechanical sense – the range of materials they can convey is very wide and the range of designs can deliver from 25 L to over 40 m3 per hour. It uses the product as the ‘bearing’ for the spiral and as such is both cost effective to purchase/ maintain and very easy to clean. Depending on the material and application Spiroflow offers nine sizes and four different spiral designs in a range of materials and finishes. Aeromechanical conveyors move material in pockets between fast moving discs inside a rigid line. For throughputs between 15–60 m3hr1 this could be the conveyor of choice. For materials with a high densification potential, such as titanium dioxide, aeromechanical conveying is the ideal option. Additionally, the

TAKE ACCOUNT OF THE MATERIAL, HAS IT BEEN CHARACTERISED & UNDERSTOOD, HOW DOES THIS GUIDE THE SOLUTION? The consistency of component concentrations in a mixture can be a key consideration in their quality. Depending on the differences (size, density, fluidity, shape etc.) the choice of conveyor can be critical to preserving the homogeneity of the ingredients during the handling operation. The integrity of fragile material, such as dry foods like breakfast cereal and pasta, clearly needs to be preserved, but this can also apply to specialist powders. For example, spray drying is often chosen as a size increasing mechanism to aid flow or maintain the integrity of a powder blend. For both fragile particles (>2mm) and fragile powders (<2mm) mechanical conveyers offer a more gentle handling solution than a pneumatic system. For applications that require the product to be contained away from the local environment (which may be to keep foreign materials out or hazardous substances in) the options within the Spiroflow conveying range can be a very good solution. Complete containment can be readily achieved – not true of older technologies like belts or bucket elevator systems. Conveying rate and route through a factory environment also needs to be addressed to define the type of transit system required. An aeromechanical conveyor is ideal for a high rate, a flexible screw conveyor for a difficult route and a pneumatic conveyor for a really tortuous path.

WHICH EQUIPMENT CONVEYS THE BEST SOLUTION? There a wide range of solutions - Flexible Screw, Aeromechanical,

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

energy usage per tonne conveyed is less than a fifth of that of a pneumatic system which can be a significant consideration in a high rate 24/7 application. They are perfect for vertical conveying, with no loss of throughput. Cableflow™ conveyors are ideal for fragile material such as a coffee granule or breakfast cereal. Compared to a traditional bucket conveyor they offer significantly better containment along with lower downtime and maintenance costs, while conveying up to 21 m3hr1of material. Tubular Drag If you want to move dense, hot or highly abrasive material then none of the equipment detailed above is likely to be suitable. Here is where a Dynaflow™ conveyor is likely to be the best choice. A Dynaflow™ drags material with a disc and chain assembly inside a heavy duty transfer line. It can convey via complex routes and at any angle. These conveying solutions are underpinned by Spiroflow’s 40 years’ process experience and an ability to measure the fundamental characteristics of the materials to be conveyed..

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ENERGY SAVING AND EFFICIENCY IN DUST & FUME CONTROL Chris Oldfield of Ecogate Ltd reports According to the Environment Agency’s Greener Business Report, poor energy efficiency is costing UK business over £6 billion a year. However, for many companies employing processing operations, identifying areas of wastage may not be immediately obvious. In industrial processes where dust extraction systems are used, more and more firms are benefiting from retrofitting energy-saving upgrades which result in dramatic savings in electricity usage. In most existing dust extraction systems the extraction fans are in constant use and operating for anything from an 8 hour shift, 5 days a week, up to 24 hours a day, 7 days a week. Additionally, with a traditional constant pressure system, the minimum extraction pressure must be adequate to properly extract from the workstation farthest from the fan. This requirement wastes considerable energy and the extraction system is often consuming as much electricity as the lighting and the rest of the process machinery combined. With an energy-saving extraction system, optimum extraction is managed dynamically according to actual workstation requirements. Installing a proven ‘Extraction-on-Demand’ system can slash electricity bills by up to 80% and will typically pay for itself in just two years. Such systems employ a central controller, automatic motorised gates, remote machine sensors and variable speed technology. When a machine comes online, a sensor signals the controller to open the motorised gate of that particular machine to provide extraction and the controller determines the optimum fan speed, which is achieved using variable speed technology. When the machine is turned off, the gate automatically closes and fan speed is adjusted accordingly. The result is an optimised system that only uses energy when required.

WHY DOES IT WORK?

Just for a change, the laws of physics are on our side! Fan speed and extraction volume are directly proportional; if you vary the fan speed, the volume changes by the same percentage. However, the relationship between volume and power is cubic, which means a relatively small change in volume gives a much larger change in power consumption – reducing fan speed by 20% reduces power consumption by nearly 50%. More typically, on-demand systems only require around 70% of the full air volume capacity. At this point, the system uses only about a third of its full-power electricity consumption. By significantly reducing the amount of electricity you use, ‘Extraction-on-Demand’ reduces the environmental footprint of your operations, moving you closer to sustainability. A recognised leader in the field of ‘Extraction-on-Demand’ systems is California-based Ecogate, Inc. whose products are distributed in the UK and Europe by Ecogate Ltd. ECOGATE® systems have been saving energy on extraction applications worldwide for over ten years, and there are hundreds of installations in place, with over 20,000 ‘Ecogates’ currently in use. In the UK, the

company provides Ecogate products and services to authorised installers, including Airplants Dust Extraction Ltd, Cades Ltd and Dust Control Systems Ltd. The ECOGATE System is a microprocessor-controlled extraction optimisation system, employing a central control unit – the greenBOX® – which constantly monitors the operation of individual machines. The system is also designed to maintain minimum airflow in the duct system, by opening additional gates when necessary, delivering good system balance and preventing dust settling in the ducting system. The ECOGATE system offers total design flexibility – whether it’s a dust plant serving two or three machines, or large production facility with a plethora of dust-creating machinery. ECOGATE offers a choice of control systems: The greenBOX 12+ controller is designed for plants with one main extraction fan and up to 12 workstations. The greenBOX 12+ can be serialised, working in tandem to control up to 24 machines. For larger manufacturing facilities, the greenBOX MASTER SRL is capable of controlling up to 4 extraction fans, handling as many as 200 workstations. Operated by a 24V DC geared motor, motorised dampers (Ecogates) are an integral component of the system. Available to suit a wide range of ducting sizes, they are fabricated in zinc-plated metal or stainless steel. Ecogates are activated via Volt Sensors which read any AC or DC voltage and detect changes in voltage when a machine is turned on or off. System monitoring and evaluation of energy savings can be managed from a central location, using Windows-based software. Extraction fan motor speed is controlled by the Ecogate Power MASTER – a variable speed drive inverter unit, with integral controller, which maximises energy savings by providing continual adjustment of fan speed. For further info call: 01924 566770 or email: info@ecogate.co.uk Website: www.ecogate.co.uk

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SAXLUND WINS A FURTHER MAJOR ORDER WITHIN BIOENERGY WORTH OVER £2.7 MILLION AT PORT CLARENCE To design and supply two automated fuel management systems providing 40MW of renewable energy The energy and environmental technology Saxlund has won another large order from Babcock & Wilcox Vølund A / S, Denmark for the delivery of its first-class management of bioenergy projects in Teesside, near Middlesbrough, North Yorkshire. Overall, this means that the company has within 12 months won over £8 million in orders with Babcock & Wilcox Vølund for various projects in the UK. Saxlund’s will design and supply of two complete, automated fuel management system, both with full capacity to provide 100% redundancy a fuel content of up to 125 MW. Previous projects are at Margam in South Wales and Templeborough Biomass Power Plant in Sheffield. The two systems will be for the reception, delivery and mixing of fuel storage. The entire fuel management system, including storage and feed systems, will be designed for efficiency, minimum maintenance and high availability, while the environmental impact in the form of dust and noise is limited. The system also offers flexibility in the use of waste wood of different types and quality. The order value is over £2.7 million and is due to handover in 2017. Speaking for the Saxlund Group, Harald Wehner, Managing Director of Saxlund

“We are proud to help Babcock & Wilcox Volund build this first-class project. We supply equipment that is critical to ensure high availability, efficiency and flexibility for our customers. With extensive operations in Germany, the UK and Sweden and around 60 years of experience, we can provide innovative and proven solutions for most applications.” International GmbH said:

Matt Drew, European Sales Director and UK Managing Director Saxlund

“I believe the quality of our materials handling systems is second to none and is the reason we have been chosen. The Port Clarence project will provide 40MW of renewable energy to the UK energy market through the combustion of waste wood, and will have the capacity to consume about 250,000 tonnes of waste wood per year. “ For more information contact Saxlund International Ltd, Southampton, Hampshire. Tel: +44 (0) 23 8063 6330 E-mail: info@saxlund.co.uk Web: www.saxlund.co.uk International added:

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JOB VACANCIES AT WRIGHTS DOWSON GROUP, GAMLINGAY, BEDFORDSHIRE ENGINEERING MANAGER Candidates should have a hands on approach, be a qualified mechanical engineer capable of operating AutoCAD and or SolidWorks, plus experience of running an engineering team to meet customer expectations and company goals. Knowledge of the bulk solids industry and screw conveyor design would be an advantage, but not essential. Remuneration package commensurate with knowledge and managerial experience to fulfil this demanding position. AUTOCAD/SOLIDWORKS MECHANICAL DESIGN ENGINEER Candidates should be suitably qualified in mechanical engineering discipline, with a good all round understanding of engineering and design office best practices. Knowledge of the bulk solids industry and screw conveyor design preferred, but not essential. Remuneration package commensurate with knowledge and experience to fulfil the position. Please send covering letter and CV to Robert Hudson – MD – r.hudson@downsongroup.com

IF YOU ARE NOT A MEMBER OF SHAPA, WHY NOT BECOME ONE? SHAPA has been the UK’s leading specialist Association for the solids handling and processing industry since its formation in 1981. Our support and assistance has allowed our members to maximise their profitability, whilst taking advantage of the many benefits afforded by the Association. WHO ARE SHAPA? With regular meetings, guest speakers, awards, exhibitions and export assistance, you will find SHAPA an invaluable aid in promoting ideas and opportunities for your business. STRUCTURE With full member involvement in the running of SHAPA, you have immediate and effective input to the operation of policy, finance, technical issues and marketing activity.

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MILESTONES Since 1981, SHAPA has grown to be the foremost authority on solids handling and processing industry matters. Here are a few milestones in our development. REDUCED CAPITAL EXPENDITURE SHAPA members, with the support of the Association, are recognised for competitive prices and the highest quality solids and powder handling products and systems. CUT OPERATING COSTS Drawing on years’ of specialist experience, SHAPA members can deliver a tailored solution designed to optimise your operation and minimise your costs.

INCREASE PRODUCTION RELIABILITY The technical and product information resources provided by SHAPA enable all members to keep abreast of the latest product developments and legislation in a wide range of solids and bulk handling technologies. SHAPA ALUMNI The Shapa Alumni Group is open to those who have previously worked in the Solids Handling Industry who woud like to keep in touch. for more information go to www.shapa.co.uk and select the Alumni web page To apply to become a member please fill out our membership application form by going to: http://goo.gl/xlMsHO You can also read about the benefits of being a member by going to http://goo.gl/Mg4QO3

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

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