Process Industry Informer June 2018

JUNE 2018

www.processindustryinformer.com

Volume 14 No.3

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

Choosing

the right bearing material Choosing the right material to match the loading and environmental conditions can drastically affect bearing performance.

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Contents

FEATURED ARTICLES IMPROVING WASTEWATER MEASUREMENT

PRODUCT SECTIONS

06

and reducing the risk of excess discharges using electromagnetic flowmeters PAGE

NEWS & EVENTS

04 – 05

APPLICATIONS

07

PROCESS MEASUREMENT & INSTRUMENTATION

10 & 11

ANALYSERS

11

SWITCHBOX SOLUTIONS

11

Heat Transfer & Energy

14

Filtration & Separation

14

HEATING & COOLING

16

Calibration

20

Building Information Modeling

20

BPMA NEWS

Self-service Predictive Analytics

33

FLUIDS HANDLING

35

Health & Safety

37

DRIVES & CONTROL

37

Bottling Applications

37

Inspection & Vision Systems

40

Water / Wastewater

40

Compressors

40

12

- An Industrial Fortune Teller

18

Taking the pressure off of maintenance

21 – 32

SENSORS

SHAPA NEWS

08

CHOOSING THE RIGHT BEARING MATERIAL

Self-powered wireless sensors

34

in the industrial Internet of Things

36

Effluent treatment – the key technologies and how they are being used

41 – 51

How to choose an AODD pump

38

A quick guide to selecting the correct AODD pump for your specific application

Printed by Bishops Printers Ltd EDITOR Phil Black: philblack@piimag.com

CIRCULATION MANAGER Jean Caunin: info@piimag.com

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OFFICE MANAGER Diane Ullmann: dianeullmann@piimag.com

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

ART DIRECTION Louise Brooks & Milana Veselinovic

Advertisement & Editorial Offices Process Industry Informer, Passfield Business Centre, Lynchborough Road, Passfield, Liphook, Hants GU30 7SB Tel: 01428 751188 Email: info@piimag.com

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

All product announcements published in Process Industry Informer are paid for. All copy submitted for publication in Process Industry Informer must be legal and must comply with the British Code of Advertising Practice and is accepted for publication, or not, at the publishers’ absolute discretion. When deemed necessary all copy may be edited and classified at the publishers’ discretion. All material contained in Process Industry Informer is published in good faith, but it is emphasised that the publishers do not in circumstances accept responsibility for the accuracy or otherwise of any advertisement or message published (nor is any kind of warranty expressed or implied by such publication) and that the publishers specifically disclaim all and any liability to advertisers, readers and user of any kind for loss or damage of any nature whatsoever and however arising, whether due to inaccuracy, error, omission or any other cause, and whether on the part of the publishers of Process Industry Informer, or their servants or agents, or any other person.

Although it is the intention of the publishers in general to run copy as supplied by advertisers, advertorial items headings, which are not charged for, will be selected by the Editor, and other minor changes may be made, at the Editor’s discretion, for the sake of the clarity, to avoid offence, for legal reasons or to ensure conformity to house style. Copy supplied over length will be cut to the amount paid for. Units and abbreviations will be standardised in accordance with house style.

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

June 2018 – Process Industry Informer

03

NEWS & EVENTS

2018 set for massive environmental monitoring event This year, two of the world’s largest environmental monitoring events will take place in the same place and at the same time – Telford, November 21st and 22nd.

WWEM 2018 will be the eighth in a series that began in 2005, and AQE 2018 will be the tenth in a series that began in 2002. As specialist events focusing on the regulations, Standards, methods and technologies in environmental monitoring, enormous synergy is created by running them together.

The WWEM (Water Wastewater & Environmental Monitoring) events have grown year on year, and AQE (Air Quality & Emissions) has expanded beyond recognition.

“Many of the delegates for these events work in both emissions to air and wastewater, so this will be great news for them,” comments organiser Marcus Pattison. “However, and it’s a big however, these events are feverishly busy; each with a packed workshop programme running alongside a conference, all of which is CPD accredited, so the need for delegates to plan their visit is even greater than usual.”

“Visitors will need to study the conference and workshop programmes on the two event websites, and plan their time accordingly. In all likelihood, this will necessitate coming on both days to make the most of the conferences, workshops and both international exhibitions.”

Anyone planning to attend should register at www.ilmexhibitions.com. By registering, visitors will be eligible for free parking and refreshments, as well as free entry to both exhibitions and all workshops. The exhibitions will feature over 230 companies representing more than 400 manufacturers, and there will be a total of over 140 free technical workshops to choose from.

ABB wins Manufacturer of the Year at 2018 Motion Control Industry awards ABB has won Manufacturer of the Year at the Motion Control Industry (MCI) awards for the second year running.

role in the reliability of industrial plant, where downtime might cost thousands of dollars a day.

The award recognises ABB’s commitment to developing technologies and services that help improve the performance of motor-driven applications across diverse industries, from food and beverage and packaging to water and oil and gas.

Recently, ABB launched a suite of digital remote services including remote assistance, condition monitoring and predictive maintenance as part of the company’s ABB AbilityTM digital platform.

Using drive data in the cloud, the manual and labour intensive information gathering of traditional maintenance assessments is removed.

ABB is one of the few companies that manufacture both variable speed drives and electric motors. This, coupled with its expertise in understanding all applications, from pumps, fans and compressors to elevators, conveyors and winches, has resulted in bespoke drives and motors packages aimed at specific industry applications. These products play a critical

For more information contact ABB Ltd, Warrington, Cheshire Tel: 01925 741517 E-mail: layla.hewitt@gb.abb.com Web: www.abb.com

In addition to the updates on regulations that will be provided by many of the conference speakers, each exhibition will feature a ‘Regulators Stand’ providing help and advice from the regulators of England, Wales, Scotland, Northern and Southern Ireland.

Both AQE 2018 and WWEM 2018 will take place at the Telford International Centre,(UK) which benefits from a number of local hotels. However, with a high proportion of visitors likely to attend over both days, the organisers are recommending early booking.

For information on WWEM or AQE: Marcus Pattison Tel. +44 (0) 1727 858840 Email info@ilmexhibitions.com

%R 0 0 E FE

NG LI LO SE HO

1

Andy Preston of ABB accepts the MCI Manufacturer of the Year award from Helen Fospero, host, and Ryan Fuller of category sponsor Hydraulics & Pneumatics magazine

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Process Industry Informer – June 2018

NEWS & EVENTS

Watson-Marlow Limited is honoured with Queen’s Award for Enterprise: Innovation 2018 on Her Majesty’s 92nd birthday The award recognises the Company’s development of its Qdos pump technology the world’s first self-contained, chemical metering pump.

Qdos, the innovative chemical metering pump wins the Queen’s Award for Enterprise: Innovation 2018. This category rewards world class innovation coupled with proof of five years of sustained sales.

Eleanor Spensley – Marketing Coordinator, James Podevyn – Sales Director and Aimee Donaldson – Project Engineer with their awards

DOUBLE SUCCESS FOR SPIROFLOW AT THE SHAPA SOLIDS HANDLING INDUSTRY AWARDS Spiroflow scooped two awards at this year’s SHAPA Solids Handling Industry Awards, held on the SS Great Britain, Bristol on 17 April.

The Clitheroe-based manufacturer of dry ingredients conveying and bulk bag handling equipment won the top accolade of Company of the Year, with employee, Aimee Donaldson, being presented with the Newcomer of the Year Award.

SHAPA has been the UK’s leading specialist Association for the solids handling and processing industry since its formation in 1981 and has over 100 members. The Solids Handling Industry awards are open to all UK registered member and non member companies and institutions operating in the Solids Handling and Processing Industry.

In achieving their Company of the Year Award, Spiroflow needed to show a consistent level of achievement, through sales and best practice. The company’s winning entry not only showed a marked increase in sales, but also an array of progressive infrastructure and technological initiatives aimed at maintaining Spiroflow’s position as a leading provider to the process industries. Key milestones have included: the expansion of production, stores, spare parts and despatch areas; a new website; the relocation and upgrade of Spiroflow’s Technology Centre; online conferencing and IT upgrades; the development of Spiroflow’s Active Management (SAM) offering; health & safety, quality and training investments; the recruitment of young, energetic graduate engineers; and finally involvement with local schools, STEM and apprenticeship schemes.

In addition, the award of Newcomer of Year Award is testament to Aimee Donaldson’s drive and passion for engineering. Having joined the Spiroflow team in 2014, Aimee is a graduate of the University of Central Lancashire with a Masters in Motorsports with Honours in Engineering. Initially recruited as a trainee sales support engineer, she has since made rapid progression within the company to her current role as a project engineer.

Qdos pumps provide more accurate, linear and repeatable metering than conventional diaphragm metering pumps and feature a single, no-tools component change with integral leak detection, reducing process downtime and lowering the overall cost of ownership.

Watson-Marlow Limited is headquartered in Falmouth in Cornwall and is a leading manufacturer of peristaltic pumps and tubing. It is part of the Watson-Marlow Fluid Technology Group, a world leader in peristaltic pumps and complete fluid path technologies.

Watson-Marlow is one of over 230 businesses from across the UK to have been recognised for its contribution to innovation, international trade, sustainable development and promoting opportunity.

Simon Nicholson, Managing Director of Watson-Marlow Limited comments: “To win a Queen’s Award for Enterprise in the category of Innovation is fantastic news for our business. It is a marker of the tremendous energy and commitment of our staff as well as their pursuit of the very best in product innovation. Every member of our team can celebrate his or her part in this prestigious win. We are truly honoured and delighted to find ourselves in receipt of a Queen’s Award for the second year in a row.”

“Qdos is no ordinary pump technology. The judges have clearly recognised the tremendous work undertaken by our product design team. Qdos provides a solution to a wide range of industrial and environmental applications that require chemical dosing. The market demanded cost effective systems, offering increased safety and low operational expenditure.

This is precisely what we delivered and as such, Qdos – which is manufactured here in our Falmouth factory - is now deployed all over the world.”

Greg Clarke, Secretary of State for Business, Energy and Industrial Strategy said: “The UK has some of the most entrepreneurial and innovative minds in the world delivering jobs, growth and greater choice for consumers and I am proud to see a wealth of these businesses being recognised today.”

For more information contact Watson-Marlow Fluid Technology Group, Falmouth, Cornwall.

Tel: 01326 370370 E-mail: info@wmftg.com Web: www.wmftg.com

In commenting on both awards, Spiroflow’s James Podevyn said: “This is a fantastic result for Spiroflow, and in particular, our dedicated and hard working employees. Much of our progression, whether it be product related, IT, customer support or technology initiatives, emanates from the extensive skill sets of the Spiroflow team. We are delighted for Aimee and her award is richly deserved - she has a great future ahead of her.”

For more information contact Spiroflow Ltd, Clitheroe, Lancs.

Tel: 01200 422525 E-mail: cathy.podevyn@spiroflow.com Web: www.spiroflow.com

I/O FOR THE MOST EXTREME CONDITIONS WAGO’s I/O system, 750 XTR, is extremely weather resistant and can operate from -40 °C up to +70 °C, making additional heating or cooling equipment unnecessary.

It is highly resistant to electromagnetic interference as well as insensitive to vibrations and impulse voltages up to 5 kV, ensuring secure communications in demanding applications. With up to 16 channels in a 12 mm wide housing it requires less space, and has lower energy and maintenance costs; taking automation into extreme environments.

To request a catalogue call 01788 568 008, e-mail ukmarketing@wago.com, or visit www.wago.com June 2018 – Process Industry Informer

05

FEATURED ARTICLE

By Alan Hunt, Electromagnetic Flow Product Manager, ABB

Improving

wastewater measurement and reducing the risk of excess discharges using electromagnetic flowmeters

Accurate measurement of wastewater flows is needed to help maintain compliance with increasingly stringent legislation aimed at minimising the impact of human activities on the environment. Alan Hunt, ABB’s Electromagnetic Flow Product Manager for UK and Ireland, explains why electromagnetic flowmeters can offer the best solution for keeping track of wastewater flows.

Industrial companies account for a significant proportion of water and energy consumption in the UK. These companies produce considerable volumes of waste, which need to be accurately monitored in order to assess and limit their impact on the environment.

Under the Environmental Permitting Regulations (EPR), any industrial company discharging 50m3 or more of effluent per day to a watercourse or the sea is obliged to self-monitor its effluent flows. In addition, some companies that discharge to a particularly sensitive aquatic life area may have to selfmonitor their effluent flows even if they are discharging below 50m3 per day if this is specified in their permit.

Introduced as part of a move to improve the measurement and control of discharge and waste levels from industrial companies, the self-monitoring obligation requires operators to comply with the Environment Agency’s MCerts certification scheme. Under this scheme, companies should be able to demonstrate to the satisfaction of an MCerts inspector that they are using the Best Available Technique (BAT) to protect the environment.

Where the self-monitoring of effluent flow is concerned, operators are subject to a ±8% uncertainty target for the measurement of total daily volume of effluent discharged, with the calculation including consideration of the characteristics of the flowmeter being used.

In practice this means that, if there are instruments or systems using a particular technology that have passed all the necessary tests and received an MCerts compliance certificate, operators must use them. Where self- monitoring of effluent flows is concerned, it is important to use a technology that not only represents the Best Available Technique but also offers the best balance of operational benefits, not least the ability to continue to deliver accurate and reliable measurement throughout its life.

From an economic perspective, accurate flowmetering is also important where an industrial site, business or other heavy water user is billed for discharging large quantities of wastewater to a public water treatment works.

In these situations, billing needs to be exactly matched to the amounts discharged. In most cases, the point at which wastewater flows are measured is the pumping station, which relays wastewater from industrial sites for treatment at one or more wastewater treatment plants.

One way of measuring these quantities is to estimate the flow by multiplying the volume of water that flows each time the pump is started by the number of pump starts over a set period of time. This gives an approximate total volume figure for a known period which can then be used to estimate the flow. One problem with this approach, however, is that does not take account of any potential losses in the system, which may arise due to factors such as leakage or unexpected variations in flow.

06

Another, more precise way, is to use a flowmeter to provide an exact and continuous measurement of the volume of water that flows through a wastewater distribution system.

Choosing the right flowmeter As the data collected on wastewater will be the starting point for ensuring any improvements in measurement accuracy as well as compliance with legislation, it is important to ensure that the flowmeters selected offer the best long-term accuracy, repeatability and reliability for the task.

There are various options available, each offering their own distinct set of advantages and drawbacks depending on the characteristics of the application, including the ability to handle high velocity flows of particulates and suspended solids as well as the overall installation space available.

The ability to handle high velocity flows where solids may be present, for example, rules out many conventional flowmetering technologies which can quickly suffer damage that reduces both their measurement accuracy and their overall working life.

Differential pressure meters such as orifice plates and flow nozzles, for example, can become clogged by the build-up of particles in the flow medium, requiring them either to be removed for cleaning or replaced. Mechanical meters are also unsuitable. With moving parts subject to wear and tear, these meters can quickly suffer reduced accuracy, leading to either under or over-registration of flows. Furthermore, the need for mechanical meters to be periodically tested, recalibrated and repaired means that they have to be removed, requiring users either to replace the meter with a temporary device or cease measurement until the meter is refitted into the line.

Ultrasonic flowmeters also suffer various drawbacks which can make them unsuitable. Transit time meters in particular can struggle to handle flows with high levels of particulate matter, requiring a strainer to be fitted. Both transit time and Doppler meters can also be affected by velocity profile distortions, requiring from 10 to 40 upstream diameters, depending on the severity of the disturbance. The turndown of ultrasonic meters is also limited within an ideal range of 20:1 to 40:1. Ultrasonic meters can also be difficult to install and set up, especially where high accuracy is required.

As a further consideration, there may also be the need for data from the meter to be accessed from a central location, particularly on large, dispersed sites or where the meter is situated in a hard to reach location.

Electromagnetic flowmeters are well-suited to the demands of wastewater flow measurement applications. Compared

to other flowmeter types, electromagnetic flowmeters offer greatly enhanced accuracy and repeatability throughout their operational life, with uncertainty of ±1% reading or better.

With no moving parts, they do not suffer from problems with wear and tear, minimizing maintenance, and require no upstream strainers to filter sediment. A choice of flow primary linings affords further protection against coating and high sediment flows, with users able to choose from a variety of materials, including ceramic linings for particularly abrasive flows.

The ability of electromagnetic flowmeters to better handle distorted velocity profiles also means that the amount of piping upstream and downstream of the meter is greatly reduced. Modern electromagnetic flowmeters are also capable of being buried, eliminating the need for the construction of costly installation chambers.

These inherent benefits are being augmented by ongoing developments in technology, both at sensor and transmitter level.

For example, our WaterMaster electromagnetic flowmeter features an octagonal bore sensor design that makes it less sensitive to flow profile disturbances. The octagonal shape effectively conditions the flow profile by flattening any distortions either upstream or downstream of the meter.

This enables excellent in-situ performance even in less than ideal installation conditions. Furthermore, by minimising the upstream and downstream pipe lengths required from the point of installation, the octagonal sensor also helps to greatly reduce the cost of fitting the meters into new pipelines.

Within the transmitter, the effects of signal noise are also minimized by the use of advanced Digital Signal Processing (DSP) technology. This enables effective separation of the real signal from the noise, providing high quality outputs especially in harsh environments involving vibration, hydraulic noise and temperature fluctuation.

An added incentive An added incentive to opt for electromagnetic flowmeters is the Water Technology List (WTL), operated jointly by the Department for Environment, Food and Rural Affairs (Defra) and HM Revenue and Customs.

The WTL scheme allows any business that purchases a water meter for monitoring water use to claim a 100% Enhanced Capital Allowance (ECA) on that purchase, allowing them to write off the cost of purchase against their taxable profits in the first year of purchase.

As well as the purchase cost, the scheme also applies to the cost of installation, covering the work involved in fitting and commissioning a water meter.

Available in the product search section of Defra’s web site at www.defra.gov.uk, the list details the various flowmeter suppliers and technologies within the WTL scheme.

Summary The combination of potential operational savings and the financial incentives around the Water Technology List scheme, provide an attractive case for re-examining the possibilities arising from using flowmeters in water and wastewater pumping applications.

Process Industry Informer – June 2018

APPLICATIONS

SG Transmission proves good things do come in small packages SG Transmission has designed a custom made, size Ø50 permanent magnet brake, for a major global motor manufacturer, which will meet the same performance criteria, whilst being 7% smaller.

The client required a 4Nm brake design solution, reduced in size to fit its existing motor frame with flange square mounting, whilst retaining all the performance benefits of the standard SG Transmission size Ø50 brake. The brake incorporated a custom flange and reverse mounted brake hub, to keep the overall length as compact as possible, this allowed the brake airgap to be pre-set by SG Transmission. A unit was then supplied which allowed the customer to fit the brake straight into its motor, significantly reducing assembly time.

A permanent magnet brake is a ‘power-off’ device which is designed so that when power is removed from the unit, the magnetic energy of a permanent magnet disc is channelled

and controlled to attract the steel armature plate across an air-gap. Therefore, holding it in its place against a stationary field housing to give the required braking effect.

Adam Russell, Design Engineer, at SG Transmission, said: “We are finding that more and more of our clients are moving away from spring applied brakes and switching to permanent magnet brakes when controlling servo motors , this is due not only to the fact that they are zero backlash, but also their compact size and high reliability.

SG Transmission can provide a migration service from one kind of brake to the other, and it is proving to reap dividends for our clients.”

SG transmission is now working on future projects with this client, providing both design and manufacturing expertise.

SG Transmission is a bespoke manufacturer of electromagnetic brakes and clutches, specialising in developing engineering and manufacturing solutions to meet specific client requirements.

Thermal Mass Flow Meters/Controllers, Vortex, Ultrasonic

Gas, Steam and Liquid applications

For more information contact GEOFIRE, Bishop Auckland, County Durham Tel: +44 (0) 1388 770 360 E-mail: enquiries@geofire.co.uk Web: www.geofire.co.uk

www.sierrainstruments.com - +44 (0)7752 799063 Martin Rowe UK sales manager - m_rowe@sierrainstruments.com

E D! 20 G E dos N D RA EN es Q T lud X E nc w No

i

Accurate, versatile chemical pumps • Cut chemical costs through higher accuracy metering • Simple drop-in installation eliminates ancillary equipment • Flow rates from 0.1 to 2,000 ml/min at 7 bar • Range expanded to include Qdos 20: optimised for sodium hypochlorite applications one minute t o o l - f r e e maintenance REVOLUTIONARY

PERISTALTIC

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wmftg.com/qdos-pumps-uk

01326 370362 June 2018 – Process Industry Informer

07

FEATURED ARTICLE

By Richard Huber, Material Scientist, Matmatch

Choosing

the right bearing material

How different materials can affect bearing performance Although bearings are mechanically quite simple, choosing the right material to match the loading and environmental conditions can drastically affect bearing performance.

Here, Richard Huber, material scientist at materials comparison website Matmatch, explains what design engineers should consider when choosing the material for their bearings.

Whether it’s in a food manufacturing plant, on an automotive assembly line or even in consumer products like skateboards and power tools, bearings play a vital role in reducing friction between the moving parts in a mechanical system.

Bearings come in all shapes and sizes, however, the most common types include plain bearings, which consist of just a shaft rotating in a hole aided by a sleeved section, and rolling-element bearings, made up of balls or cylindrical rollers between the rotating inner and outer rings. As well as this, bearings contain other elements such as raceways to guide the balls and cages to ensure correct alignment and spacing.

The bearing housing and structure is most commonly made from steel, the raceways and cages (or retainers) are typically made from steel or plastic and the balls can be made from steel, ceramic or plastic.

To allow design engineers to easily select the right material for the job, Matmatch is aiming to become the largest material property database freely accessible on the internet today. Within this database, there are several material types that can be selected for bearings.

Steels Steel is widely available and performs well under high loading due to its high radial and static load capacity, allowing it to achieve a high speed of rotation without posing a risk of permanently deforming the balls.

This is because most bearings in industrial applications are made using chrome steel (SAE 52100). This has higher levels of carbon content and about 1.5 per cent chromium content. The manufacturing process involves a controlled heat treatment stage that takes the surface hardness to around 60–64 on the Rockwell hardness scale (HRc).

This not only gives chrome steel a smoother, harder finish, it also means that it can withstand higher temperatures of up to 120 degrees Celsius.

However, steel is heavy, noisy and the low chromium content of chrome steel means that it has a low resistance to chemicals and corrosion. This means that, despite the high hardness, any exposure to water and acidic compounds in the lubricant, or even dust and debris, can lead to increased wear, and fatigue on the steel balls and raceway; the prolonged impact of which, if left unchecked, will lead to the ultimate catastrophic failure of the bearing.

This is particularly important for food manufacturing environments, for example, where the ambient levels of heat and humidity regularly change. One machine may be frying and baking food items, while another machine further down the line may be chilling and flash freezing the product. To this end, bearing users may consider opting for a stainless steel that typically contains a higher chromium content of around 18 per cent, which gives it a higher level of corrosion resistance. AISI 440C stainless steel is made using a 08

standard manufacturing process that involves rapid heating and quenching, which makes the steel Martensitic, meaning that it gives the steel a hard crystalline structure.

So, although 440C stainless steel has a slightly lower hardness — and a lower load carrying capacity — than chrome steel, it can sustain temperatures typically up to 250 degrees Celsius. This is useful for bearing applications where a high speed needs to be maintained continuously.

One of the disadvantages of both of these types of steel is that their carbon content gives them magnetic properties that make them unsuitable for use in medical equipment such as MRI imaging machines. Here, engineers should consider austenitic stainless steels such as AISI 316 (carbon – 0.08% Max).

The low carbon content makes this type of steel nonmagnetic. However, it is important to note that this also prevents the steel from being effectively hardened so has a low load carrying capacity and is therefore limited to lower rotational speeds.

Ceramic For pharmaceutical, food and chemical processing applications, bearings can be exposed to high levels of chemical, detergent and acidic conditions and placed under heavy loads. Here, engineers may be better served by bearings that use ceramic balls. Although the retainers and rings may still be made of steel, the balls will be made from ceramic.

Plastic Plastic is ideal for non-magnetic, non-conductive and highly corrosive areas. Here, the bearings offer a very lightweight yet high strength alternative. Plastics used in bearings can range widely, including materials such as polyoxymethylene (POM-C), general polyamide (PA6/66), polyetheretherketone (PEEK), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE, Teflon), and phenolic impregnated fibres.

Plastics are good at normal and high speeds; they are self-lubricating, corrosion resistant and operate quietly and smoothly, capable of reaching temperatures up to 150 degrees Celsius. This is achieved because of plastic's low coefficient of friction (COF), which remains consistent over time as plastic exhibits little wear.

However, caution should be exercised at very high temperatures and in applications where the bearing is subject to high loads because this can cause permanent deformation of the balls and cage.

As industrial and consumer applications become more complex, it is important that engineers not only select the right type of bearing, but the right bearing material for the application. Using a materials database is the first step on the journey to better performance, cost savings and improved product life.

Ball bearings made from ceramic materials such as silicon nitride (Si3N4) offer smoother surfaces, lower thermal expansion, high hardness (over 70 HRc), low corrosion and low electrical conductivity.

Ceramic ball bearings can be around 60 per cent lighter, 120 per cent harder andaround 70 per cent stiffer than their steel counterparts, while still achieving a much higher temperature rating of over 700 degrees Celsius. Ceramic balls also require less lubrication — often being capable of lubrication-free operation — offer lower friction levels and remain cool at high speeds. Crucially, ceramic bearings can beused in nonmagnetic applications.

The downside is that ceramic bearings can suffer from lower load capacities and are more sensitive to thermal shock, which can lead to cracking. In these situations, choosing alternative types of ceramic such as zirconia (ZrO2) and silicon carbide (SiC) may offer the best result.

Process Industry Informer – June 2018

When you think about level measurement all day, amazing things happen.

Introducing the Pulsar® R86 from Magnetrol.® At MAGNETROL, we’re obsessed with level measurement because we know how important it is to your operations and your bottom line. And all of that level thinking has led to a smarter non-contact radar. The new Pulsar® R86 is the 26GHz model that features smaller process connections, higher resolution, higher temperature ranges and an antenna that extends from 4 to 72 inches.

And no other non-contact radar offers these advanced diagnostics: • Automatic waveform capture with intuitive “Help Text” • Setup and Echo Rejection Wizards • Tank Profile feature that “learns the tank” Now you can give your facility radar solutions for every level measurement need with the new Pulsar® R86 Non-contact Radar and the industry-leading Eclipse® 706 Guided Wave Radar.

Learn more at R86.magnetrol.com

www.magnetrol.com

© 2018 Magnetrol International, Incorporated

PROCESS MEASUREMENT & INSTRUMENTATION

A British firm has devised a device to save time and money for thousands of companies Adding water to powder or granule mixes has long been done using pails or hosepipes. Time consuming, open to accident and operator error, there has never been a viable alternative. Aquameter Ltd looks set to change that.

Their micro-controlled Abacus system delivers exact, pre-selected quantities of water from a single pipe -straight into the mixing vessel. This precise metering of the water means the operator can recreate batch consistency each time.

LQ800 Multi Channel Water Analyser Controller - New From ECD

Operation is simple - the quantity of water required is programmed in, the RUN button pushed, and the water flows. A solenoid valve located in the water pipe closes the flow at the completion of the cycle - when the pre-set quantity has been reached.

Introducing the new Model LQ800 Multi Channel Controller from ECD. The LQ800 provides a complete analytical fluid measurement and process solution, designed to operate with up to eight digital analytical and process sensors. The measurement parameter options include above 50 unique separate liquid measurement sensors including: pH, ORP, conductivity, resistivity, dissolved oxygen, selective ion, turbidity, flow, and also level, alongside many other fluid analytical measurements.

Complete with varying configurations for each given application, as can be seen in full on the LQ800 data sheet.

The unit is already in use world wide. Derek Baxter, International Projects Director with Filtrona International in Jarrow, says of the system: “We use the unit for metering water into a carbon-powder mix. Were it not for these units we would be using buckets of water, a line of hose, or a constantly changing mark on the tank - not that convenient.”

The LQ800 Controller digitally communicates with any ECD Intelligent Sensor.

Configuration for the correct parameter is then possible via the menu and display screens.

This smart technology makes using the device hassle-free, and simple to operate.

He goes on: “With this thing we just dial new numbers in, and away we go - it’s obviously more accurate; using the meter than relying on staff to put it in by pail. “

Contact Bell Flow Systems for more information www.bellflowsystems.co.uk

For further information please contact; John Morton aquameter limited 8 Woodlands Drive HODDESDON EN11 8AZ Tel: 01992 442 861 E-mail: john@aquameter.co.uk Web: www.aquameter.co.uk

Process Integrity Preserved

by Non-Invasive PFA Ultrasonic Flowmeter

MEAN MACHINE

Titan Enterprises announces MetraFlow® - an exciting new addition to the company’s expanding ultrasonic flowmeter range.

The new MetraFlow ultrasonic flowmeter from Titan Enterprises incorporates a chemically resistant Perfluoralkoxy Alkane (PFA) tube onto which are mounted high sensitivity ultrasonic sensors. There are no dead areas, changes in fluid direction or obstructions, just a tube.

As a result - MetraFlow can make nonintrusive flow measurements preserving the cleanliness of your process.

Applications including drug production, electronic device creation, medical research and food manufacture, require that a flowmeter has no inclusions or dead areas as this can lead to

FOG, RAG, PLASTIC and any other solid or fibrous debris will cause blockages and disruption with costly downtime to all process streams from STRAWBERRIES to SEWAGE.

contamination issues for the liquids used in these processes.

Drawing upon Titan’s proprietary highly accurate, ultrasonic time of flight algorithms enables MetraFlow® to give a wide operating flow range with an accuracy of ±0.5% FSD or up to ±1% of reading over the 50:1 flow range.

Two versions of the MetraFlow® ultrasonic flowmeter are available covering flow ranges of 20 to 1000ml/ min (1/8-inch tube) and 100 to 5000 ml/min (¼-inch tube). USB interconnectivity makes the flowmeter easy to set-up and use whether you wish to use digital or analogue outputs or both. The local display gives rate and total as well as annunciators for units and time base.

For further information please visit www.flowmeters.co.uk/tag/metraflow-flow-meter/ or contact Titan Enterprises on +44-1935-812790 or sales@flowmeters.com.uk

There are many 'solids handling' pumps on the market today but only one MEAN MACHINE.

www.pumpmix.co.uk sales@pumpmix.co.uk Tel: 01487 830123 10

AB17-1029

The VAUGHAN chopper pump is the solution to a common pumping problem and has proved it for over 50 years

Process Industry Informer – June 2018

PROCESS MEASUREMENT & INSTRUMENTATION

Bell Flow Systems now offering the New Dynasonics TFX-500w Ultrasonic Clamp-on Flow Meter The TFX-500w is designed for measuring water flow in industrial applications.

It measures water flow bi-directionally and has a clamp-on design, avoiding the need to cut the pipe. It is well suited to existing projects and there is no loss of pressure because of the non-invasive design of this ultrasonic flow meter.

The TFX-500w is capable of measuring flow rate, velocity and water flow with precision and accuracy and comes in sizes ½ inch to 10 inch. Temperature range of -40 to 70 °C. It is capable of measuring flow from 0.38 to 37,000 L/min.

Data communications options include the Modbus RTU and BACnet MS/TP. It can also be fully integrated with the Badger Meter Beacon and AquaCUE Advanced Metering Analytics (AMA) cloud-based software suites.

ANALYSERS

Tunable Diode Laser Oxygen Analysers in Critical Applications Oxygen measurement and control is essential for process optimisation and reliability in many industries, and it is important that O2 concentration be controlled or concentration maintained to ensure process control and safety.

Harsh process conditions and consequent maintenance present challenges in procuring precise and consistent measurements.

Oxygen analysers based on Tunable Diode Laser (TDL) Spectroscopy provide highly accurate and reliable performance in many applications where other technologies face application challenges such as safety monitoring, flare systems, and combustion and emission control.

TDL oxygen analysers offer superior accuracy and durability by measuring oxygen in situ, or directly from the gas stream without any sampling or conditioning. TDL analysers work on the principle of laser absorption

spectroscopy, with a focused and tunable laser beam used to analyse absorption lines that are characteristic of the particular gas species being measured.

The benefits of TDL analysers include higher resolution, speed and accuracy, resistance against cross interference and corrosion, easier calibration, reduced maintenance and operating lower costs. Offering innovative probe design, single flange connection, SpectraID technology, predictive diagnostics and a range of unique process adaptions, the GPro 500 series TDL oxygen sensor from METTLER TOLEDO combines the benefits of “fit-and-forget” in-line sensors with the performance of a powerful gas analyser.

Download the Probe-type TDL Oxygen Analysers in Critical Applications White Paper here: https://goo.gl/v5jEdu Call: 0116 234 5095 Email: enquire.mtuk@mt.com

The Dynasonics TFX-500w is designed for water systems, wastewater effluent, agricultural irrigation and industrial discharge.

Contact Bell Flow Systems for more information www.bellflowsystems.co.uk

SWITCHBOX SOLUTIONS

Safety-first approach for new APL7 Switchbox

Actuated Solutions is announcing the launch of the APL7 switchbox to the UK market. Designed with safety in mind, the product boasts an ATEX approved aluminium body (for use in hazardous environments) and, unusual for this type of product, an integral single coil solenoid valve.

The APL7 can offer a cost-effective solution when compared to a standard switchbox with a separate solenoid valve, as only one cable and one cable gland is required.

Available in 110VAC, 220VAC or 24VDC, the APL7 is IP67 rated and includes a beacon visual indicator, quick-set cams and captive cover bolts as standard. Additionally, a Namur drive makes it easy to mount to actuators.

As with all ASL’s products, The APL7 switchbox is supplied with full documentation to assure customers of the highest levels of safety and authentication.

For more information on ASL and the APL7 switchbox,please contact Actuated Solutions Ltd, Bognor Regis, West Sussex Tel: 01243 827469 E-mail: sales@actuated-solutiuons.co.uk Web: www.actuated-solutions.co.uk

June 2018 – Process Industry Informer

11

FEATURED ARTICLE

By Artur Beyer, Industry Principal, Chemicals, TrendMiner (www.trendminer.com)

Self-service Predictive Analytics - An Industrial Fortune Teller

Changing raw material prices, commoditization, increasing regulatory stringency and various other market dynamics all impact process industry margins. In such an active market, it is necessary to be as flexible as possible without tying up big amounts of capital over years to come. This article will look at how a golden fingerprint can be created by modelling past successes. This means that brownfield plants can instead look towards a sustainable future by utilizing process expertise in combination with the plethora of stored process data. One area of improvement is predictive maintenance in order to decrease unplanned downtime.

Recently a lot has been written about predictive operational performance within process manufacturing industries. The bulk of articles are related to predictive maintenance, where applied sensors are used to analyze and predict equipment behaviour.

This is mainly focused on the most critical assets through centrally led, time consuming and expensive predictive data modelling projects. To include get operational performance prediction for all assets, a new analytics approach is required; self-service predictive analytics for the subject matter experts.

Another is by using hypothesis generation for diagnosing issues that fuel new event-based predictions. Behaviour in one part of the production line can then be correlated with (future) behaviour downstream. Automatic regression of process parameters is, for example, used to make soft sensors to predict product quality.

Asset Performance & Predictive Maintenance Asset performance, or Overall Equipment Effectiveness (OEE), depends greatly on the process in which the asset operates. Instead of using equipment-related sensor data for performance analysis, all process-related sensor data should be taken into account. This is called “contextualization of asset performance with process data,” and with this, data-based predictive maintenance becomes possible.

Within a water distribution network, only 5% of all pumping stations were responsible for over 50% of the total maintenance costs. With self-service analytics, using scatter plots and statistical fingerprints, the pumps could be monitored within their best operating zones. Alarms were added and users are now notified when equipment is expected to fail, allowing them time to take proactive action. This has improved performance reliability and lowered overall operational costs.

One last use case is within a petroleum refinery where hydrogen fluoride is used as catalyst in the alkylation unit. It is regenerated in a stripper that is drained to a drum multiple times a day based on the level in the column. After a few days, four thermocouples at different heights in the drum indicate when the drum is full and must be drained. With self-service discovery and diagnostic analytics, it was shown that the time until the drum is full (indirectly) depends on the acid flow to the stripper column. Using self-service predictive analytics, it can now be determined when the drum will require maintenance.

This provides plenty of advance time to schedule the drainage work and lower related the maintenance costs.

A Smarter Approach Predictive maintenance solutions have traditionally involved data scientists or central improvement experts for building comprehensive analytics models. Aside from being costly and time-consuming, this way of working has other major disadvantages: it creates a bottle neck in the organization, underutilizes subject matter experts and leaves many (smaller) predictive analytics cases unaddressed.

A new, integrated and more efficient approach is self-service analytics. This novel method, doesn’t require the expertise of a data scientist, nor does it require an extensive overhaul to your existing infrastructure. The insights into your process and asset behaviours are based on a wealth of historical and real-time data, and with this information, subject matter experts can take proactive measures to reduce downtime and avoid unnecessary risks.

Different ways to execute a powerful strategy There are three different ways to use this new approach: – The first is event-based: if a certain signature behaviour is detected which can affect another part in the process that typically occurs later, a notification can be generated.

– The second is probabilistic: the current behaviour is interpreted and a likeliness of future behaviour is calculated.

– The third type is regressive: the prediction is based on certain conditions that must be met and verified.

An example of how self-service analytics can be practical in use is by creating fingerprints, which are created using any variety of signature patterns found in the past. By using defined fingerprints for event-based prediction, automatic alerts can be sent to the appropriate stakeholders, such as control room personnel or field engineers, to take appropriate action in the event of process deviation. The notifications can even include recommendations for mitigating actions.

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The goal of predictive maintenance is to be able to perform maintenance at a time when it is not only the most costeffective, but also when it will have the least impact on operations. By representing all sensor-generated data in a graph, especially when multiple tags need investigation, it’s hard to find correlations. Self- service analytics tools allows the user to quickly explore and filter data visually and search through large amounts of process data (easily up to multiple years of historical data). The advanced analytics capabilities can also help determine root cause analysis (RCA), test hypothesis (discovery analytics) and quickly find similar behavioural occurrences.

Through diagnostic analysis, the process engineer can understand the effects of process changes (comparing before vs. after) and find potential influence factors for specific issues.

With this information monitors can be created to safeguard best operating zones and maintenance can be predicted.

Practical Use Cases with Self-service Predictive Analytics One example where asset performance directly relates to process behaviour is the fouling of heat exchangers. In a reactor with subsequent heating and cooling phases, the controlled cooling phase is the most time- consuming, and it’s almost impossible to monitor fouling when the reactor is used for different product grades and different recipes are required for each grade. Fouling of heat exchangers increases the cooling time, but scheduling maintenance too early leads to unwarranted downtime and scheduling too late leads to degraded performance, increased energy consumption and potential risks.

In the instance of the production of a polymer, a monitor was set up to look at cooling the times of their most highly produced products. If the duration of the cooling phase starts to increase, a warning is sent to the engineers who can then schedule timely maintenance. The gained benefits are extended asset availability, operational and maintenance cost reduction, and reduction of safety risk. The overall impact in this instance was a 1%+ overall revenue increase of the entire production line.

Concluding Thoughts Traditional predictive maintenance is often timeconsuming and isolated from the subject matter experts and consequently only used on the most critical assets. But with this new approach, the day-to-day process experts can be empowered to utilize their knowledge with use of the information hidden in the data historian, and with this they can drive their own predictive maintenance strategies for all equipment within the production line.

Through the use of self-service analytics, every asset can be assessed for performance and predictive maintenance. This method is your crystal ball and the information it provides can result in a reduction of maintenance-related labour costs, reduction in unexpected failures or shutdowns, reduction in repair and overhaul time, and an increase in uptime. And if you look into the future, you just might see a reduction in cost and increase in yield.

Process Industry Informer – June 2018

Heat Transfer & Energy

Filtration & Separation

High quality lime from eggshells with eggshell dryer Van Beek has developed the eggshell dryer for drying crushed eggshells in a continuous industrial process. This dryer heats the eggshells to 130 degrees to give a pathogen-free, fine-grained and high quality lime with a maximum moisture content of 1%.

No odour nuisance This end product can be marketed as a soil improver or lime for the animal feed or cement industry. By removing the moisture odour nuisance is a thing of the past.

Less than 4% moisture The eggshell dryer is a machine with a single screw and operates as a paddle dryer. The machine requires little installation space in an automated line that breaks the eggs to separate the contents from the shells. After

Bespoke Stainless Steel Duplex, Triplex, Multiplex Filter Systems

dehumidification the line crushes the shells, after which they land in the eggshell dryer. This removes the last moisture from them, leaving less than 4% moisture.

Axium Process’ robust and versatile duplex, triplex and multiplex stainless steel filter systems are improving process efficiencies and providing substantial cost savings in respect of reduced downtime and screen disposal costs for processors operating in the pharmaceutical, food, beverage, confectionery and chemical industries.

Designs The eggshell dryer exists in designs for an output of 250, 500 or 1000 kilo per hour.

Van Beek produces the eggshell dryer under the trade name Celsius. The screws for it come from the renowned Van Beek workshop. These screws are known for their wear-resistance and clean finish.

Something for you?

Do you have a process in which eggshells or perhaps another substance must be dried? Van Beek would be pleased to help you with this.

For more information contact Van Beek B.V. Netherlands Tel: 31 (0) 416 382 292 Fax: 31 (0) 416 378 350 E-mail: info@celsius.nl Web: www.van-beek.nl

or for powder mixing applications such as dispersing powders into suspension. For fine particulate applications, the company has developed its Fine-Screen sintered mesh range which offers excellent strength and rigidity providing filtration levels from 5 micron up to 200 micron.

Engineered to cater for footprint, flow rate and dirt loading restrictions, the company’s duplex, triplex and multiplex filter options are ideally suited for applications where stage filtering is a requirement. Customised options include support framework, sample points, drain isolation and vent valves as well as pressure gauges on the outlet and inlet to monitor performance. The filter’s robust construction enables automatic or manual backflush facilities which can be fitted to the filter without fear of damaging the elements.

Axium’s standard range of stainless steel filters provide filtration levels from 5 micron up to 6000 micron and are available with stainless steel wedge-wire or sintered mesh screens. Manufactured in 316L stainless steel to a high specification, the filters are simple and easy to maintain, have built-in safety features and require no specialist tooling.

Suitable for a wide range of applications, Axium’s filters provide a reliable solution for critical applications such as a pre-filter for pumps or debris capture for CIP. The Pure-Screen wedge-wire filter range is ideally suited for applications where product consistency and smoothness is essential

For more information contact: Axium Process Ltd, Hendy, Swansea Tel: +44 (0) 1792 883 882, Fax: +44 (0) 1792 886 049 Email: info@axiumprocess.com Web: www.axiumprocess.com

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Leaders in temperature measurement

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Thermocouple Connectors

In Stock For Immediate Worldwide Despatch Heading 3 Manufactured

by Labfacility

Miniature Thermocouple Plug

Miniature connectors have flat plug pins Standard connectors have solid plug pins Wide range of accessories available

Miniature Thermocouple Plug Miniature Rectangular Fascia Socket

PCB Mounting Thermocouple Socket

Miniature Quick Wire Thermocouple Plug

Standard Thermocouple Plug

Standard Quick Wire Thermocouple Socket

Standard Thermocouple Duplex Plug

Available in IEC, ANSI or JIS colours Available in Thermocouple types K, J, T, E, N, R/S, CU & B Contacts are polarised to prevent incorrect connection

www.labfacility.com Bognor Regis tel: +44 (0)1243 871280 14

sales@labfacility.com Sheffield tel: +44 (0)1909 569446 Process Industry Informer – June 2018

HEAT EXCHANGERS

MAXIMUM EFFICIENCY

MINIMUM SPACE

Lowara Gasketed Plate Heat Exchanger (GPX) technology offers maximum efficiency in less space, with outstanding application flexibility.

Innovative plate design allows GPX heat exchangers to provide more heat transfer using less space. They perform with one-third to one-fifth the surface area of conventional shell and tube heat exchangers designed for the same application. Their efficient design allows the heat exchanger to be used in a variety of applications and installations, including: District Heating and Cooling, Thermal Storage, Heat Pumps and HVAC.

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

HEATING & COOLING

AXFlow launches the next generation in mixing andheating technology AxFlow is launching APV’s new and innovative Cavitator for heating and mixing liquids using the forces of cavitation in a controlled manner rather than heated surfaces, impellers and blades which are traditionally employed by such devices.

When cavitation bubbles collapse they produce powerful shockwaves that can cut the process material into microscopic sizes. This increases the surface contact area between the liquids, gases and/or solids being mixed and maximizes the efficiency of the procedure for processes such as hydration, emulsification and gas/liquid mixing.

This proven technique pioneered in the chemical and petrochemical industries, can heat liquids in seconds without the need for high temperature metal surfaces thereby eliminating scaling of equipment and scorching of product. The mixing characteristics are virtually shear-free making the Cavitator ideal for use with sensitive products.

AxFlow is the exclusive distributor of APV food industry components in the UK. For further product details, contact: Malcolm Walker AxFlow Ltd Tel: 020 8579 2111 Email: info@axflow.co.uk www.axflow.co.uk

Introducing a new range of Industrial Process Chillers The UltraChill range of process chillers go from 0.89 to 160 kW. These compact, energy efficient units are suitable for a wide range of process cooling applications and industry sectors, including automotive, engineering, food and drinks production, pharmaceutical, plastics, print and packaging, medical and scientific.

The UltraChill range are available in varying formats and come with a wide range of standard options enabling easy adaption to best suit individual processes and applications. All units come with a fully corrosion resistant, nonferrous coolant circuit, including powerful circulating pump and high efficiency, copper brazed, stainless steel plate heat exchanger. A package of safety interlocks help protect both the chiller and process, whilst an advanced digital controller with diagnostics and alarms, provide a comprehensive user interface.

Highly competitive, the UltraChill range are available on short lead times and supported nationwide by a fully trained network of engineers, ensuring ongoing, quick and reliable support.

Thermal Exchange Ltd is an ISO 9001 Company specialising in providing process cooling and thermal management systems for industrial, medical and scientific applications.

Based in Leicester since 1982, Thermal Exchange both manufacture and distribute a wide range of standard temperature control equipment and also welcome enquiries for special design requirements.

For more information contact Thermal Exchange Ltd on +44 116 254 6652 or E-mail sales@thermalexchange.co.uk Web: www.thermalexchange.co.uk

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Process Industry Informer – June 2018

SUPER HYGIENIC

POSITIVE DISPLACEMENT LOBE PUMP

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

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

FEATURED ARTICLE

By Mark Whitmore, General Manager, Boge compressors

Taking the

pressure off

of maintenance

The reliability of compressors has steadily improved in the last decade, due to factors such as new monitoring and control technologies, higher manufacturing standards and techniques such as predictive maintenance. Despite this, compressors still require routine maintenance, as well as upgrading or replacing as they age, or as the needs of the customer change over time. But what if a compressor technology existed that eliminated most maintenance requirements? Mark Whitmore of BOGE explains.

compressor, the air is compressed entirely via the action of rotary screws (two meshing helical screws, known as rotors).

In other words, it is a ‘dry running unit’ whose compression chamber is not lubricated and whose screws operate contact free. This means there is no oil to contaminate the compressed air.

Another advancement in compressor technology are air bearings. At the heart of the compressor are two compact permanent magnet (PM), high-speed motors each having a central rotor suspended on self-stabilising air foil bearings.

Two precision balanced titanium impellors of different sizes and blade arrangements are mounted at each end of each rotor. At rotational speeds typically in excess of 100,000rpm, air is drawn in via an intake funnel and a specially designed spiral casing to be boosted in three stages to reach operating pressures quickly and efficiently, with minimal energy losses thanks to the frictionless air bearing configuration.

Compressed air might be out of sight and out of mind but when it breaks down, or doesn’t work properly, then the maintenance manager is under pressure to resume normal service. There are a range of maintenance areas that need to be given attention in a traditional compressor and these include the checking of filters, monitoring for over-heating, leaks, water residue and keeping the right pressure: Filters – Just as a car’s service covers checking its oil and filters, so the same can be said of an air compressor. The oil and filters must not only be checked, but changed regularly to ensure optimum operation. Each compressor will have specific service interval timings which are indicated in the manufacturer’s manual, however as some compressors operate in dusty work spaces, frequent checking is essential.

Bearings and other components, such as the oil separator, can be severely affected by dust and dirt particles and these can prevent shorten the life of the equipment Hot under the collar – Air compressors are particularly prone to over-heating. In addition, they also create a significant amount of heat whilst in operation, which needs to be removed. If the compressor runs for too long near the boundary of its warning temperature for even a limited time, then it can cause severe damage to the entire system.

Monitoring the compressor’s operating temperature and identifying any temperature problems as early as possible is vital to its long-term health.

Leaks – However small a leak in the compressed air system, it shouldn’t be ignored. In fact, in many applications, a leak can account for up to 30% of the total operational cost of the compressor. Common areas for leaks are connection joints like valves, unions, couplings, fittings, etc. As well as wasting energy and money, these leaks can also result in lost pressure,potentially reducing the end use product’s performance. So, it is worth fixing leaks as soon as they are identified, to minimise time and cost losses.

Water – Water and air compressors don’t mix well, and this means that the maintenance team has to be vigilant when it comes to monitoring the dryers and condensate drains. As well as damaging the compressor, tools and the end product, pipe components within the compressor can be particularly affected. Regular checks for water in the compressed air line are quick yet vital.

Set the pressure – By setting the pressure of the compressor at the level that is actually needed, rather than at a higher rate ‘just in case’, helps the maintenance team keep the system in balance and ensures that energy is conserved and money saved.

Oil-free - Another area that can be an issue for maintenance managers is that oil suspended in the air can create maintenance problems. Although many air compressors rely on oil injection to seal their compression cavities and remove heat from the air supply, the potential with an oil-free

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High speed turbo compressors use an impeller driven at very high speeds. They contain no oil, which removes the need for oil changes or oil filter replacements, as well as eliminating the risk of contaminating products (whether that’s food, medical supplies, packaging, etc.). On top of this, there are no gears in the machine and fewer components to change overall; in fact, they have only one moving part, ensuring ease of maintenance from day one.

Oil-free compressors can use a variety of basic designs and operating principles. A high proportion are positive displacement compressors, which create pressure by volume reduction. Rotary screw compressors, pull air into the compressor and ‘squeeze’ it by rotating elements in the compression chamber to a defined pressure. Piston compressors use a reciprocating piston to compress the air and other compressors use a dynamic compression approach, generating pressure by accelerating the incoming air to high speeds.

Indeed, the air bearing is a novel feature, it is virtually maintenance free, unlike magnetic bearings, which are widely used in other types of turbo compressor. Magnetic bearings also require a power back-up device to be fitted to protect them in the event of a mains power failure.

Other operating efficiencies are derived from the impellor, diffuser and spiral casing design, which effectively reduces air pressure on the intake side. This has the effect of sucking fresh air through the motor, eliminating the need for a separate fan cooling motor and control unit.

Cost-effective oil-free compressors One of the issues with oil-free compressors is that traditionally, the maintenance costs associated with operating them have been typically higher than oil-injected compressors, preventing wide scale uptake of oil-free.

However, the latest oil-free compressor technology, such as the High-Speed Turbo (HST) from BOGE, has lower maintenance costs than both oil-free and oil-injected compressors. This means the industry now has access to the most effective way of producing oil-free compressed air, at a cost estimated to be 30% less than previously possible with screw compressors.

Latest technology compressors are 50% smaller and lighter than traditional oil-free machines. They are also quieter typically 63dBA for the 55kW unit, as opposed to 80dBA for a raditional screw compressor.

The inherently highly efficient PM motors are also inverter controlled enabling supply to be matched precisely and instantaneously to the demand.

Precision high speed turbo technology, linked with the use of advanced electronic control systems, has created a new generation of oil-free, Class 0 compressors that offer companies throughout the food and beverage, electrical and pharmaceutical sectors the potential to improve the quality, productivity and reliability of their production processes, while simultaneously reducing operating costs.

The reliability of compressors has steadily improved over the last decade, however thanks to innovations such as this next generation compressor, routine maintenance has become even easier for maintenance teams.

Process Industry Informer – June 2018

June 2018 – Process Industry Informer

19

Calibration

Building Information Modeling

BILFINGER TEBODIN OFFERS INDUSTRY A DIGITAL FUTURE Bilfinger Tebodin, the global consulting and engineering firm, is offering clients the very latest in digital technology to design both new facilities and change existing plants.

One element of this is Building Information Modeling (BIM), a collaborative way of working, which unlocks more efficient methods of designing, creating and maintaining of assets. BIM is now widely used, and increasingly specified as mandatory for both residential and commercial construction. However the technology is still new to the industrial sector, a position that the company is changing through her investment in digital technology now available to clients on a local and global basis.

Ian Dunkley, Managing Director of Bilfinger Tebodin in the United Kingdom, commented, “BIM offers clients incredible advantages when investing in new facilities. Modern industrial processes can be complex, partly due to the number of stakeholders and different engineering disciplines required. BIM enables all the information to be shared during the design process and enhances communications across the project team wherever they are in the world”.

“Our engineers are able to design complete process and industrial plants digitally from concept to construction with innovative solutions to industrial design challenges. This seamless collaboration produces considerable savings and dramatically reduces costs and project timescales. Designs can be optimized not just in 3D and 4D, but right up to 7D to incorporate future maintenance costs.

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It creates a common environment for all stakeholders which can be viewed in virtual reality.”

The technology has been successfully applied by Bilfinger Tebodin on the Great Wall Motors Company’s car factory in Russia. This giant facility (225,000 m2), with a production capacity of 150,000 vehicles per year, was designed by Bilfinger Tebodin involving more than 100 engineers across seven countries.

Another digital tool Bilfinger Tebodin has developed is ‘Industrial 360°’, an innovative scanning system capturing industrial sites in a photorealistic way.

This together with 3D point data from the site itself creates a transparent information model in HD. The virtual walkthrough can be used for design modifications, maintenance objectives, safety inspections, turnarounds and training.

The technology has been extensively used for factory modifications at large petrochemical companies, HAZOP studies and updates of safety valve calculations, new state-of-the-art laboratories in the pharmaceutical sector, renovation of an outdated production unit in the food sector and expansion of an existing glue-production facility.

Ian Dunkley continued, “The two technologies, for projected and existing facilities, are great examples of how important we view this digital future and the innovative service we can now offer to clients not only in the UK but on a global basis. We have over 40 engineers of diverse disciplines at our office in Warrington and are already in conversations with a number of clients about the benefits of and applications for the new technology – the future is definitely digital!”

Scans of a Bilfinger plant are available at www.goo.gl/yguzSV, whilst scans of a Bilfinger office are available at www.goo.gl/smWdMq Further details are available from Bilfinger Tebodin UK at www.tebodin. bilfinger.com or on (01925) 649308.

SIGNATROL INVESTS IN CALIBRATION WITH NEW OPTI-CAL KIT Data logging specialists, Signatrol Limited has invested in the calibration service it offers customers with the purchase of a Michell Instruments Opti-Cal. The new equipment will enable Signatrol to not only calibrate its own data loggers and SpYdaq transmitters but customer instruments or data loggers too, at any humidity point from 10% to 90% at ambient temperatures from +15°C to +50°C. Signatrol was previously able to calibrate at 11%, 43% and 75% but at ambient temperature. The new Opti-Cal system will now enable Signatrol to increase the the number of pieces calibrated at any one time to 20 pcs SL54TH / SL54TH-A, so reducing the time taken to calibrate a large batch and removing the need for setup charges.

ABOVE: Bilfinger Tebodin’s Industrial 360° scanning and software reproduces facilities in a photorealistic environment.

For more information contact Signatrol Ltd, Tewkesbury Glos.

Tel: 01684 299399 Web: www.signatrol.com

LEFT: Bilfinger Tebodin’s BIM technology offers clients the ability to ‘see’ and test their investments in a digital environment.

Process Industry Informer – June 2018

SUMMER EDITION 2018 Headlines from the BPMA’s Marketing Forum Chairman, Shaun Hampson

As BREXIT concerns continue for many members, the BPMA has joined EURIS in which to coordinate Britain’s members to trade in the future single European market.

Euris is focused on the associated regulations and standards affecting 5000 product manufacturers who represent a combined turnover in excess of £110 Billion.

CPD accreditation has been granted for the BPMA Classroom-based, independent training courses. With Chartered Engineers in mind, there are five courses which come together to give knowledge of Fundamentals

of Pumping Technology. The next two courses will run on 10th-11th September. The Essentials of Pumping Technology, e-Learning course has also benefited from a new exciting voice make-over. This course is believed to be the most comprehensive pumping technology course available.

Compliance toughens greatly with two new directives which will greatly impact the pump-related supply sector. The GDPR came into force on 25th May 2018 and introduced large changes to the Data Protection Act. Secondly, the WEEE Directive is planned for 15th August 2018 and governs the safe removal, disposal, and possible collection of pump related equipment from the perspective of the Producer.

The Health & Safety Executive (HSE) has recently raised serious concerns with the BPMA about the nonconformity of some Mechanical Seal Sealant Systems.

The issue covers the integrity, compliance, and CE marking of Sealant Systems that are used for Double Mechanical Seals.

Oxford Economics are reporting a strong economic upcycle. At its strongest position for at least three years, this is mirrored for the Pump market which is thought to have expanded by 5.6% last year to a total value of US$65,788 million. Following two years of decline, the most important driver is an investment recovery in the developed world.

The Annual Pump Awards saw some bright faces and smiles with some well-deserved winners including: Wilo, Xylem, Danfoss Drives, Clyde Associated Engineers, KSB, ABB. Luke Gardener of Grundfos Pumps went home with the prestigious Engineer of the Year award, and the Lifetime Achievement was Awarded to Chris Rea OBE, for AESSEAL. There have been a number of recent innovations, released this year and include the i-ALERT2 sensor from Goulds UK; High efficiency low flow magnetic drive pumps from HMD Kontro; and a Mechanical seal failure diagnostics “App” from Flowserve.

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T RA I N I N G

FOREWORD Summer 2018 Welcome to the Pump Industry News and I hope you have all enjoyed a successful first quarter in 2018. Since our last edition the BPMA has decided to join EURIS to help the BPMA on issues relating to Brexit.

Euris has a focus on product manufacturers covered by the Single Market and the supporting regulations and standards. EURIS members include such notable bodies as BEAMA, GAMBICA, EAMA, REA, CESA, FETA, MTA, BFPA, BPF , TechWorks and now BPMA , which between them represent a turnover of over £110 Billion and some 5000 businesses across electrotechnical, electronics, plastics, lighting, renewables and mechanical engineering products.

I am sure this membership will lead to many interesting meetings and debates in the coming months.

Regards Duncan Lewis BPMA President

E-Learning Introduction to Pumping Technology £180.00 plus vat Providing standardised terminology and a straightforward approach to the various pump types. It is targeted at all employees who need to understand the language of the pump industry.

Students will:• Learn why a pump is important • Gain an appreciation of the wide range of pump types and terminology used • Find out how pumps are driven • Gain an overview of pumping issues and Systems

BPMA LectureBased Training The BPMA have produced 5 Independent Classroom-based courses covering the fundamentals of Pumping Technology, each course now carries CPD accreditation

PUMPING FUNDAMENTALS Next date: September 10th 2018

Aimed at those purchasing and operating pumps this course introduces delegates to the role of pumps and pumping and the effects of liquid qualities.this is the perfect course for those new to this sector or those who need to know the basics of Pump technology These are all stand-alone courses, however, BPMA recommends that delegates take, or have taken the Pumping Fundamentals course before then going on to select any one of the other courses that would best enhance their knowledge

PUMP SELECTION –

Next Date: September 11th 2018 This is an Ideal course for those individuals whose role includes the planning and specification of pumping operations. It extends the knowledge gained on the Pumping Fundamentals course and illustrates a procedure from evaluation of enquiry data, through to the issuing of a tender document.

Each course is £300 plus Vat per delegate or £250 plus Vat for any delegates from BPMA Member companies For more information and availability on any of these courses please email Steve Smith on s.smith@bpma. org.uk or go to www.bpma.org.uk to download

• Ofqual has approved the course at LEVEL TWO (QCF) with 2 credits and the course carries CPD Accreditation The Introduction to Pumping Technology course will require up to 20 hours to complete

Essentials of Pumping Technology - £600.00 plus vat The Essentials of Pumping Technology is aimed at those delegates who through experience and knowledge of the industry feel able to undertake what we believe to be the most comprehensive Pump Training course available Students will be provided with:• The KNOWLEDGE they will need to complete set tasks in pumping without close supervision.

• An UNDERSTANDING of number and physical properties including units and dimensions needed for operating pumps.

• The ability to SELECT types of pump for particular applications.

• LEARN the theory of Rotodynamic pumps, curves, efficiency points and the Affinity Law. • LEARN the theory of ROTARY PD Pumps, and their similarities and differences versus • Rotodynamic pumps.

• LEARN the theory of POSITIVE DISPLACEMENT Pumps, and their specific features.

Each chapter concludes with a short test and at and the end of the course there is a final assessment. A pass ate of 60% must be achieved in the final assessment in order to gain NOCN certification of 9 credits at Level Four This course covers more ground than that required by the NOCN, hence not all the questions in the final test form part of the NOCN assessment. The BPMA will therefore award their own industry recognised certificate, based on the whole of the Course, which will confer on the successful student an additional benefit to that of the NOCN award, along with a certificate of CPD The BPMA award* will be graded as PASS at 60%, CREDIT at 75% and DISTINCTION at 90%.

The Essentials of Pumping Technology course will require up to 90 hours to complete Industry professionals should aim to be awarded the Distinction.

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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

T RA I N I N G

BPMA CPSA Course CPSA (Certified Pump System Auditor) - an industry specifi professional qualification developed by the BPMA (British PumpManufacturers Association Limited) which is already anestablished and highly regarded body within the industry.

The objective of the scheme is to help improve the levels of professionalism in the sector by creating a universally recognised and respected industry ‘standard’ for individuals assessing the performance of a pumping system.

Monday 12th November - Thursday 15th November 2018.

This will take place at The Park Inn, Birmingham West and includes 3 nights B & B accommodation at the same hotel.

Who should attend and what is involved?

CPSA is open to any competent engineer.

To successfully achieve the CPSA designation (and the benefits that accrue), candidates must do all of the following: • First attend a 3-day Pumping System Requirements and Analysis training course and pass an examination.

• On the next day attend a 1-day course covering both the ISO 14414 Standard for Energy Assessments of Pump Systems and Pump System Optimisation • Post course carry out a Pump System Audit in accordance with ISO 14414.

• Produce a Pump System Audit report in accordance with ISO 14414.

• Demonstrate active involvement in the industry.

Who will benefit from taking this course?

• Pump engineers (sales, service, commissioning, etc).

• Upper and middle management.

• Working for a manufacturer, distributor, consultant, contractor or end user in the Pump industry, who is Involved in pumping equipment related products and services.

• Interested in personal growth, ambitious, inspirational and competitive.

Key Benefits • Improve your personal competitive position.

• Gain industry recognition by achieving a qualification that is accepted and respected by key employers, industry bodies and your peers.

• A unique qualification for staff specific to the pump industry.

• Compete more effectively through having a better qualified, more knowledgeable and more

professional workforce.

• Increase motivation and engagement amongst key customer facing employees by developing their own skills and knowledge as well as encouraging and facilitating their own personal and professional development.

Certification Engineers who are trained in accordance with the CPSA requirements will receive the following certification: • A certificate from the US Department of Energy (DOE) confirming they have become a “Qualified Pumping System Specialist”. In addition their name will be listed on the DOE website.

• A certificate from the BPMA stating that the engineer has completed a 1/2-day course on ISO 14414 Standard for Energy Assessments of a Pumping System.

• A certificate from the BPMA stating that the engineer has completed a 1/2-day Pump System Optimisation course.

For more information and availability on any of these courses please email s.smith@bpma.org.uk or go to www.bpma.org.uk to download a BPMA Training Guide

ROTEX® split hub

Reduce your downtime...

KTR manufactures flexible couplings for power transmission from 3Nm to 2,750,000Nm as standard. Designs include ROTEX® & BoWex®, the original jaw and nylon sleeve gear couplings respectively. KTR also offer torque limiters to protect your system, split hub designs to reduce your downtime, and a wide range of bellhousings to suit any pump and motor combination.

www.ktr.com/uk 23

Compliance Matters and Economic Update

HEALTH & SAFETY CONCERNS OVER MECHANICAL SEAL SEALANT SYSTEMS

Economic outlook from Oxford economics

For over three quarters of a century, the British Pump Manufacturers Association (BPMA) has been serving the interests of UK and Irish suppliers of liquid pumps and pumping equipment. Its mission throughout that time has been to influence the pump sector environment and aid the competitiveness of its 82 strong membership.

Primary to this task is increasing sector awareness through the provision of technical support and independent pump technology training to manufacturers, distributors, operators and purchasers of pumping equipment.

Through its own membership of both Europump (European Association of Pump Manufacturers) and EURIS (European Union Relationship Industrial Strategy), BPMA engages with a host of other trade bodies and organisations across the international electro-technical arena, on all the key issues and disciplines affecting standards, product certification and compliance, including of course the impact of Brexit on the UK pump sector.

The latest set of guidance issued to BPMA members deals with WEEE2 and the rules governing Sealant Systems in Double Mechanical Seals, as required by the Pressure Equipment Directive.

BPMA ISSUES WEEE2 WEEE2 Directive 2012/19/EU information for the Pump Industry This Directive is due to come into force on 15th August 2018 and whilst there is no known market surveillance in place, high penalties for non-compliance have been announced. For two years BPMA staff and a core group of its members have been working with Defra and the Environmental Agency to create a Position Paper specifically for pump manufacturers. This document has now been completed and circulated to the full BPMA membership. It contains definitions and comments which are the pump industry’s interpretation of the WEEE Directive 2012/19/EU and how it affects the removal and safe disposal of pumps and pump related equipment. The document contains links to other guidance material, which collectively provide all the information needed to fully understand the scope of responsibility. This includes details on both the ‘Producer’ and the ‘Package Producer’ and their respective responsibilities for collection.

BPMA Members (and for that matter, all other parties operating in the pump sector) will need to register with their local Environmental agency - https://www.gov.uk/ guidance/weee-producer-compliance-scheme-apply-for- approval.

They will also need to register with an approved Compliance Scheme operator.

Mechanical Seal and Sealant System Information The Health & Safety Executive (HSE) has recently been in contact with the BPMA regarding a serious concern over the integrity and compliance of Sealant Systems that are used in Double Mechanical Seals.

As a subsequence, detailed information has now been sent to every BPMA member company. This highlights important issues regarding non-compliance due to no CE marking, non-adoption of the safety measures required under the Pressure Equipment Directive, as well as with the lack of design, manufacturing, traceability and conformity assessment by a Notified Body.

By distributing this material throughout its membership, the BPMA is ensuring its members are fully aware of the issues and concerns that the HSE has in relation to the conformity of these sealant systems.

BPMA Director, Steve Schofield, said of these two communications, “The BPMA takes its responsibilities in relation to international standards and product certification extremely seriously. It regards compliance in these matters as an integral part of its membership parameters, which in turn offers credence to its ‘Buy with Confidence’ ethos. As such, not only is it of great importance to keep our members fully abreast of all developments in this area, we feel it is also important to keep the wider ‘pump using’ market informed as to the work our members undertake to ensure they remain fully compliant. Buying pumps and pump related systems from a BPMA member should therefore provide all the required assurances.”

Reader Enquiries to: Steve Smith, Administrator, British Pump Manufacturers Association Ltd West Bromwich, West Midlands. Tel : +44 (0)121 601 6691 Email: s.smith@bpma.org.uk Web : www.bpma.org.uk 24

A strong upcycle whose momentum accelerated throughout 2017 has put the global industrial economy in its strongest position for at least three years. This growth is mirrored in the evolution of the pump market: we estimate that global pump consumption (excluding parts) expanded by 5.6% last year to a total value of US$65,788 million – following two straight years of market declines.

The most important factor driving this turnaround is an investment recovery in the developed world. Spare capacity has fallen close to pre-global financial crisis levels and, coupled with a solid demand outlook, strong business confidence and ready access to finance, investment in advanced economies should rise this year at its fastest rate since the crisis began in 2008. A significant business tax cut in the US will provide additional tailwinds there, while in Europe there is considerable pent-up investment demand after years of weakness in the wake of the Eurozone sovereign debt crisis.

A second factor is strong trade flows, which are an important forward-looking indicator of industrial activity. We have been surprised at the durability of the acceleration in global export flows, with momentum shifting away from China towards North America and Europe (although there are high downside risks to this, if the current protectionist skirmishes snowball into a broader trade war).

Industry News

BPMA supports first EURIS Summit……… and the creation of a European Network As part of it membership of EURIS (European Union Relationship and Industrial Strategy), the BPMA recently attended the organisation’s first summit on Brexit.

Representing industrial product supply sectors, which collectively account for over 25% of the UK’s total goods imports and exports, this important event saw industry associations from across Europe come together to discuss and agree a joint UK-EU industry working plan to ensure a successful Brexit for product manufacturers.

Held on the 23rd floor of the iconic Shard building, the ‘high-level’ gathering involved contributions from Government advisers and CEOs of trade bodies from across Europe, including Germany, Portugal and Sweden, as well as contributions from the UK product supply sector.

This newly created European ‘industrial product supply’ Network will be an advisory body for the potential impacts of the changing relationship between the UK and EU; for Governments, manufacturers and the media and will be offering real solutions to the challenges presented by Brexit for the sector as well as ideas on how to maximise the opportunities that Brexit presents.

Dr Howard Porter, EURIS Chair, said, “We are delighted to be able to announce the creation of this EURIS European Network. The industrial product supply sector has come together in a constructive manner to establish a working party to deliver the best Brexit for our industry. This is an important time for our sector and we look forward to announcing the outputs of our network in the coming months”.

Steve Brambley, EURIS Vice-Chair, said “There are many areas where UK and EU industry can work together to achieve the best outcome for all of us and

the EURIS European summit has been an excellent starting point for this discussion. The announcement of the creation of a European EURIS Network is an exciting development and one which EURIS members will be working closely on moving forward”.

The BPMA was represented at the event by its President, Duncan Lewis (MD of Xylem Water Solutions), its immediate Past President, Peter Reynolds (MD of Grundfos Pumps) and its CEO, Steve Schofield.

Commenting immediately after the summit, Duncan Lewis said, “I was pleased to have attended the meeting and represent the interests of the pump sector, in what is a crucial subject area for all companies, large and small.

The discussions were extremely positive and seemed to be conducted without a hint of politics”. I feel sure this first event will enable some traction to be gained and enable EURIS and is European Network to make a positive contribution to the post-Brexit landscape”.

For further information about EURIS please contact Harriet Dyball on harriet@euristaskforce.org or visit www.euristaskforce.org

Presented in a spirit of great openness and cooperation, the interactive nature of the meeting helped to identify and cement a great deal of common ground. It the best possible Brexit outcome for the industrial product supply sector across the single market.

Here is the new design.

KSB Pumps - All your waste water needs Municipal, domestic or industrial waste water: the submersible motor pumps of the Amarex KRT type series are the perfect match for all waste water transport requirements. And so are the waste water pumps of the Sewatec series. They, too, are first choice for waste water applications.

For more information please visit: www.ksb.com

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Careers & Recognition

The BPMA have a vacancy, could it be you?

BPMA Vacancy Position: Technical Services Officer Salary Package circa £35k - £40k The British Pump Manufacturers Association Limited (BPMA) is a not for profit trade association representing the interests of UK and Irish suppliers of liquid pumps and pumping equipment and we are currently looking for a Technical Services Officer.

Ideally, the person will have a pump related background and experience in sales and marketing. Initially, they will be required to manage specific projects whilst learning the ethos of the BPMA. When established, it is expected that other responsibilities will be delegated and subsequently developed by the Technical Services Officer.

In this role, the UK and occasional overseas travel will be necessary.

This person will need to be self-motivated, an excellent communicator who should possess a wide range of abilities and skills which will also include decision making. The candidate will report directly to the BPMA Chief Executive and it is essential that they will be able to work alone and be a member of a small team

BPMA Rewards Engineering Excellence Once Again In a celebration of pumping prowess, the BPMA staged its 18 th Annual Pump Industry Awards Presentation Dinner at the tail end of March.

Held at the prestigious Heythrop Park Resort Hotel in the heart of Oxfordshire, this key industry event was attended by over 200 senior executives from across the pump manufacturing and distribution sector, along with their pump-using customers.

Hosted by Broadcaster and Journalist, Andrea Byrne, with a stunning musical performance by the vocal trio Skye, the evening proved once again to be a superb evening of reward and celebration for all those involved with this important sector of UK industry. The achievements and endeavours of some 34 Finalists were presented to the enthralled audience in an atmosphere of great anticipation, before the eventual winners were announced.

We have great pleasure in presenting those very worthy winners, as follows:Winner - Technical Innovation of the Year – Products Sponsored by Process Industry Informer Awarded to Wilo UK Ceram-Teflon Coatings

A copy of the job responsibilities is available from s.schofield@bpma.org.uk

Winner - Technical Innovation of the Year – Projects Sponsored by Wilo Awarded to Xylem Water Solutions Foss Barrier Project

To apply for this position please send your full CV together with a covering letter to Steve Schofield, BPMA, National Metalforming Centre, 47 Birmingham Road, West Bromwich, West Midlands B70 6PY.

Winner - Environmental Contribution of the Year Sponsored by SPP Pumps Awarded to Danfoss Drives for its contribution to the Aarhus Water Project Winner - Distributor of the Year Sponsored by WEG UK Awarded to Clyde Associated Engineers

We welcome our latest new member Since its formation in 1993 by Derek Mountney and Gillian Mountney, Seal & Pump Engineering (UK) Ltd based in Burton-upon-Trent has evolved from a single spring mechanical seal supplier, to becoming one of the UK’s specialist pump, mechanical seal and spares distributors.

Alongside our partnering workshop we now conduct localised pump repairs and refurbishment. Additionally we can reverse engineer bespoke or obsolete equipment, limiting you down time and removing the costs for pipework alterations.

Our sales team are fully trained on all manufacturers equipment we offer and we have members who have completed the BPMA Essentials course for pumping.

With constant industry updates we make sure we are ahead of the game when it comes to solving your pump or sealing requirements.

Our on-site engineers are: Fully Electrically Certified, Safecontractor, Confined Space Trained and CSCS Trained We thank you for taking the time to learn about us at Seal and Pump Engineering. We look forward For more information contact Seal & Pump Engineering UK LTD, Burton-onTrent, Staffordshire.

Tel: 01283 512866 E–mail: info@sealandpump.co.uk Web: www.sealandpump.co.uk

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Manufacturer of the Year Sponsored by Siemens Awarded to KSB Supplier of the Year Sponsored by Tomlinson Hall & Co Awarded to ABB Engineer of the Year Sponsored by World Pumps Awarded to Luke Gardener, Grundfos Pumps This year, the Judging Panel decided to present an additional award for what it saw as an excellent example of how the correct selection of pumps and their associated systems can have a tremendous impact in improving energy efficiency across any given plant or project.

Judges Special Award Sponsored by Flowserve SIHI Awarded to Danfoss Drives for the holistic approach to energy saving across the Aarhus Water Project The final award of the evening is always given to someone, who on the opinion of the BMPA is deserving of recognition for their ongoing efforts and commitment towards the progression of the pump sector. It was this year presented to a very notable recipient.

Lifetime Achievement Sponsored by the BPMA Awarded to Chris Rea OBE, AESSEAL

Speaking after the event Chris summed up his pride in receiving this accolade by saying, “My wife and I were having a thoroughly enjoyable evening as guests of the BPMA at the 2018 Pump Industry Awards, which transformed into truly a memorable occasion when I was announced as the winner of the Lifetime Achievement Award.

Both personally and professionally I have enjoyed the association with the British Pump Manufacturers’ Association for over 30 years. It is a great industry to be in and it is our fantastic customers, many of whom are part of the BPMA, that have fuelled the growth and development of the AESSEAL Group of Companies.

Most of us think recognition from our peers is really special so the Lifetime Achievement Award is already on the wall and will provide me many future fond memories of a great evening”.

Another happy attendee was long-time supporter, Colin Simpson, Business Development Director at Thomlinson Hall & Co who commented, “As both award sponsor of ‘Supplier of the Year’, and also nominated finalist in the ‘Distributor of the Year’, we thought the event this year was excellent.

Our guests for the evening commented on the “positive vibe in the room”, which we also felt. The number of new participants this year was noticeable and added a different dimension to the evening. Networking pre and post event was fantastic with a friendly feel of cooperation in abundance. Well done to all those involved”.

BPMA Director, Steve Schofield, said of the evening, “This year’s awards dinner was another triumph for both the BPMA and the industry it serves. I have received nothing but praise from sponsors, winners and finalists alike for a great evening of fun, celebration and networking.

Our chosen Charity for this event, WaterAid, also enjoyed considerable success, with a record £6,000.00 being raised through the Raffle. This is a fantastic amount of money, which will go a long way in helping WaterAid carry out its fine work in some of the poorest countries around the world. Thank you to all those companies who donated prizes and of course to our guests who were so generous on the night”.

Full details on all the winners and finalists, along with images of the awards presentation ceremony can be found on the dedicated PI awards website – www.pumpindustryawards.com.

Entries for the 2019 awards programme will open in September, so if you know of a pump product, project, company, or individual that you believe is worthy of wider recognition, please do let us know.

Reader Enquiries to: Steve Smith, Administrator, British Pump Manufacturers Association Ltd, West Bromwich, West Midlands Tel : +44 (0)121 601 6691 Email : s.smith@bpma.org.uk Web : www.bpma.org.uk

Data Protection

GDPR, What is it good for?

The General Data Protection Regulation, introduced May 25th, 2018 introduced changes and enhancements to the Data Protection Act of 1998. Why do we need these changes to the legislation?, well, if you can cast your mind back to 1998, which doesn’t seem too far for some of us and remember what technology was like back then, fax machines, VHS recorders and landlines, things have changed.

What does GDPR mean for my Business

3. How long the data will be used or held

Scope

4. Who the data will be shared with

• All EU citizens personal data falls under the scope of GDPR, whatever country or jurisdiction this is held in, as well as for any processing outside the E.U.

• Lawful Processing – Processing shall be lawful only if and to the extent that at least one of the following applies

• “Data Subject” definition is widened to include IP ddresses, biometrics, photographic images and anything that can identify a person

Consent

• Suppliers ( processors) need to comply with GDPR

• Controller - This is the person or organisation that defines what data is collected and for what purpose

And Companies who have access to this data have a responsibility to ensure that they have a legitimate reason for keeping this data and protecting it from malicious threats and misuse.

»» Legal Obligation »» Vital Interest

Transparency & usage

We still have the same information about us that we need to keep private, but now we have a Smartphone with more technology in it than Nasa had when they launched rockets to the moon, and this is where our problems lie, social media, internet banking, passwords for everything all kept on clouds and on our phones, tablet or laptop. All information that we need, but that we have to protect and ensure doesn’t get into the wrong hands.

»» Performance of Contract

»» Public Interest »» Legitimate Interest

• Processor – The person or organization who does something to the data on behalf of the controller

These useful links below will give you more information and should answer any questions you may on GDPR

• Processing is anything you do with data:

ICO Website: https://goo.gl/tHLkg7

- collection, recording, organising, structuring or storage - adaption or alteration - retrieval, consultation or use

GDPR Text: https://gdpr-info.eu/ GDPR Coalition http://gdprcoalition.ie/

- erasure or destruction • Controllers and Processors must ensure the individuals know 1. Why this data is being taken 2. How it will be used or processed

PUMP GENIUS

Pumping Control Software WEG’s Pump Genius process control software is designed to reduce pumping system operation and maintenance costs whilst increasing process accuracy and protection.

Working with the CFW11 variable speed drive the software provides multiple pump control and protection as well as system monitoring, flow and pressure management for up to six pumps.

For more information visit www.weg.net

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SOLUTIONS FORUM

SUBMERSIBLE DRY-WELL VS TRADITIONAL DRY-WELL WHICH IS BEST FOR WASTE WATER PUMPING

By Andrew Barry, General Manager – Wastewater Pumping - Xylem

What are the differences between submersible drywell and Traditional dry-well pump installations?

Which would be better for my wastewater or stormwater pumping station?

Answer: Dry-well pump installations can be categorised as pump systems that canbfunction when submerged in water for extended periods of time, and those that cannot. The suitability of each to a specific application will depend largely on thelayout of the pumping station, as well as the perceived likelihood of flooding.

DRY-WELL PUMP INSTALLATIONS Traditional dry-well pump installations are designed mainly in conjunction with large, vertical pumps. The dry well is located separate to the wet well, connected via a series of pipes. Traditional dry well pumps involve the use of non-submersible motors – this is primarily based on the assumption that dry wells are not intended to house water and are unlikely to flood although, as we will see, this assumption is now being tested as weather patterns become more unpredictable and extreme.

Traditional dry-well pump designs have either been close-coupled, or long-coupled. Close-coupled pumps contain a motor that is bolted directly to the pump end, with the motor shaft extended through the pump and generally rely on the motor bearings to take the radial and axial loads. They benefit from automatic correct alignment, as well as a more compact footprint for smaller civil structures.

In long-coupled pumps, the motor is connected to the pump with a separate coupling device with bearings in a housing which forms part of the pump end. The advantage of such a design is that the motor can be removed without disturbing the rest of the pump. It is also easier to access the mechanical seal and bearings without removing the motor, although alignment between the pump and motor is more difficult but critical in order to prevent the premature failure of bearings and coupling parts. This can lead to long-coupled pumps being more susceptible to both heavy vibrations and

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noise especially when extended shafts are used between the pump and its motors.

However, inherently with any dry well design the level of liquid in the wet well is always going to be above the level of the pumps and therefore the possibility of leakage is always present. Therefore both close and long-coupled non-submersible pumps are problematic in these circumstances as the motors are not designed to function underwater and could be damaged in the event of a flood. A long-coupled non-submersible pump could, arguably, mitigate this risk somewhat by removing the motor from the pumping area, but it will still be compromised and require extra maintenance to the interconnecting shaft and couplings.

In the event of any flooding, a traditional, nonsubmersible pump will need to be removed, checked and, in some cases, repaired, before it can resume its duties. This gives rise to high maintenance costs.

Further disadvantages include a need for the pump’s motor to be cooled due to its enclosed environment. And oil chamber levels must also be maintained at all times.

Despite these challenges, traditional, non-submersible pumps remain popular with many consultants due to their capacity to function after a mechanical seal failure. Many would also argue that the pump’s ease of maintenance lessens the impact of flooding somewhat.

makes them both compact, quiet-running and, therefore, a highly suitable option for pumping stations located in densely populated areas. Also due to their compact size, they are ideal for retrofitting into existing dry wells where access can be difficult and pipework modifications may be required.

Dry installed submersible pumps can be mounted either vertically or horizontally, and the form chosen will largely depend on the layout and design of the dry well or wet well. Vertical designs are often preferred for low-lying or underground dry wells because they provide a smaller footprint and can be lifted out directly for maintenance.

The submersible pump offers few disadvantages compared to traditional, non- submersible pumps, although maintenance is arguably less straightforward.

Seal failure, for example, requires immediate action and will often take longer to repair than a seal failure on a dry, non-submersible pump. However the lack of oil lubricated bearings and external couplings means that other maintenance, which is required by traditional designs is non-existent.

The pump’s ability to function underwater largely outweighs these challenges, however, because less maintenance is required over the long-term. With increasingly unpredictable weather patterns, the submersible pump is often the better choice, both in terms of ease of maintenance, and peace of mind.

A BRIEF NOTE ON IMMERSIBLE MOTORS Although it may be tempting to consider immersible motors fitted to traditional pumps as an effective, low-cost alternative to submersible pumps, it is important to remember that they arguably offer little advantage, save in upfront costs. Immersible pumps can be operated when submerged, but their limitations mean that the motor is likely to be damaged if submerged for extended periods of time and the pump will still need to be fully overhauled following a flooding event.

DRY INSTALLED SUBMERSIBLE INSTALLATIONS Submersible installations entered the market over 60 years’ ago and have since become a reliable option for wastewater and storm-water pumping stations. Although originally designed to be installed within the wet well and run continually submerged, they have found increased use installed within the dry well, particularly those that are liable to flooding.

As their name suggests, submersible motors are capable of operating underwater for extended periods of time. All submersible pumps are close-coupled, which

CONCLUSION When specifying pumps for wastewater and storm-water pumping stations, it is important to reflect on the pumping station’s design, as well as aspects such as: likelihood of flooding, ease of maintenance, footprint, spatial restrictions, local environment, cost of upkeep, and the likely concentration of debris and solids, beforea decision is made on the best pump options available.

N EWS

See the BPMA’s Guide Leaving the European Union in March 2019 will have subsequent consequences on existing European Legislation within the UK. The UK transposes EU legislation into statutory Instruments and these will need to be individually reviewed to see if they require change or removal.

It is still not known if the UK will adopt CE marking and a Declaration of Conformity after Brexit.

To Assist BPMA has now joined Euris which is an association of mechanical & electrical associations working together to obtain information for their respective members. Euris has direct access into UK Government.

Euris - www.euristaskforce.org/about-euris/ Best Practice Guides Revision of Variable Speed Pumping guide It was confirmed that this Guide was now published and available from BPMA This guide is the result of co-operation between three different industries whose goal was to produce a document that would clearly define in simple terms the information required when planning to use an electronic Variable Speed Driven Pumping System. The guide focuses mainly on applications within the Industrial Sector, however the principles used will be applicable to most pumping applications.

To request a copy of the Guide contact Steve Smith, Administrator, British Pump Manufacturers Association Ltd, West Bromwich, West Midlands. Tel: +44 (0) 121 601 6691 E-mail: s.smith@bpma.org.uk

BPMA Follows-up its Brexit Position Statement with Membership of EURIS The British Pump Manufacturers Association (BPMA) which represents the business interests of UK and Irish suppliers of liquid pumps and pumping equipment throughout both the domestic and international arena has joined with other leading trade associations in its membership of EURIS. The European Union Relationship and Industrial Strategy is an advisory body for the potential impacts of the changing relationship between the UK and EU for the UK Government, manufacturers and media. EURIS members include such notable bodies as BEAMA, GAMBICA, EAMA, REA, CESA, FETA, MTA, BFPA and TechWorks, which between them represent over 4000 companies across electro-technical, electronics, renewables and mechanical engineering products.

It has a focus on product manufacturers covered by the Single Market and the supporting regulations and standards. The member associations have

extensive relationships with equivalent European trade bodies, and parts of the European Commission.

The EURIS Taskforce produces Position Papers and Reports relating to the Brexit process relevant to the manufacturing sector. It also issues a weekly economic report to its members based on a tracked set of macro market indicators ranging from international trade and the general economy through to productivity costs and price indices.

Steve Schofield, Director and CEO of BPMA commented, “Following hard on the heels of our own Brexit Position Paper, which we issued to Government at the end of last year, I am delighted that the BPMA Council has decided to join EURIS.” He continued, “Through our membership of this advisory body, we can ensure that our Members are kept abreast of all developments relating to Brexit and its likely impact on the UK’s engineering sector.”

Steve Brambley, CEO of GAMBICA and Vice Chair of EURIS, added, “We are delighted to welcome BPMA into membership, and to enhance the strong and cooperative working relations that already exist between our various organisations through the auspices of EURIS.” Further information on EURIS can be found via www.euristaskforce.org.

Further information on BPMA can be found via www.bpma.org.uk.

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N EWS

BPMA joins other Trade Bodies at CE Mark Briefing

BPMA Director Talks to Modern Building Services

MAKING LOW FLOW MORE EFFICIENT

As part of its ongoing commitment to international standards and product certification, the British Pump Manufacturers Association was one of 16 trade organisations who attended a recent briefing at the Houses of Parliament.

MBS is one of the leading communication channels in the UK addressing the complex world of building services. It does so through both a monthly ‘hard copy’ publication, which it distributes to over 23,000 readers, and a highly regarded online provision. Editorially, it not only looks at the traditional areas of building services but also seeks to unify the myriad roles of everyone engaged in what is becoming an increasingly sophisticated sector from design and newbuild to lifetime maintenance and refurbishment.

Combining the proven technologies of Sundyne Barske Wheel hydraulics with the HMD Kontro sealless magnetic drive, the GSPLF (LF for Low Flow) sealless pump has been developed to fill a gap in the market for a highefficiency low flow magnetic drive centrifugal pump with a single stage high head capability. The GSPLF meets the requirements of API 685 and has full ATEX compliance, making it ideal for chemical and hydrocarbon processing applications.

The meeting was hosted by Neil Coyle MP, who was joined by several representatives from the Department for Business, Energy and Industrial Strategy (BEIS), and covered the important topic of CE Marking post Brexit.

Following a brief welcome and introduction by Neil Coyle, the agenda followed three primary items: • Retaining the CE Mark Post Brexit • A Potential UK Mark or Equivalent • Conclusions and Follow-up Actions Clearly any move way from the existing system of CE Marking for all products that are shipped throughout the single market is a huge undertaking, and so given its work on various standards committees and sub-committees within Europe over recent decades, the BPMA’s place at this meeting was seen to be both important and very much welcomed by all those in attendance.

The diversity of the industry sectors represented was extremely broad, covering such disparate areas as industrial trucks, giftware, heating and hot water, mineral products, educational supplies, toys and hobbies, building services as well and pumps and pump related equipment.

Representatives from the British Standard Institute (BSI) and the British Retail Consortium (BRC) were also in attendance, further illustrating the importance placed on this issue.

Commenting on this meeting, BPMA Director & CEO, Steve Schofield said, “There are some crucially important issues affecting the UK’s manufacturing sector that need to be fully understood, and then borne in mind, when negotiating the final stages of Brexit; CE Marking is one such issue. I am pleased that through BEIS, the Government is at last seeking advice and input from industry. Events like this seek to do just that, and so I welcome the initiative.

However, as things stand there is currently no alternative to the CE Mark for the UK if negotiations fail regarding the Customs Union with Europe, which is a major concern to all the sectors involved. None-the-less, the BPMA, along with its counterparts from other industries will continue to push for the best possible outcome on all the issues governing the movement of manufactured goods and materials in a post Brexit world”.

Reader Enquiries to: Steve Smith, Administrator, British Pump Manufacturers Association Ltd, West Bromwich, West Midlands Tel : +44 (0)121 601 6691 Email : s.smith@bpma.org.uk Web : www.bpma.org.uk

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Pumps and pump related systems have always played a Sundyne has over 50 years of key role in all manner of building services, and it remains experience in offering Barske an important market for many BPMA members.

Wheel pumps, designed to provide efficiency in the low It is therefore important that as a part of the BPMA’s specific speed regime often ongoing PR activities, we share our news and information referred to as low flow, high head applications. with all those operating in this arena.

These pumps have an open impeller with straight blades Steve Schofield, BPMA Director & CEO recently spoke to and a tapered conical diffuser to produce the desired the Editor of Modern Building Services on the challenges performance. Development and testing demonstrates facing the pump market, and how the Association is that this combination produces a head factor (ratio of supporting its growing membership. This includes developed head to theoretical head) considerably higher of course its membership of EURIS, and its ongoing than that of traditional back-swept Francis vane impellers. endeavours to help ensure that its members’ interests are The combination of Sundyne Barske Wheel hydraulics protected throughout the Brexit negotiations. with the HMD sealless magnetic drive, reliability, design The discussion took the form of a televised interview, flexibility, and efficiency is further optimised, ensuring trouble-free, safe and environmentally conscious which is available to view on MBS TV, via this link. plant operation. An additional advantage of the GSPLF It is hoped that other such interviews can be arranged is the flexibility inherent in the diffuser and impeller with other sector specific publications over the coming combination, which can easily be rerated should the duty weeks and months, to help further present and portray point change without replacing the pressure casing. the work of both the BPMA and its 82 strong membership.

HMD Kontro has more than 25 years’ experience in Reader Enquiries to: Steve Smith, Administrator, British API applications and a 70 year track record in magnetic Pump Manufacturers Association Ltd drive technology, being the first company to develop a magnetic drive sealless pump.

West Bromwich, West Midlands. Tel : +44 (0)121 601 6691 Email : s.smith@bpma.org.uk Further information, including a copy of the GSPLF brochure can be seen and downloaded from theSundyne Web : www.bpma.org.uk HMD website at www.sundyne.com/hmdkontro.

Alternatively, please telephone +44 1323 452141 or email vince.lee@sundyne.com.

Grundfos Pump School enrolling now The Grundfos Pump School has re-opened its doors and is now offering a choice of 11 courses covering topics that relate to a wide range of applications including fire, dosing and wastewater.

This year we are pleased to introduce 2 new courses to the curriculum that are specifically aimed at people working with pump solutions in industrial and building services applications.

Courses are held over one day and include the opportunity to get ‘hands on’ with various pump solutions. There are a range of dates available for the remainder of 2018 and a choice of venues.

Courses are already proving to be very popular so early on-line booking is recommended. To view more details relating to the many options available, or to directly book a course(s) visit www.grundfos.co.uk and click on the Training link and then on Pump School and you will be able to view the courses and directly book your preference.

N EWS

A global-facing company… with deep local roots Billingham-based pump distributor and manufacturer Tomlinson Hall has harnessed its success and industry reach to make a real difference to its local community.

Year Title in both 2015 and 2017 to Prior’s Mill Church of England Primary School in Billingham – which also used the donation to support STEM subjects, a Science Week and a school visit to Newcastle’s Life Science Centre.

The company, which was founded in 1919 and is a proud BPMA member, has recently lent its support to a number of initiatives which support young people and benefit community projects.

Tomlinson Hall also supports the Billingham Legacy Foundation, an independent charitable grant making body which invests in the community of Billingham for the benefit of the people of Billingham. The company has sponsored – and helped to organise – three golf days in aid of the foundation since 2016, which have brought together businesses from the pump industry, and chemical processing and utilities sectors. More than £5000 has been raised for the foundation to date as a result.

The company manufactures its own innovative liquid ring vacuum pump, Liquivac, on its Billingham premises.

It is also the approved UK distributor of many leading pump brands, such as DEPA, ELRO and also Richter, and distributes pumps for other leading manufacturers including Grundfos, Flux, Calpeda and ITT Goulds.

As part of its commitment to education and skills, Tomlinson Hall has helped to support the scientists of the future by donating £2000 to Billingham South Community Primary School. Tomlinson Hall was named Engineering Firm of the Year 2018 at the North East of England Process Industry Cluster (NEPIC) Annual Industry Awards and received £2000 to donate to a local school of its choiceto support STEM-related projects.

Tomlinson Hall donated the money to Billingham South Community Primary School and this has helped to fund the school’s Science Week and provide valuable resources to enrich its pupils’ educational experience in STEM subjects.

In addition, Tomlinson Hall donated the £2000 prize money it received after winning the NEPIC SME Of The

landscape for nearly 100 years and we feel that it’s important to put something back into our local area”.

Tomlinson Hall works across the UK and in overseas markets including Europe, the Middle East, the Americas and Asia. It offers a total service to industry – including pump selection and supply, site visits, problem solving, servicing and repairs.

For more information contact Tomlinson- Hall by Tel: 01642 379500 E-mail: enquiries@tomlinson-hall.co.uk Web: www.tomlinson-hall.co.uk

In addition, Tomlinson Hall has demonstrated its commitment to sport in North East England bym supporting the Gazette Sports Awards in Middlesbrough and sponsoring Stockton Pumas and Stockton Rockets basketball teams.

Colin Simpson, Business Development Director of Tomlinson Hall – who is also a patron of the Billingham Legacy Foundation – said: “At Tomlinson Hall, we believe that business and the community should work together – whether that is to support our young people and give them the best grounding possible in STEM subjects, or helping organisations like the Billingham Legacy Foundation to make a positive difference to the lives of people on our doorstep.

“As a business, we have been part of Teesside’s industrial

Left to right: Andy Buckworth (Executive Director Stem Technical Training, Northern Skills Group), Edwin Squire (Headmaster, Billingham South Community Primary School), Ian Wright (former Chief Executive, NEPIC), Colin Simpson (Business Development Director, Tomlinson Hall) and Sara Raffell (Internal Sales, Tomlinson Hall) at Billingham South Community Primary School.

New suspended pumps with the hydraulic system of standardised chemical pumps The Estigia type series extends the KSB SE & Co. KGaA, Frankenthal, product portfolio for the chemical and petrochemical industries and other applications. It was showcased at this year’s ACHEMA trade fair in Frankfurt (11 to 15 June).

The low-pressure suspended pumps are designed for vertical wet installation in a closed tank under atmospheric pressure. For the installation depth, various lengths ranging from a minimum of 852 mm to a maximum of 6402 mm are available and three discharge pipe diameters can be selected for each pump size.

Given the vertical design, the pumps only require very little space. When the immersion depth exceeds 2400 mm, a special design element between the support column sections and the discharge pipe makes for significantly reduced vibrations.

The casing cover of the pump is fitted with a product-lubricated plain bearing made of high-grade, wear-resistant silicon carbide.

This results in a long service life and long maintenance intervals. The pump set is easy to install and dismantle with its integrated cover plate serving as the tank cover.

The material variants on offer are cast iron, stainless steel and duplex steel. Replaceable casing wear rings prevent possible wear on casing and impeller. The Estigia type series is characterised by a high efficiency and low operating costs.

The pump set can be supplied with shaft bearings lubricated by the fluid handled, an external liquid or an electric grease pump. A so-called cantilever design is also available. This version is designed to ISO 5199, with flexible coupling and grease-lubricated rolling element bearings arranged outside the fluid handled. The pump is suitable for fluid temperatures of -30 °C to +100 °C. It can be driven by variable speed and fixed speed electric motors, with or without ATEX approval.

Calpeda are pleased to announce that Jon Bennett has been appointed to the role of General Manager of its UK subsidiary Calpeda Limited.

Jon has been a member of the Calpeda UK team for a number of years in various roles most recently National Sales Manager.

The new appointment is part of a series of management changes scheduled to take effect over the next few months following Ken Hall’s new appointment with Calpeda S.p.A as Regional Manager, head of operations across sub-Saharan Africa. Ken will continue to be a member of the UK board of Directors, retaining his position of Managing Director, but Jon will now be responsible, reporting to the board, for the day to day operations of the company.

We are sure that Jon will have other announcements to make in the coming months about the company’s operational structure as he takes the business forward.

For more information contact KSB Ltd. Tel: +44 (0) 1509 231 872 E-mail: sales@ksb.com Web: www.ksb.com

Everyone at Calpeda congratulates him on his hard won appointment as he now joins the Calpeda family team as one of our senior managers responsible for a subsidiary.

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N EWS

ITT unveils i-ALERT® Ai Platform The simple online asset intelligence (Ai) platform is the latest service to be introduced since the i-ALERT2 Bluetooth Smart-enabled machine health monitor was launched in May 2015. The breakthrough innovation and the various features added over the past two years enable customers to spend less time collecting data from their rotating equipment and more time solving problems.

i-ALERT Ai Online Platform With the i-ALERT Ai platform (https://i-alert.ai/), customers can monitor and manage all their i-ALERT enabled machines and sensors in a simple web interface.

This subscription service requires no software to download or dedicated hardware to run. It allows customers to view trend data, machine notes, technical data and vibration spectrum data collected via the i-ALERT2 application (app), all visualized in a simple timeline.

Data Collection Time Reduced by 50 Percent This online web interface complements the route customization feature introduced in 2016, which cuts collection of machine performance data by as much as 50 percent. Customers can manage the data collection via the i-ALERT mobile app by setting up designated routes and the app will automatically guide a user to which assets and what type of date to collect on the route. Once a route is completed, the app will automatically generate a report and email it to the customer.

features and benefits are: ◾Asset Intelligence: Monitor the equipment health of any rotating machine such as pumps, motors, fans, mixers, gear boxes and more. It tracks 3-axis vibration, temperature, kurtosis and machine runtime. It logs data at every hour or on an alarm event.

• Easy to Use: With the free mobile app and simple interface, it puts machine monitoring in the hands of the everyday user.

• Save Time: The app will quickly scan multiple machines at once and cover more equipment with fewer resources, freeing time for analysis and troubleshooting.

Prevent a crisis before it happens with the new Motor Scan technology from WEG

• Stay Safe: A Bluetooth® Smart wireless connection allows monitoring from a safe distance.

The new WEG Motor Scan enables real-time monitoring of motors via a smart device App in order to maximize uptime and facilitate preventative/ predictive maintenance

• Early Detection: Unplanned machine failures can be avoided with the early detection feature of the i-ALERT monitoring solution. Customers can now view realtime and historical data, diagnostic information and machine records. This provides them with the data necessary to make informed decisions.

• Solve Problems: Advanced vibration diagnostic tools are available to anyone who can use a smartphone or tablet. With the Ai platform, customers will be able to monitor i-ALERT2 enabled machines anywhere they have an internet connection.

“With the i-ALERT Ai platform, customers have access to a seamless monitoring solution that is easy to use and access. The i-ALERT2 monitor is certified in 78 countries and the mobile app is available on iOS and Android platforms.

Features & Benefits With the i-ALERT2 sensor, the mobile app and the Ai platform, customers can have a seamless monitoring solution that will enable them to safely inspect multiple pieces of equipment and be alerted of potential problems before they become critical failures. Broadly, some of the

Request a copy of the iAlert Application guide from – gouldssalesuk@itt.com or telephone 1256 311904

Grundfos give ARLA food for thought Arla Foods are one of the biggest players in the dairy arena with many household brand names in their portfolio.

Originating in Denmark, they now have production facilities in many European countries. As you would expect, food production is highly regulated and there are many restrictions to not only ensure that the produce itself meets the highest standards, but that any residual by- products are properly treated to not place additional strain on the environment. Delivering such exacting standards is frequently complex and expensive.

When Arla wanted to increase their mozzarella production, they turned to Grundfos for assistance, as within the production process, water needs to be separated out from the milk. This residual ‘cow water’ as it is colloquially known, includes the nitrogenous compound urea, that traditional treatment plants struggle to deal with and therefore it needed to be sent off-site to be treated which was an expensive process. Grundfos introduced them to their BioBooster – one of Grundfos’ next generation solutions. These stand-alone units clean wastewater in a biological process, that through its ultrafiltration membranes, eliminates bacteria at its source by removing organic and bacterial contamination.

This treated water complies with strict discharge limits and achieves all necessary water reuse standards.

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WEG, a leading global manufacturer of motors and drive technology, has unveiled its brand new Motor Scan product targeted to deliver remote monitoring of WEG Motors in order to maximize uptime and enable predictive/ preventative maintenance. This new technology allows maintenance professionals to make informed decisions about the health of installed motors and react accordingly depending on the data captured. The WEG Motor Scan system uses Industry 4.0’s digital technology, including Industrial Internet of Things (IIoT) and Big Data Analytics to give clients a competitive edge in this dynamic and challenging business environment.

Available for frame sizes from 100 to 450, WEG’s sensor measures the vibration and temperature of motors to detect anomalies. Easily retrofitted via a mounting clamp, the sensor tracks vibration, surface temperature as well as running hours, and will provide data on speed, start/stop time, load and efficiency via Bluetooth. For ease of use the captured data is stored in the cloud and the user can use an App, available for both iOS and Android devices, on their smartphone or tablet to access it. Users can also access the data on laptops and desktops via a dedicated web portal. Powerful analytics help to process the data and predict pending failures or hidden problems based on frequency spectrum analysis. Warning levels are pre-set based on acceptable baselines of temperature/ vibration and software is able to plot performance curves with the captured data.

Essentially, WEG Motor Scan takes the monotony out of manually collecting and monitoring data, removes the guesswork of preventive maintenance and eliminates the inefficiency of reactive maintenance. Also, by training maintenance professionals to take on the specialised requirements of predictive maintenance, it provides the opportunity for companies to upskill staff and expand their capability.

In this instance the outcome has been that at this Arla site alone they can clean 450 m3 of water daily - that can be reused in a suitable process or despatched into a local water course - a true win/win situation. This winning combination was reinforced at the recent Global Water Summit that saw readers votes secured this Arla/ Grundfos project the prestigious Industrial Water Project of the Year award.

If this Grundfos BioBooster solution has given you food for thought as to how it could benefit your operation, email us at grundfos-uk@sales.grundfos.com

“The WEG Motor Scan can predict and avert a crisis before it happens. It is just like having a crystal ball that lets you know what is going to happen in the future. We find that fixing a problem before it happens is the most costeffective form of maintenance and this provides direct benefits to our clients. Clients can reduce cost, improve profitability and use their resources more efficiently,” said Andrew Glover, European Low Voltage Motors Product Manager. “The WEG Motor Scan leverages IIoT and analytics to connect sensors and other devices to collect and analyse real-time data to provide transparency for taking immediate pre-emptive actions.

Our new solution helps clients to stay competitive in this ever-evolving and challenging environment.”

For more information contact WEG (UK) Ltd, Redditch, Worcestershire.

Tel: +44 (0) 1527 513800 E-mail: wegsales@wegelectricmotors.co.uk Web: www.weg.net

SENSORS

VISION SENSORS RATED IP69K FOR FOOD & PHARMA APPLICATIONS The BAUMER Verisens vision sensor range now includes models in stainless steel housings which are IP 69K rated to enable wash down and therefore meet the specific requirements of applications within the food and pharmaceutical industries. Whilst complex and sophisticated image processing systems, the XF Series are designed to enable simple set-up and intuitive operation, even for the non-expert.

The new XF-105/205 models are based on the proven VeriSens XF Series ensuring a high performance and providing users with up to 19 feature checks. The XF Series, which can also read code and text, incorporate the patented FEX image processor which provides stable image evaluation and is claimed to be the first sensor of its type which can be configured via a web interface.

Configuration is simple thanks to the standard VeriSens Application Suite Software, while other models incorporate infrared illumination and integrated daylight filter which supresses daylight impacting on the image evaluation, or flashlight effects caused by integrated illumination.

Further details available at: https://goo.gl/39Xd3R Tel: +44 1793 783839 E-mail: sales.uk@baumer.com Web: www.baumer.com/ch/en/

The Fastest Flow Controller in the World born in the lab, proven in the factory

Mass flow controllers and meters for dead-on, rock steady gas and liquid flows Used in burner control, chemical separation, sub-atmosphere coating—and so much more • 200:1 turndown ratio saves costs and connections • Over 100 gas calibrations on board means no K-Factor inaccuracies • Micro flow: 25 nµlpm—to high flow: 5000 nlpm • Multivariate digital reporting of pressures, temperatures, mass and volume flows • 50 ms high speed control response ensures spike-free processes Alicat distributor in UK:

Premier Control Technologies 01953 609 930 sales@pctflow.com

http://alicat.com June 2018 – Process Industry Informer

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FEATURED ARTICLE

By Matthias Kassner, Vice President Product Marketing, EnOcean GmbH

Self-powered wireless sensors

in the industrial Internet of Things Sensors have a key function in industrial production. For example, they can be used for quality and process monitoring or condition-based maintenance. The application spectrum is large and is evolving mainly due to the increasing use of self-powered wireless sensors in the direction of an industrial Internet of things. By combining wireless function with energy- efficient operation, sensors can also be used directly on moving parts or in a hermetically encapsulated environment, for example flow, pressure and temperature of liquids or gases.

ECT310_11_cmyk-300dpi-wht: ECT 310 Perpetuum is a ultra-low-voltage DC/DC converter for powering battery-less EnOcean radio modules by Thermal Energy.

In industrial production, the vast majority of sensors work with wires. This approach, however, prevents many applications directly from having moving parts. Wireless sensors offer an alternative here, but the problem of power supply and therefore the maintenance involved must be carefully considered. A new class of sensors combines wireless functionality with energy-efficient operation, enabling new applications without downstream maintenance.

This paper examines the requirements of sensors in the industrial internet of things and discusses the possibilities and limitations of radio-based sensors.

Maintenance-free process monitoring The goal of process monitoring is to ensure a defined productivity, ie to achieve a production quantity based on a certain amount of time, material and personnel. Deviations in the production process must be detected and avoided as far as possible.

At the same time, the integration of wireless sensors into the production facilities offers decisive advantages: hermetically encapsulated, wireless sensors can be used, for example, in pipelines to measure the flow, pressure and temperature of liquids or gases.

Energetic sensors in quality control

Ideally, tools with integrated sensors, which fit directly into existing production processes, would not require special training and generate no follow-up costs.

These requirements can be met by energy-efficient sensors, as the following example shows: In many cases, a relevant data acquisition must be close to the boundary between the tool and the workpiece. Parameters such as feed, contact pressure, surface temperature, vibration and noise can be recorded, which can be subjected to a downstream analysis.

A challenge here is that the monitoring often has to be carried out at moving and / or difficult to access locations. The use of conventional wired sensors is thus difficult to achieve.

Compact, wireless sensors offer decisive advantages for this application. Since they do not require any wiring, they can be mounted directly on moving parts. Furthermore, these sensors can also be used in a hermetically encapsulated environment (for example, in a vacuum or under a protective atmosphere).

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The main difficulty in implementing a condition-based maintenance is the continuous monitoring of the object in order to be able to reliably determine the time of the necessary maintenance.

Even with a superficial view of the number of critical parameters of a machine tool, it is quickly clear that it would not be possible or indeed very difficult to monitor all relevant data. The associated costs would only be useful in very rare cases.

However, in many cases it is possible to gain valuable information by monitoring fewer, simpler parameters.

Quality monitoring is a central aspect of the production process. It ensures that the final product of the production process is characterized by previously defined parameters.

In order to achieve this goal, a variety of parameters must be monitored, for example environmental factors such as temperature, humidity and air quality; process factors such as speed, force, pressure and temperature or material factors such as considering the starting materials used.

Many of these parameters are suitable for automated monitoring by sensors. In practice, however, this is not yet fully implemented. The reasons are complex, the most common aspects are the necessary investment in new tools, machines or sensors, the necessary training of the employees, the costs of maintenance and a difficult estimate of profitability.

be desirable for machines from the point of view of cost efficiency, since maintenance is only necessary when this is required.

Elektromechanischer Wandler_ECO_200_ŠEnOcean: The energy module ECO 200 is an energy converter for linear motion. The energy output at every actuation of the spring is sufficient to transmit 3 sub-telegrams with a PTM 330 module. Possible applications are miniaturized switches and sensors in building technology and industrial automation.

Examples of such parameters are temperature, since wear often leads to higher friction which, in turn, leads to a temperature rise on the machine. Another parameter is sound because experienced employees can often recognize wear and tear on machines based on deviating noises. Vibration also plays a role, since the combination of wear and friction frequently leads to asymmetries in the machine geometry, which are expressed through vibrations, particularly in the case of rotating machines. Wireless sensors, which can be directly integrated into the machine, also offer decisive advantages.

Condition-based maintenance with battery-free sensors A central aspect of quality assurance is the monitoring of machines used for production. These are subject to wear and tear and early recognition of any problems and therefore timely countermeasures for affected items are therefore important prerequisites for continuous quality assurance and to protect against production losses.

A fundamental problem of maintenance scheduling is calculating the intervals between each maintenance visit.

On the one hand, the time between maintenance visits must be sufficiently short to detect possible deviations before the occurrence of a major problem. On the other hand, maintenance is costly in terms of time labour and inactive machines.

Ideal would be the so-called condition-based maintenance, defining acceptable ranges. A typical example of this is the regulation of the minimum depth of tread on car tyres.

When the depth of the tyres is below the defined limit, it is time to change them. Such an approach would undoubtedly

Miniaturisierte Solarzelle_ŠEnOcean: The indoor solar cells ECS 300 and ECS 310 are designed for use with the EnOcean STM sensor modules.

Self-powered radio sensors open up new possibilities From the foregoing considerations, it becomes clear that wireless sensors offer decisive advantages for various applications in production. However, these advantages have to be weighed against the challenge that cable sensors must be continuously supplied with energy.

Particularly when used in places which are difficult to access (for example, integrated in machines, tools, leads, etc.), the disadvantage of a possible maintenance due to the necessary battery change must be carefully considered. Battery

Process Industry Informer – June 2018

FLUIDS HANDLING

Hydra-Cell… Reducing the Cost of Precision Metering and Dosing Hydra-Cell pumps are claimed to offer the most economical solution for precision metering and dosing thanks to their simple, clever design with multiple hydraulically balanced diaphragms in a single pump head.

Kombo switch module - With wireless radio switches and sensors, trades can be networked particularly flexibly and intelligently controlled. Gateways connect the components to other systems such as KNX, BACnet or DALI.

solenoids (energy-efficient) wireless radio sensors allow completely new approaches.

Battery-powered radio sensors use light, movement or temperature differences in their immediate environment as a source of energy. In this process, energy converters "harvest" the smallest amounts of energy for the operation and the radio communication of sensors, switches or actuators.

Unlike typical API 675 diaphragm pumps, which are big, slow moving and deliver a large volume on each stroke, Hydra-Cell pumps work at high speed, delivering a small volume from each cell but at high frequency, which is why the pumps can be physically smaller in relation to flow capability and consequently less expensive to acquire and operate.

Hydra-Cell’s multiple diaphragms work in sequence to produce a virtually pulseless liquid flow, removing the need for pulsation dampeners in most installations, saving further installation and maintenance costs. Pipe strain and system leaks are also reduced.

Unlike plunger type metering pumps, Hydra-Cell pumps have no dynamic seals, cups or energy sapping packings through which hazardous fluids might escape or through which air could enter the system on the suction stroke to cause degradation or crystallisation of the pumped liquid. And most importantly, Hydra-Cell pumps require no expensive seal maintenance.

Compact in design, robust in construction, reliable in operation and exhibiting high energy efficiency, HydraCell pumps enjoy a long service life with exceptionally low lifecycle costs.

For more information contact Wanner International Ltd, Church Crookham, Hampshire.

Tel: 01252 816847 E-mail: sales@wannerint.com Web: www.hydra-cell.eu

Hydra-Cell pumps are exceptionally energy efficient (80% and above), which also reduces power requirement and energy costs.

In the industrial sector, in particular kinetic and thermal energy generators are of interest. Kinetic energy generators gain energy from movement, for example, by lateral movement (as when a switch is pressed), vibration or rotation about an axis. Thermal energy generators use temperature differences to generate energy. Here, the combination of a thermoelectric converter and a voltage amplifier can already convert temperature differences of two degrees Celsius into usable current.

The energy gained by such energy generators is often low. Their use therefore requires the optimization of the entire sensor architecture to include efficient measurement methods and energy-saving radio solutions. Such sensors have been developed by EnOcean since 2001 and are now used in several million sensor nodes.

The way to the battery-free internet of things Today, wireless sensors (for example, as limit switches) and wireless incremental encoders (for example for voltage monitoring in rotary chucks or for monitoring the tightening torque in torque wrenches) are already widely used today.

In both cases, the tool remains unchanged in form and mode of operation, thus enabling simple use in existing systems.

For these applications, there are already energyefficient implementations which enable a permanently maintenance-free operation. Environmental parameters such as temperature and humidity can already be measured well today. There is great interest in sensors that detect corrosion. Here too, energy-efficient operation is also conceivable in many cases.

The project “Optimized Resource Efficiency in Production through Energy- Energetic Sensor Technology and Interaction with Mobile Users” or ESIMA ,has developed an energy-efficient compressed-air sensor that simultaneously measures pressure and flow and transmits the data by radio to a base station.

The project partners, including Festo, Varta, Daimler and EnOcean, have integrated this sensor directly into a turbine-generator unit. This can be operated directly with the compressed air used in the production process and provides the necessary electrical energy for supplying the electrical components.

COMPACT, FULLY INTEGRAL DOSING SYSTEMS FOR FINE CHEMICAL & PHARMACEUTICAL APPLICATIONS A Modular Dosing System (MoDoS®) which provides highly accurate and continuous delivery of fluids in laboratory, pilot-plant or continuous production processes has been introduced by fluids handling specialists MICHAEL SMITH ENGINEERS. Each tailor-made MoDoS modular pump system is fully equipped and ready-to-use and incorporates a HNP Mikrosysteme internal gear pump, filters, sensors, valves, fluid connections and controllers, all housed within a compact and sturdy aluminium frame.

The integral micro-annular gear pumps from HNP Mikrosysteme are chemically inert and particularly suited to handling aggressive and corrosive fluids.

Their ranges of hermitically sealed pumps with a magnetic drive can be incorporated into the MoDos dosing unit, so there are no issues with rotating seals failing.

The systems, which are ideal for fine chemical or pharmaceutical applications, can be specified for capacities ranging from 0.003 up to 1152 ml/min, differential pressures up to 80 bar and on liquids with viscosities from 0.3 to 1000 mPa. The range comprises five models; Mini, Lab, Slim, Pilot and Pro with each model able to be fully customised to suit specific application requirements The MoDoS Pilot and Pro systems incorporate a dual flushable filter system for easy maintenance. The Pro model is mounted on swivel castors for easy transport The open design of each system ensures easy access and exchange of all the key components and the corrosion resistant wetted materials means extended pump life and increased time between servicing.

More at: https://goo.gl/Ye3G8y For more information contact Michael Smith Engineers Ltd, Woking, Surrey.

Tel: FREEPHONE: 0800 316 7891 Email: Info@michael-smith-engineers.co.uk www.michael-smith-engineers.co.uk/

Versatile projects in the area of condition-based ​​ maintenance based on monitoring of temperature, vibration or acoustics are in the development stage.

These applications are only the beginning of a series of new applications. They show that the use of energyefficient wireless sensors offers new possibilities for better monitoring of important production parameters within the industry 4.0.

June 2018 – Process Industry Informer

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FEATURED ARTICLE

By Dr Richard Coulton, CEO, Siltbuster

Effluent treatment – the key technologies and how they are being used The focus of UK manufacturing is typically, and understandably, on driving up plant throughput.

While this is a valid and sensible objective, it can put a big strain on the effluent treatment plants of many companies. These plants play a critical part in the production process, dealing with the wastewater produced as a natural by-product of day-to-day operations. Yet they are often situated at the back of factories – overlooked and under invested in.

Here, Dr Richard Coulton, CEO of Siltbuster Process Solutions, the leading water treatment specialists, highlights the impact that effluent treatment problems are having on compliance and explains how the latest technologies can be used to improve the situation.

Through our role of providing effluent treatment equipment to the UK’s manufacturing community, we have gained a good sense of how wastewater treatment plants are managed.

Although they are frequently out of sight, we firmly believe they should be anything but out of mind, so wanted to better understand how and why companies prioritise, invest in and manage their effluent treatment plants. To achieve this, we commissioned an independent study among the production directors and engineers responsible for over 156 manufacturing sites in the UK and the findings were very revealing.

Why investment in effluent treatment needs to be a priority According to the study, 30% of companies had had a significant effluent treatment problem in the previous year which put their compliance at risk, with effluent treatment plant failure or breakdown the most common cause (31%).

A third of the companies questioned said investing in waste treatment plant is a priority, but 28% of production heads reported that their treatment plan is under invested in. 41% of the companies last invested in the plant more than five years ago and 23% more than 10 years ago.

15% believe this is because the Board is only interested in investing in new production lines; a further 13% say that effluent treatment is viewed as a peripheral area that senior management doesn’t want to think about.

The study went on to suggest this is symptomatic of the low profile which effluent treatment generally has within some organisations. For instance, although 64% of companies want their plants to deliver major innovations, 31% of production heads complain that they are not involved in new product development until all the decision making is done.

This is a major issue as product innovation and effluent treatment are closely linked; a new product formulation can cause a change in effluent characteristics and for 26% of our respondents, this leads to treatment problems.

In another example of organisations failing to consider the knock-on impact of their business decisions on wastewater treatment, 69% of companies studied are under pressure from senior management to boost plant throughput, yet one in five has no additional treatment capacity to cope with such an increase in production. In this situation, something has to give and if care isn’t taken, that could be compliance.

I believe that greater consideration needs to be given to the effect of production decisions, including changing shift patterns, the use of new cleaning chemicals or introducing new product formulations, on treatment plants. At the moment, unexpected effluent treatment problems cause considerable disruption and can incur huge costs.

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But by considering how to respond to these problems and putting contingency plans in place, effluent treatment needn’t be a problem and businesses can be reassured that they will remain compliant. The good news is that the technology to achieve this is available.

The latest effluent treatment technologies One technology that should be high on the list for consideration is Dissolved Air Flotation (DAF), which we see being used in many interesting ways.

DAF units are commonly used for the removal of fats, oils and greases, suspended solids and associated Biochemical Oxygen Demand (BOD), which would typically have poor settling characteristics. DAF units create ‘white-water’ by dissolving air under pressure into recirculated water - as the pressure is released when the water is returned back into the DAF unit, micro-fine air bubbles are formed, which attach themselves onto the solids, and rise to the surface. Here, the accumulating solids thicken and dewater before being removed by means of a mechanical scraper. The addition of lamella plates to a DAF allows a relatively high flow rate to be treated by a compact unit. For instance, at one typical customer’s site, our 2.4m wide x 6m long unit was used to treat a peak flow rate of 144m3/h and DAF solutions are available whether the flow rate is 1m3 or 150 m3 per hour.

In building-block fashion, modular DAF units can be easily combined with other equipment to create tailored solutions, where ancillary mixed reaction tanks, containerised dosing and pumping equipment can be deployed with the DAF to provide additional treatment capacity when it is needed.

This flexibility means DAFs can be used in a variety of creative ways to aid problem solving.

For example, producers of seasonal products can experience significant production spikes which create big waste treatment issues and serious cost implications. To manage this, we are

increasingly seeing manufacturers using temporary DAF equipment to add extra effluent treatment capacity during busy periods.

Over 30% of the companies involved in our study had experienced an emergency effluent treatment problem which put their compliance at risk and, again, DAFs are ideal in this scenario. They can be installed very quickly and easily and, if necessary, can be fully operational within just hours of arrival.

DAF technology is also an easy way to boost permanent treatment capacity, keeping companies compliant by managing effluent treatment as production increases.

Moving Bed Bio-Reactors, or MBBRs, are another technology that we have been focused on developing to support the market for the better management of effluent. While it’s true that MBBR is not a new technology having been in successful operation in Scandinavia since the late 1980s, its use has yet to become established in the UK. This surprises me as, in comparison with a popular technology like Submerged Aerated Filter systems, the MBBR process offers greater treatment capacity per unit volume and so, on a like for like basis is significantly less expensive.

We have been able to successfully apply MBBR technology to a number of temporary and permanent applications including BOD removal from municipal sewage, nitrification and the treatment of various industrial effluents ranging from whiskey distilleries to carrot juice. In doing so we have learnt an awful lot about the technology and the high removal rates it can sustain. As a result, we are more convinced than ever that MBBR has a significant role to play in industrial waste water treatment. MBBR technology has been extensively embraced by the rest of the world, and our successful UK trials have demonstrated that it can work equally well here, in a multitude of situations.

Process Industry Informer – June 2018

Health & Safety

Mapping the world of CIP, bio-waste treatment and critical process solutions Processing solutions specialists Suncombe has released a Product Map to explain, in visual format, its strengths and capabilities in the technologies of Clean in Place (CIP), Bio-waste decontamination treatment and other critical process solutions. The company has an extensive portfolio of equipment and wanted to offer a visual representation of the main areas of expertise it offers.

Explaining the reasoning behind the Product Map’s creation, Steve Overton, Suncombe’s technical director said, “In the increasingly specialised world in which we operate, many clients come to us for very specific products and solutions and never really get to see our other capabilities. So the Product Map is a very easy way for us to show in more detail the range of our equipment – which has been exclusively developed over more than 50 years of operation.”

“Because of the very complex regulatory and operationally challenging environments that we typically work in, it can happen that a client has to operate in a ‘silo’ for a specific project – quite understandably. So he or she only knows us for a particular process or solution.

The Product Map is an easy way to show how much more we are able to offer, which can be of value in other areas of the processing facility,” he added.

The Product Map takes the form of an ‘exploded’ floor plan where equipment from storage and distribution vessels, through mobile and static CIP, skids, mixing vessels, various decontamination units and finally parts and IBC washers are laid out in a logical process operational format.

DRIVES & CONTROL

“While many of our customers need custom solutions, these are all based on the expertise our ‘in house’ design and build teams have developed and our basic, core products,” according to Dave Adams, director for the company.

“We would like existing customers as well as potential new clients to appreciate that we offer a wide range of process solutions – from basic, almost ‘entry level’ equipment, through to the most sophisticated and tailored systems. The Product Map is a very quick and easy reference point for that,” he explained.

The full range of Suncombe equipment, including details of its project planning expertise, validation and traceability of all aspects of production, and the range of machine options can be found at: www.suncombe.com Tel: +44 (0)208 443 3454

E-Mail: mail@suncombe.com

Media Redundancy Protocol (MRP) added to Fortress Interlock’s amGardpro proNET module

Complimentary service protects drive investment from day one A new service from ABB gives users of medium- and high- power variable speed drives complimentary access to a host of services throughout the warranty period.

Drive users now receive access to on-site repair, rapid exchange of faulty parts with access to original spares, telephone support during office hours and technical query escalation.

Customers only need to register the drive at the point of commissioning to activate the service. The registration can be handled by ABB directly or through one of its authorised value providers. Alternatively, customers can download a registration app and enrol the drive themselves.

Both telephone and ABB Ability™ cloud-based remote support offer advice, guidance and issue resolution. This benefits those customers who are trying to get a drive up and running or seeking reassurance that the drive operates as intended. Reduced downtime and plant interruption is further enhanced by escalation to global experts who handle advanced user queries. For medium voltage drives, rare instances of drive failure or condition monitoring can benefit from ABB Ability remote support from specialist teams.

The service is available for all ABB industrial drives including: ACS880, ACS1000, ACS2000, ACS5000, ACS6000, ACS6080, ACS580MV, Megadrive-LCI and DCS880.

Fortress Interlocks’ proNET safety and communications module adds industrial Ethernet communications to its amGardpro range of safety interlocks. This enables the amGardpro’s features to be distributed IO (input-output) on a PROFINET network, with safety information exchanged using PROFIsafe extensions.

E-mail: layla.hewitt@gb.abb.com

down-time after a fault in the communication wiring is significantly reduced and any wiring repairs can be postponed to a more convenient time.

The company has now added Media Redundancy Protocol (MRP) capability to the amGardpro proNET module. MRP is an open standard for ring topologies in industrial networks such as PROFINET, enabling recovery times of up to 200ms in switch loop scenarios.

The way MRP works is that a ‘ring manager’ switch will drop (block) all packet forwarding on one of its two designated ring ports, effectively breaking the switch loop. All the traffic from devices connected to all the switches in the loop will still have a path to each other, with redundant links, but without the harmful switch loop. This means that

For more information contact ABB Ltd, Warrington.

Tel: 01925 741111

Web: www.suncombe.com

Fortress Interlocks Phone: +44 (0)1902 349000 Fax: +44 (0)1902 349090 Email: sales@fortressinterlocks.com Web: www.fortressinterlocks.com

Bottling Applications

Web: www.abb.co.uk

GET A BETTER GRIP ON YOUR BOTTLES Air Grip® is a patented, highly efficient, safe and flexible bottle gripping system which has been developed by YASKAWA for use with MOTOMAN® robots to meet the demands for today’s bottling plants. The unique combination of state-of-the-art industrial robots equipped with innovative robust rubber grippers ensures safe handling of bottles at very high speeds without damaging the screw caps.

The AirGrip gripper tool meets the increasing demand for a flexible application in bottling plants where the same basic concept can be used for both small and large applications and for a wide variety of purposes.

The bottles are lifted by compressed air with minimal mechanical stress which helps to reduce maintenance requirements. Also, because the cuffs are open at the top there is no restriction in bottle height. The cuffs are available in 5 standard sizes from 0.5, 1.0, 1.5 and 2.0 litres while customised designs are also possible.

June 2018 – Process Industry Informer

In one bottling application for a major soft drink manufacturer 1.5 litre PET bottles are being handled at a rate of 47,000 bottles per hour. Other sites where the system has improved the efficiency, include a number of major European breweries.

Depending on the application, for example handling trays from a pallet, or bottles into trays, the AirGrip concept includes a MOTOMAN-MPL160, or MOTOMAN-MPL80 robot, the AirGrip device, a conveyor, a pallet magazine and an operator’s control panel.

View the AirGrip Video: www.airgrip.com Further details available from Paul Seale: Tel: +44 (0) 1295 272755 info.uk@yaskawa.eu.com www.yaskawa.eu.com

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FEATURED ARTICLE

By Walter Leeten, Product Marketing Specialist Process, Graco

How to choose an AODD pump A quick guide to selecting the correct AODD pump for your specific application The focus of UK manufacturing is typically, and understandably, on driving up plant throughput. While this is a valid and sensible objective, it can put a big strain on the effluent treatment plants of many companies. These plants play a critical part in the production process, dealing with the wastewater produced as a natural by-product of day-to-day operations. Yet they are often situated at the back of factories – overlooked and under invested in. the sludge is separated from the coating material and further processed through a filter press. The main requirements are chemical compatibility and a leak-free design. Fitting the bill is a Graco Husky 1050, 1590 or 2150 pump with a PVDF body and PTFE inner parts. When a sodium hydroxide bath is included, the pump should have a polypropylene body and Santoprene inner components.

Aluminium for example offers only medium corrosion and abrasion resistance and is not suitable for halogenated hydrocarbons, while polypropylene has a much wider chemical compatibility. However, polypropylene has a limited temperature range, so for higher temperatures other materials need to be chosen. PVDF (Kynar) displays strong chemical resistance of acids and bases, a good abrasion resistance and high temperature resistance. PTFE displays the widest chemical compatibility, extreme corrosion resistance, has a very low frictional coefficient, is non-adhesive, provides high heat resistance, but offers poor abrasion resistance. Another key material for AODD pumps is Santoprene, which offers good abrasion and chemical resistance, and suitability for use with some solvents, caustic solutions, dilute acids, and alcohols.

The next consideration is the application. What flow rate do you need, where is the feed tank relative to the pump, and what is the overall suction length, vertical rise, and discharge distance? All these play a role in determining the inlet and outlet hose diameter.

Whether a pump with an ATEX certification is necessary or not also has an influence. If not, then a polypropylene or PVDF pump can be chosen. If ATEX certification is needed then a conductive polypropylene offers chemical resistivity at a low cost, while Hastelloy offers even higher resistance to chemicals, is mechanically robust, but is expensive.

Let’s now consider what type of AODD pump to select for specific applications.

Paint circulation and transfer A challenge with this application is that a very long hose length is often required, sometimes up to 250 meters, so it’s important to get the right combination between fluid pressure and volume. Paint suspension is another challenge. For example, metallic paints or zinc epoxies need to remain in suspension, which rules out a pressurized system.

Moreover, paint is sensitive to shear, so a pump needs to be selected that avoids shear. A typical Graco solution for paint circulation and transfer is a Husky 716, 1050, 1590, 2150, 3300 or 1050e model. The wetted section is metal, the diaphragms PTFE (over-molded or 2-piece) and Santoprene, and the seats constructed from polypropylene, Santoprene, PVDF or stainless steel.

Graphite transfer in pipe manufacturing During the manufacturing process of a pipe, graphite needs to be transferred as a lubricant to the mandrel. The graphite in powder form is mixed with water. Challenges include a high application temperature, and a material that is viscous, thixotropic and abrasive. A conventional piston pump is no use for this application as it will separate the graphite from

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Ceramics

the water and clog the pump. The Graco solution would be a Husky 2150 aluminum pump with a 2-inch outlet pipe, stainless steel balls, and a Santoprene diaphragm.

Pumping an injectable gel inside a wall Such an application is common in the construction industry, for example to control moisture in a cellar. Controlled manual dispensing is necessary of a highly viscous material. Low pumping volume and low pressure is used to inject the gel.

If a material such as Siloxane is used, the pump should be corrosion resistant. Graco recommends its Husky 307 Acetal pump, which has an acetal body for corrosion resistivity along with PTFE inner parts. Acetal offers wide solvent resistance and withstands extreme fatigue while offering a good level of abrasion resistance.

Chemical transfer in heap leaching

The challenge faced by pumps in the ceramics industry is the presence of highly abrasive, high viscosity ceramic slips and slurries which have to be transferred in large volumes.

Generally a 1”, 1½” or 2” aluminium pump is suitable. The wetted section can be metal or plastic, with Santoprene balls, stainless steel seats, and Geolast or Santoprene diaphragms.

For larger castings the larger size pumps should be selected.

Ask Graco for specific information Graco provides a wealth of information and tools to help you decide which AODD pump to select for each specific application. For example, Graco’s detailed Materials of Construction Guide outlines all the materials commonly used in the manufacture of AODD pump, along with their temperature range and an indication of price. It indicates whether each material is suitable for mild chemicals, aggressive chemicals, high temperatures and abrasives.

Graco also provides pump performance charts to help you determine what the air consumption will be at a certain fluid pressure and flow, as well as an online diaphragm pump selector tool at www.graco.com/husky. For specific questions, contact Walter Leeten at walter.leeten@graco.com.

To extract minerals from stone, the crushed ore heap is sprinkled with an acid (e.g. sulfuric) that penetrates the ore and dissolves the minerals. The leach solution then needs to be pumped into the mixing and separation process.

Obviously the key requirement is for a pump that resists strong acids and cyanide solutions. It should also provide high flow, as large quantities of acids are used, while a leak-free design is essential to avoid contamination of the environment. A good solution is a 2-inch Graco Husky pump with a stainless steel center and fluid section, and Santoprene inner parts. A polypropylene center and fluid section is also possible. For higher flow rates a 3-inch pump would be preferable.

Metal plating This application concerns the plating of small metal components with protective or decorative coatings of zinc.

AODD pumps are suitable for this application, and are used for the transfer of the plating material from the chemical kitchen to the dipping tanks and back to the kitchen where

Process Industry Informer – June 2018

June 2018 – Process Industry Informer

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Inspection & Vision Systems

Water / Wastewater

New Fluke Ti400 PRO and Ti300 PRO Infrared Cameras offer a more intuitive interface and better colour differentiation Fluke has introduced upgraded versions of two of its best-selling infrared cameras. The new Fluke Ti400 PRO and Ti300 PRO Infrared Cameras feature a more intuitive touch screen interface with a higher contrast display and compatibility with optional smart telephoto, wide-angle and macro lenses which can be interchanged without calibration.

The cameras provide fast, one-handed operation to perform multiple inspections quickly and accurately – ideal for predictive/preventive maintenance, for industrial, commercial and HVAC electricians, facilities managers and energy auditors. More information about the new thermal cameras and the rest of the Professional Series of IR cameras can be found at www.fluke.co.uk/ti Both the Fluke Ti400 PRO, with 320 x 240 resolution, and the Ti300 PRO, with 240 x 180 resolution, feature LaserSharp™ Auto Focus, which, with the touch of a button, uses a built-in laser distance meter to calculate and display the distance to target and snaps the image into focus. An alternative advanced manual focus mode can be used.

They also feature Fluke IR-Fusion® technology, which captures a visible light image in addition to the infrared image and combines them with three different operating modes (Picture-in-Picture, full visible light, and AutoBlend™), and are provided with Fluke Connect SmartView® Desktop Software, for optimising and analysing thermal images, generating customisable reports and exporting images in multiple formats to the Fluke Connect Cloud.

Fluke Connect Compatible The new infrared cameras integrate into Fluke Connect® the company’s full-feature platform that permits Fluke tool users to receive, store, visualise, and report electronic measurement data from more than 40 Fluke Connect wireless test tools. This allows technicians to record and share thermal images, along with electrical and other measurements, in real time via their smartphones or tablets and automatically upload them to the cloud.

The Fluke Connect system provides access to maintenance records simultaneously at the inspection site and from the office or an off-site location, enabling faster decision making. It also enables real-time collaboration between team members with ShareLive™ video calls, increasing productivity in the field.

Xylem’s new adaptable wastewater mixer delivers next-level mixing efficiency

Images sync wirelessly direct from the camera to the Fluke Connect system, so images can be attached to an asset record or work order using optional software. Reports can be created and shared directly from the job site via email.

Leading global water technology company, Xylem, has launched a compact submersible wastewater mixer featuring easily adaptable output capabilities and delivering energy savings of approximately 50 percent.

These two new models follow the earlier introduction of the Ti480 PRO and Ti450 PRO InfraRed Cameras both of which offer some additional features not available on the Ti300PRO and Ti400PRO such as MultiSharp™ Focus and SuperResolution.

Xylem’s new Flygt 4220 mixer enhances the resilience and sustainability of wastewater treatment plants, enabling operators to easily manage changing mixing conditions by simply adjusting the mixer output. As the Flygt 4220 can be controlled to deliver only the output required, a plant’s energy consumption can be significantly reduced.

For more information about all Fluke products, please contact Fluke UK Ltd, Northampton Tel: 0207 942 0700 Web: www.fluke.co.uk

E-mail: industrial@uk.fluke.nl

Compressors

Gardner Denver seals the deal with HACCP standard vacuum pump enclosure for Proseal Gardner Denver has supplied a leading food packaging machine manufacturer with an innovative solution to help ensure it meets required hygiene and safety standards.

Proseal uses oil-lubricated, rotary vane pumps from Gardner Denver for its vacuum/gas packing technologies, to help ensure goods are tightly sealed.

For food packaging business, best hygiene practice demands that these machines must be washed down at the end of every shift, which naturally poses a problem for vacuum pumps located in these facilities.

The harsh working environments and corrosive cleaning agents used by food manufacturers mean there is a very real risk of rusting and reduced pump performance over time. To overcome this challenge, it has developed a specially designed enclosure for its Elmo Rietschle VC 303 vacuum pump, which means it can be sited alongside Proseal’s vacuum/gas packing machines in wet environments.

The cover has been developed in line with the Hazard Analysis and Critical Control Point (HACCP) principles, which establish the

appropriate food safety management procedures that businesses should have in place. Made from stainless steel, the cover means the vacuum pump can withstand wet environments, ensuring Proseal can help its customers maintain the highest hygiene standards, without affecting the vacuum pump’s performance.

With a capacity of 300 m3/h and an ultimate vacuum of 0.1 mbar, Elmo Rietschle’s VC 303 vacuum pump offers a robust and economical solution to Proseal and other manufacturers supplying to the food industry.

For more information on Gardner Denver, please visit www.gardnerdenver.com/industrials

“Plant operators are looking for mixer technology that enables them to increase operational efficiency, improve performance based on their specific system demands, and provide realtime data to extend product lifecycle and reduce downtime and maintenance costs,” said Johan Tegstam, Director, Product Management for Xylem.

He continues: “The beauty of our new Flygt 4220 mixer lies in its adaptability. Plant operators can easily modify the mixer output, via a tank-side control panel, a programmable controller or plant-wide control system, to match current mixing needs.

This functionality dramatically reduces energy consumption compared to traditional fixed output mixers, significantly improves process productivity and future proofs a facility’s mixing efficiency.

We’ve designed the Flygt 4220 mixer to deliver comprehensive information about the mixer’s performance and status, including speed, power, alarms, running time and energy consumption.

The mixer features a number of auto-correction functions, including overload control to protect the equipment and secure process results.”

Wastewater mixing is not a static process, as mixing requirements will vary over time depending on a range of factors including flow rates, oxygen demand, and seasonal variations. Conventional mixers operate at a fixed output which often results in wasted energy, unnecessary wear and increased maintenance due to inefficient operation of the mixer.

“The Flygt 4220 mixer fits all common installation systems and is ideal for retrofits, slotting easily into an existing installation. It is a great choice for municipal or industrial wastewater or sludge mixing applications,” concluded Tegstam.

The Flygt 4220 mixer is based on Xylem’s Flygt Dirigo platform of integrated power electronics, including an IE4 super premium efficiency motor that delivers market-leading efficiency, and is available in 1.5, two, three and four horsepower versions.

The mixer’s capacity to deliver a wide range of duty points – unlike the fixed output generated by single-speed mixers – enables a single Flygt 4220 to replace multiple conventional mixers and will require fewer complete mixers and parts in stock.

Flygt 4220 also offers lower investment for rebuild or replacement as it can be redeployed across different tanks and applications.

The Flygt 4220 joins the larger Flygt 4320 mixer, launched in 2015, as part of Xylem’s range of adaptive wastewater mixers.

For more information on Xylem, please contact 0115 940 0111 or visit www.xylem.com/uk

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Process Industry Informer – June 2018

June 2018 Solids Handling & Processing Supplement

NEWS

Looking to the future

By Ian Birkinshaw, General Secretary – Solids Handling & Process Association

Award is Amiee Donaldson and we congratulate her on her success.

It’s an interesting time!

As we approach the half way point in the Year of Engineering, SHAPA is pleased to be involved in the government sponsored initiative that aims to promote the world of engineering to young people. A quote from the government website www.yearofengineering.gov.uk/ about states “The Year of Engineering is a government campaign, which celebrates the world and wonder of engineering. It also forms an important part of our Industrial Strategy, which is committed to boosting engineering across the UK, ensuring everyone has the skills needed to thrive in a modern economy. From spaceships to ice skates, the bubbles in chocolate bars to life saving cancer treatment, engineering touches every part of our lives. However, not enough young people – especially young girls – think it’s a world for them. As a result, the industry is struggling to recruit future talent.

What’s more, young people are missing out on the chance to make a positive difference to both their futures, that of the planet and everything that calls it home.” SHAPA is a registered partner in the Year of Engineering initiative helping to bring the excitement of engineering to young people.

SHAPA’s focus on young people does not stop there as SHAPA also promotes engineering to young people through the Arkwright’s Trust and the Solids Handling Industry Awards. SHAPA sponsors Georgina Edwards through the Arkwright’s trust who has been involving herself in many areas of engineering over the last year.

Georgina regularly updates her progress on the SHAPA website and you can see the enthusiasm Georgina has for engineering through posts to her blog at www.shapa. co.uk/GeoginaBlog.php Georgina’s recent adventures into the world of engineering included forming a team from school and entering into the F1 in schools competition where they reached the national finals held at Silverstone.

The skills they developed as part of this competition included, 3D design, Aerodynamics, 3D printing, CNC programming, finance and marketing. All skills which will help them all as they move into the world of engineering.

A new category of Newcomer of the Year has been added to the list of categories for the Solids Handling Industry Awards, which this year were held on the SS Great Britain in Bristol. This new category has been introduced to promote and recognise the contribution and the role of young engineers within the industry. The nominations were of an exceptionally high standard with the shortlisted candidates being, Aimee Donaldson from Spiroflow, Harry Lampert from Vent-Tech and Nathan Thornley from Dustcheck. All of the shortlisted candidates have excelled within their own specialisms and have shown a desire and enthusiasm for engineering which can benefit not only themselves, but the solids handling industry at large. The winner of the 2018 Solids Handling Industry Newcomer

With the new GDPR regulations in force from the 25th May 2018, a subject that has dominated marketers for the last couple of years, hopefully all the necessary changes to your policies and procedures are now in place.

However, we cannot stand still, the pace of change is ever increasing and seemingly never ending, no sooner than one challenge has been overcome there is another one on the horizon. Therefore, in today’s constantly changing environment, with new technology, digital connectivity, legislation, environmental issues and the uncertainty that Brexit is bringing to UK manufacturing, the need for relevant, accurate, well informed and unbiased information is more important than ever. Continued professional development and relevant training is key to ensuring those who contribute to the success of the solids handling industry have the relevant tools to stay ahead and maintain an advantage in the global marketplace.

This is where SHAPA with nearly 40 years of unrivalled experience in the solids handling industry can help.

Over the last 12 months SHAPA has held a series of highly successful training workshops on Atex, Digital Marketing, Financial Training and Negotiation Skills. In May this year SHAPA held the 10th running of the Digital Marketing Workshop. As the digital world continues to move forward and evolve, trying to keep abreast of the needs of individuals and companies alike while keeping up with the latest technology is a challenge for small and large companies alike. It is essential to your success that you ensure you are not falling behind.

The topics in the 10th anniversary workshop included 10 new features on Google, how to improve your website visibility, Social Media and how to make your website GDPR compliant. Later in the year SHAPA are planning an introduction to solids handling course aimed at both young engineers and those who are new to the bulk and solids handling industry who may not have an engineering background. The workshop will be covering areas including characterisation, materials, equipment and processes required for a good solids handling system and is to be held at a major UK confectionary manufacturer.

The workshop will include practical examples and will demonstrate how systems and processes are keenly aligned to those used in a modern domestic kitchen.

For further information on these courses and how you can attend just visit the SHAPA website www.shapa.co.uk Rewarding success Once again SHAPA is at the forefront of promoting best practice and celebrating success within the solids handling industry with the highly successful Solids Handling Industry Awards. This year’s awards were a great success with many more entries as the awards go from strength to strength. The award categories once again included Innovation, Export Success and SHAPA

Company of the Year, as well as the Newcomer of the year mentioned earlier. These awards were open to UK registered, SHAPA member and non-member companies and institutions operating in the solids handling and processing industry. The awards were presented at the Solids Handling Awards Dinner, which this year was held on the 17th April in the SS Great Britain in Bristol.

Once again, the judging panel found it difficult to finalise the results due to the exceptionally high standard of all the nominees, however a winner was found for all the categories.

The award winners were, R & B Industrial in the Innovation category, they have developed their SmartAir patented system which accurately balances airflow requirements, which in turn offers significant savings in energy costs and environmental benefits for its users. The Export Award once again was won by Russell Finex who have continued with their export expansion which has led to a significant increase in export sales over the last three years. The SHAPA Company of the Year award winner was Spiroflow who have investigated and utilised advances in robotics, diagnostics and weighing innovations in their products and systems solutions.

SHAPA wishes to congratulate all the nominees for this year’s Solids Handling Awards which were of an exceptionally high standard and show that our industry is successfully developing new products and new markets with exceptional results. For more information on SHAPA and the Solids Handling Awards, visit the SHAPA website at www.shapa.co.uk and don’t miss out on your opportunity to apply for the 2019 awards which will be launched in December 2018.

In these challenging times SHAPA and its member companies continue to thrive and in addition to promoting the successes of the industry, the need for future development has not been overlooked.

Further information on the training workshops and the awards including application forms can be found on the SHAPA website at www.shapa.co.uk

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Game Engineering with ABN and a new feed production facility in a refurbished mill Our recent project for ABN involved restoring a disused mill to become a new feed production site for the company. After conducting a site survey using 3D mapping technology, Game Engineering cleared and prepared the site for its new production system.

The company also supplied all the mechanical handling including the conveyors and elevators, as well as the ducting and surge hoppers and all the structural steelwork.

From the receipt of the order, Game Engineering had just six months to complete the restoration which required a total of ten members of staff that were kept busy for the entire project. Justin Ward, Game Engineering Project Manager, commented “the mill dated back to the 1970s, which meant that a total refit was necessary from electrical and water supply through to the system installation. The result is a mill that produces between 250 and 300 tph daily but which could, if necessary, achieve 430 tph daily.”

Tel 01522 868021 sales@game-eingeineering.com www.game-engineering.com

LOW-PROFILE FLEXIBLE SCREW CONVEYOR ROLLS UNDER MEZZANINES, DISCHARGES ANYWHERE

THE UK’S LARGEST MANUFACTURER OF ALUMINIUM SILOS • • • • •

35 years supplying the food & plastics industries Fully ATEX compliant Aluminium & stainless steel silo fabrication CE mark accreditation SafeContractor approved

A new Low Profile Flexible Screw Conveyor with integral bin and castor- mounted frame can roll below mezzanines and other low-headroom areas, receive material from overhead equipment, and discharge the material into process equipment and vessels throughout the plant.

Ready to plug-in and run, the self-contained unit features a “push type” drive system positioned at the lower intake end of the conveyor, versus a standard “pull-type” drive positioned at the upper discharge end of the conveyor, reducing overall height by approximately 610 mm.

At 250ℓ, the integral bin accommodates the contents of approximately one-third of a bulk bag measuring 1 x 1 x 1 metres, or several typical 25 kg bags, depending on bulk density.

A specialised BEV-CON™ screw within the straight conveyor tube is engineered to move a range of difficult-to-convey bulk materials that tend to cake, pack, smear or plug, as well as fragile products prone to breakage, with no separation of blends.

With the exception of the polymer tube, all material contact surfaces are of stainless steel finished to food, pharmaceutical, dairy or industrial standards for rapid wash down and/or corrosion resistance.

The company also manufacture bulk bag dischargers, bulk bag fillers, pneumatic conveying systems, tubular cable conveyors, manual dumping stations, drum/box/ container tippers, weigh batching systems, and automated plant-wide systems integrated with new or existing process equipment.

+44 (0) 1275 845901 sales@bartonfabs.co.uk bartonfabs.co.uk

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For information contact Flexicon Europe Ltd, +44 (0)1227 374710, sales@flexicon.co.uk www.flexicon.co.uk

Barton’s silo saves sack slitting Barton Fabrications has installed a new silo at Bevex manufacturing plant in Coalville, Leicestershire. Part of the global L’ISOLANTE K-FLEX Group, Bevex manufactures tubing and pythons for the drinks dispense industry.

Bevex is seeing increasing demand for its extruded tubing products, which traditionally use bags of LDPE plastic granules to feed the production process. The new 30 ton aluminium silo replaces the need for bagged feedstock, dramatically reducing manual handling requirements and improving operational efficiency.

Commenting on the silo installation, Dirk Parker, UK General Manager of L’ISOLANTE K-FLEX UK Ltd said: “We are delighted with the new Barton silo. We used to manually handle and slit bags of polymer to fill the hoppers to maintain supplies to our tube extrusion equipment. The silo has replaced this process ensuring a continuous supply of feedstock and greatly improving our operational efficiency.

“We try to purchase as locally as possible and were very pleased to place the silo order with a UK owned company. The installation process ran smoothly and we are very happy with the service provided by Barton.”

The aluminium silo installed at the site is 10m high with a diameter of 3m and is fitted with load cells to provide an instant readout of silo contents.

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

BULK BAG CONDITIONER HAS LASER SAFETY CURTAIN A new BLOCK-BUSTER® Bulk Bag Conditioner from Flexicon Corporation features a laser safety curtain that automatically stops the system hydraulic rams, scissor lift and turntable if the laser beam is obstructed, eliminating the need for safety-hinged doors and interlock switches for operator safety.

The conditioner loosens densely packed bulk solid materials in bulk bags by means of hydraulic rams with specially contoured end plates that press and release opposing sides of the bag. A hydraulically-actuated, variable-height scissor lift with accordion style dust skirt and turntable allows conditioning of the bag on all sides at all heights. The number and pressure of hydraulic ram actuations, the height of the turntable, and the number of 90-degree rotations are user adjustable. The system controller and hydraulic pump can be mounted on the exterior of the frame or remotely.

The new conditioner is intended for bulk bags containing hygroscopic chemicals, certain types of spice blends, heat-sensitive products, and other materials prone to solidifying to the point at which pneumatically- actuated flow promotion accessories integral to bulk bag dischargers are inefficient or completely ineffective.

Available as a stand-alone unit or integral component of a bulk bag discharger, the unit measures 2210 mm H X 3378 mm W X 1981 mm D, accommodates bulk bags of all popular sizes, and requires only an electrical power connection for operation.

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For information contact Flexicon Europe Ltd, +44 (0)1227 374710, sales@flexicon.co.uk www.flexicon.co.uk

THE

PRESSURE IS ON! High Pressure Rotary Valve The DMN-WESTINGHOUSE HP valve with specially designed inlet is very suitable for handling granular formed products under a high pressure of maximum 3.5 bar g.

The valve has a very important advantage in air leakage: the special configuration of body, rotor and seals does not only protect product against degradation, it also does not allow any axial air leakage.

DMN-WESTINGHOUSE T +44 1249 818 400 | dmn@dmnuk.com

max 3.5 bar g

Features: • Special inlet for maximum protection against product degradation • High filling efficiency • Lowest air leakage through special seals • Robust construction • Easy assembly and disassembly

www.dmnwestinghouse.uk

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NEW - Hypergienic Rotary Valves from Gericke RotaVal Gericke RotaVal have launched two new rotary valves specifically designed for the pharmaceutical and food industry. The valves are fully machined from solid stainless steel and embody a range of detailed features.

Both valves offer rapid access for cleaning, the HGMC is a manual easy clean rotary valve and the HGMF is a railed fast clean version. With both valves offering easy and fast cleaning they ensure minimum down times and the ability to be cleaned by plant operators without the need for any special tools.

All surfaces are self- draining and full clean-in- place is available. There is a special multi-function shaft seal design including an FDA double lip seal assembly which provides the clean-in- place, drying and air purge.

Optional features include pharmaceutical standard seals to provide secure joint between body, end covers and inlet/outlet connections. The valves can be fully tested and certified against 10 barg internal explosion and flame containment and there are isolator versions available.

Sizes of valves from 80mm to 250mm meeting the most stringent pharmaceutical and food needs.

For more information contact Gericke RotaVal, Tel: 00 44 1249 651138 E-mail: sales@rotaval.co.uk Web: www.rotaval.co.uk

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Trantec’s new powder sampler range‌sampling made easy For quality assurance, regular inspection of materials is essential. Trantec Solids Handling Ltd is a UK leader in the manufacture of Powder Samplers, providing safe, accurate, sampling of fine powders, granules, flakes and grain for the food, pharmaceutical, chemical and environmental industries.

Consisting of a power unit, which drives just one moving component (the Auger-Screw), Trantec’s Powder Samplers offer minimal maintenance. Their simplistic design means cost-effective construction is achieved with low power consumption as standard.

Configured for the volumetric collection of powders, the sampling can be continuous or as batches. The Powder Sampler is inserted into the bag/sack or vessel and the rotating auger screw transports the material directly into a sample bag or container attached to the outlet.

We manufacture our samplers in a selection of construction materials, including mild steel, stainless steel 304 and 316 with a variety of polish finishes including mirror finish for food and pharmaceutical applications.

For more information Tel: 01282 777566 or send an email to sales@trantec.info

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Bulk Solids Specifications and Reality Checks

By Richard Farnish – Principal Research Fellow Department on Mechanical & Design Engineering of University of Greenwich

M

any processes that rely on reliable bulk solids handling for the efficient operation do so with minimal problems. It is often the case that such process plants are ‘blessed’ by using granular or powdered materials that vary relatively little throughout the year (if seasonal) or which are sources from a very limited range of supply source - maybe even a single source in some instances. However, a significant number of companies have systems that need to have sufficient flexibility to cope with input stock that can be potentially quite variable.

When materials are being brought to site it is common that these will have been adequately defined by agreed specifications. It is also equally common for the same specifications to be issued as part of the tendering process where new equipment or plant expansions are proposed. It is self evident from these last two statements that confidence in the validity of the information provided is usually quite high, particularly so for plants that do not have well provisioned QA facilities to determine their own information or verify what is received to site. The highest risk in these circumstances is to base contractually binding projects on the assumption that a supplied data sheet is not only current, but also that it contains pertinent and concise information. Such risks to a given project can cause considerable problems for contract issuers and equipment designers/installers – particularly so when the material actually loaded into the plant bears little relation to what was indicated by the documentation.

A reoccurring problem can often be that even when the data sheet is accurate, it is assumed that this represents the condition of the bulk material at the point within the plant where the new equipment is required to fit into the process. An example of this could relate to the delivery to site of a bulk material that is friable (i.e. prone to breakage). Such materials could take the form of pelletised, granulated or agglomerated forms of particles.

In such cases, the documented specification would almost certainly only relate to the end of the processes used to manufacture the particles and could, at best, reflect the ‘delivered to end user’ condition (although segregation effects could already be influencing local

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sampling effectiveness). It does not take very many mechanical or pneumatic transfer steps and buffering operations to bring about major changes in the bulk characteristics of the material passing through the process. Such changes will often be visually detectible in the form of increased dust and more frequent ‘hanging up’ of materials in hoppers and silos. Similarly, it may be the case that belt spillage becomes more frequent and pneumatic conveying systems begin to block.

Characterisation of the bulk materials within the plant can easily pick up on shifts in size distribution associated with particle degradation, but more advanced techniques are required to measure changes in the bulk flow behaviour and bulk transportation characteristics i.e. hopper flow in the case of the former and pneumatic conveying in the case of the latter.

Firstly ensure your equipment Clearly for any project, risk minimisation is at the forefront of most engineers’ minds and in this respect the importance of understanding the bulk condition of the input materials at the point in the process where equipment is being specified or designed for must be one of first considerations. Projects where such consideration have not taken place can often be plagued with intermittent discharge from hopper, variable feed rates in metering equipment, high dust loadings on filters and poor pneumatic conveying content packing between the coarser particles within the distribution of sizes to the extent that once fines content reaches about 30% volume, the entire bulk behaviour is dictated by the fines content.

Such an example would be that sometimes found with wood pellet, whereby 25% wt fines correlates to 40% volume –giving the impression that the entire bulk is largely dust! The specification for wood pellets would typically indicate a fines content of about 8% wt (where the fines are defined as being sub 3.15mm), however the 25% wt example is fair from a rare occurrence due

to progressive pellet breakage through the supply chain and amplification of the progressively broadening size distribution through plant that unintentionally segregates the size fractions. The net result for a process designed for a maximum of 8%wt fines that is asked to handle 25% wt (and that may be conservative!) fines can be severe.

Similarly, granular products can also be subjected to similar breakage mechanisms through multiple handling processes such that the end of the process is required to operate with reliability and accuracy using a bulk material that is far removed from the free-flowing material that formed the basis for the specification and design of the packing equipment. Where drifts in bulk behaviour occur, much reliance is placed on control systems to ramp process up or down to compensate, but there is only so much variation that can be countered in this way. The result of metering variability can be a ‘give away’ on pack weight of up to 4% in some extreme instances.

Clearly, a large number of problems that occur industry can be traced back to bulk materials being handled that exhibit a bulk behaviour that was neither anticipated nor taken into account at the specification writing / design stage. A consideration of the likelihood of a given bulk solids changing as it is handled should form an important element of risk minimisation for industrial project management and project implementation strategy. The knowledge and test methods exist and should be applied to support the delivery of cost effective and timely projects.

Evaluation of Filter Performances The filtration of particles from air flows (whether in pneumatic conveying systems or environmental air) is of increasing importance to many industrial sectors from a Health & Safety and operational cost perspectives.

Have you heard?

In order to support industry in optimising its selection of filter media, The Wolfson Centre for Bulk Solids Handling Technology has recently invested in the development of a test rig within which samples of filter media, in flat or pleated forms, can be evaluated for filtration performance and likely life cycle performance.

Filtration performance is evaluated based on pressure drop over time for a conventional loading cycle, whilst service life performance is evaluated on the ability of the filter media to release particles and the subsequent pressure drop recovery towards the previous ‘clean’ condition.

Particle ‘break though’ for the filter can also be evaluated during the test.

For more information please contact Richard Farnish by emailing wolfson-enquiries@gre.ac.uk or call 020 8331 8646 Since our humble beginnings in 1986, we are proud to have grown to a team of over 70 experienced engineers, fabricators and project managers. Working around your existing production, we implement cost-effective solutions as quoted, resulting in you being fully operational with minimal downtime. Key services include:

• Process Design Engineering • Turnkey Process Solutions • Site Installation & Commissioning • Site Management • Bespoke Machinery Manufacture • Project Management

We offer Turnkey Process Solutions Tel: 01522 868021 Email: sales@game-engineering.com www.game-engineering.com

Speak to the experts in…  Pressure & Vacuum Lean Phase Pneumatic Conveying  Storage, Discharge, Feeding & Weighing  FIBC’s, Sacks, Boxes, Drums, Load Handling & Manipulation  Turnkey Project Management & Regulatory Compliance  Project Management & 3D Design

Aptech (Powder Systems) Ltd Unit 1 Sutton Court, Bath St, Market Harborough, LE16 9EQ

Tel: 01858 410737 Fax: 01858 434273 sales@aptech.uk.com www.aptech.uk.com

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Boone Mixers at Novidon Work Together for Perfect Scale-up Wrexham-based Novidon have chosen Boone Mixers for both laboratory test and factory production of carboxymethylated starch products, for use in oil and other drilling applications. The performance of the production unit, a 4000 litre Horizontal Paddle Blade Mixer, is accurately modelled in the laboratory by a Boone Universal Lab Mixer. Both mixers feature contraflow paddle blade design, and each is designed to allow pressurised steam injection, a critical part of the process.

Boone’s relationship with Novidon dates to 2007, when the company needed to replace a mixing system that was beyond repair. Engineering Manager Mike Shoemark approached Boone. The highly viscous nature of the materials suggested a horizontal mixer and Boone proposed a Horizontal Paddle Blade Mixer (HPBM) complete with pressurised steam addition, which ‘cooks’ and gels the starch mix, at five points in its semi-omega shaped mixing shell.

The semi-omega is a ‘short and tall’ shape shared by all horizontal Boone mixers that ensures highly efficient mixing with easy clean and energy efficiency. Mike Shoemark commented ‘Despite the batch size going from 1300 to 4000 litres, the drive power reduced from 110Kw to 55Kw, with obvious energy savings, and were able to reduce from 24 batches per day to 11.’

To meet research and development challenges, Novidon subsequently purchased a Boone Universal Lab Mixer (ULM). The variable speed ULM allows process conditions to be replicated perfectly, so that quality checks, formulation adjustments and research can be conducted on a manageable scale without taking up valuable production time. To allow Novidon to fully create the conditions encountered by the production mixer, Boone supplied the ULM as a pressure rated unit complete with steam addition. The lab mixer allows Novidon to research different methods of carboxymethylation, of potato starch for the production of oil well and other industrial drilling fluid loss inhibitors/lubricants. Mike Shoemark said ‘We are very impressed with the mixer. The cooked starch is very high viscosity and the lab mixer turns it with ease’.

The on-going success of both the Boone mixing systems and of Novidon themselves has been further underlined with the recent award of an order for a further 4000L HPBM mixer to double production at the Wrexham site.

For more information contact JR Boone Ltd, Congleton, Cheshire.

Tel: +44 (0) 1260 272894 E-mail: sales@jrboone.com Web: www. jrboone.com

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GYRO EX Bin Activating Feeder/ Discharger Accurate Feeding and Discharging GYRO EX Bin Activating Feeder/Discharger The GYRO EX bin activating feeder and discharger produces a controlled gyratory motion to positively withdraw granular materials from bins, storage silos and hoppers at any desired feed rate for a more consistent and reliable discharge. At the heart of the GYRO EX bin activating feeder and discharger is the drive that produces a radial force creating a uniform circular motion on both the upper activation cone and the lower discharge cone. It is this annular radial vibratory motion which imparts the force to the material, assuring a more reliable and predictable material discharge.

A unique feature of the GYRO EX bin activating feeder and discharger is that the stored material load is completely supported by the upper bin activation cone which has a lower cone angle than the discharge cone, assuring an uninterrupted and positive discharge of the stored material. The GYRO EX bin activating feeder and discharger can also be started and stopped as desired because material is not allowed to accumulate or stagnate in the lower discharge cone which might create packing or plugging problems.

Irrespective of the particle size, the GYRO EX bin activating feeder and discharger is well suited for almost any size material and the rate can easily be increased or decreased by adjusting the gap between the inlet opening and the upper activation cone.

For more information go to http://www. krausvibratory.com/products/gyroex.html or contact Dynamic Air Ltd, Milton Keynes, Bucks. Phone: 44 1908 622344 E-mail: sales@dynamicair.co.uk or Web: www.dynamicair.com

On the level, every mm counts Every engineer wants the best accuracy level sensor they can get, but this specification often comes at an extra premium.

Not today. The VEGAPULS 64 80 GHz contactless radar level transmitter now has increased its accuracy down to 1mm as standard, at no extra cost.

This means, whether in storage or processing, you will get the best repeatability and accuracy of measurement on ranges up to 30m. Combine this with the sensors proven focusing, its ability to deal with build up, how it can operate even on the smallest of mounting connections, or that it even works through valves and down long nozzles - this all results in a great level solution for your process. Don’t take our word for it, ask the tens of thousands of users already utilising this 80 GHz technology.

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

Tel: (+ 44) 01444 870055 E-mail: info@vega.com Web: www.vega.com/uk

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Hosokawa’s Dispensary Booth Design Proves Tipping Point for Pharmaceutical Manufacturer A bespoke containment solution to support dispensing and weighing out of active/excipient pharmaceutical powders, has recently been installed at the North of England facility of a leading, innovative pharmaceutical manufacturer. The system is capable of meeting low OEL levels during drum tip, invert, dock and mill and IBC transfer, (all fully interlocked with client MES).

The downflow booth offers an extended safe working zone of 2m and meets the facility single level space and layout requirements. It includes a cooling package and low noise operations for a more comfortable working environment.

Raw materials for dispensing into IBCs are presented in a range of multiple drum sizes to be discharged into an IBC using a drum tipper and post hoist inverter. Space restrictions determined that drums be lifted and inverted using either the drum tipper or post hoist to allow for the 120⁰ or 180⁰ rotation required to invert for discharge. If the raw material requires milling the material enters the IBC via the mill which is part of the dispensing train but which only has the impellor and screen fitted when required.

A vacuum lifter is used to lift raw material drums off the pallet and place the drum on the inverter where it is clamped into position and fitted with drum discharge cones for easy, dust free discharge of drum contents. Drums are then lifted and lowered onto the mill and docked and locked into position for discharge.

A downward inflating packing head located below the mill outlet inflates against the IBC inlet to ensure closed transfer of materials from mill to IBC. A mill frame with combined IBC guide rails ensures the IBC is perfectly docked for filling prevented product egress, which may present a health and safety hazard.

The customer commented, ‘We have worked with Hosokawa on similar installations and always find them easy to work with. The input from Hosokawa’s experienced engineers is invaluable, not least in the early design stages with physical and visual mock ups that reassure all members of our team that we have the best design possible for the task’.

For further information, please contact: Hosokawa Micron Ltd, Rivington Road, Whitehouse Industrial Estate, Runcorn, Cheshire, WA7 3DS. Tel: +44 (0) 1928 755100 Fax:+44 (0) 1928 714325 Email: info@hmluk.hosokawa.com www.hosokawa.co.uk

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PRODUCT & SERVICES DIRECTORy BUTTERFLY VALVES

CONSULTING

DUST CONTROL

LIQUID RING VACUUM PUMPS

162 CHILTERN DRIVE, SURBITON, SURREY KT5 8LS TEL.: 0208 399 9991 FAX: 0208 390 2004 www.dustengineering.com

VALVES

EXPLOSION PROTECTION

Nylon Screens

Industrial Datacoms

MIXERS & BLENDERS

PIPE COUPLINGS

PIPEWORK SYSTEMS

SIEVING

TRAINING

Water AnalysiS

Sifting Machines

WEIGHING SOLUTIONS

To advertise here: email info@piimag.com or call 01428 751188

The Pitreabie Business Park, Queensbury Road, Dunfermline KY 8UL TEL.: 0333 300 1851 FAX: 01527 590310 EMAIL: sales@preciamolen.co.uk web: preciamolen.com

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Process Industry Informer – June 2018