Process Industry Informer May 2017 by Process Industry Informer

www.processindustryinformer.com

MAY 2017 Volume 13 No.3

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

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

CONTENTS

FEATURED ARTICLE

THE GUIDE TO

GEAR OIL MAINTENANCE An effective oil maintenance program boosts productivity and profit

The first mathematical equation many of us learn is that 1 + 1 = 2. While this might seem logical and straightforward, it actually takes over 300 pages of complex mathematical sums to prove. This is just one of many seemingly simple tasks that are actually deceptively complex. The same is true of changing the gear oil in your machinery, as Mark Burnett, VP of the Lubricants and Fuel Additives Innovation Platform at NCH Europe, explains.

ear oil is the cornerstone of industrial manufacturing machinery. Without effective gear oil, machinery is at an increased risk of break down as the result of poor lubrication. This results in expensive repairs and replacements, with a loss of productivity further exacerbating costs. Unplanned downtime is clearly not desirable and the current economic climate across Europe only makes matters worse. A recent analysis of European industrial markets found that production is nine percent below what it was prior to the recent recession. While some sectors such as machinery and equipment are keeping a positive CAGR (Compound Annual Growth), sectors such as mining and metalworking are experiencing negative growth rates. European businesses are now in a position where it is vital that they avoid downtime. However, the process of lubricating gears is not as straightforward as simply buying an effective oil and putting it into a system. When inexpertly administered, the danger is that the oil becomes contaminated, potentially in just a few hours, and can be rendered ineffective. This would lead to elevated energy consumption and higher operating temperatures, which would normally lead in turn to a reduction in oil life. This vicious cycle of fluid replacement becomes very expensive over time and isn’t sustainable environmentally or financially. Fortunately, while the procedure is more complicated than just refilling machinery, it doesn’t have to be too taxing. By following a three-step process, an effective oil maintenance program can be as simple as one, two, three.

GOOD TIME FOR A CHANGE The first step in ensuring that gear oil is changed effectively is

establishing the best time to run the process. This is another example of a task that seems obvious, but it is alarming that only 20 percent of oil changes actually happen at the right time. That leaves the majority of businesses either changing their oil too soon or too late. On the surface this may not seem like a major issue, as changing oil too soon simply leads businesses to spend on new oil more frequently. However, replacing oil too late can be dangerous and expensive, causing increased gear wear that results in machine damage and the need for further maintenance. So how do you know when the best time to change your gear oil is? While many engineers top up a machine with oil and expect it to last a long time without changing, it is not the longevity but the quality of the oil itself that must be measured. As such, maintenance engineers must take into account oil condition and contamination level, testing samples where necessary. For example, oxidation is a naturally occurring process that affects oil over time. In the presence of oxygen, the oil begins to break down and this reduces the service life of the oil itself. In addition to this, it also produces sludge that makes equipment work harder and drives up operation costs. If left long enough, the acidity of oxidised oil will steadily increase and result in corrosion and pitting. While this is problematic if left for extended periods of time, this acidity can be used to accurately assess oil condition. By measuring increases in the system’s total acid number (TAN), maintenance engineers and plant managers can identify acceptable limits of oil acidity and act accordingly. However, TAN is only one factor in a gearbox’s overall condition and there are many other considerations such as the operational health of the machinery itself. It is crucial that engineers consider all aspects to ensure optimum performance. This is why NCH Europe developed the NCH Oil Service Program (NOSP), which allows us to analyse gear oil and identify the right time to change oil. NOSP also provides businesses with accurate reports each time a change is due, breaking down the results of the analysis and comparing the current sample with historical data. By using advanced insight into gear oil, engineers can ensure that changes happen at the right time to avoid damaging machinery. However, in order to extend oil life and maximise performance, engineers must first clear away contaminants.

FLUSH AND CLEAN One of the most commonly forgotten stages of the oil change process is cleaning the system before refilling with fresh oil. In fast-paced environments, it can be tempting to cut corners and opt for just refilling without cleaning. However, this leads to oil that is ineffective and heavy with contaminants mere hours after use. These contaminants quickly form deposits on metal surfaces in the system, raising operating temperature and reducing power transmission through the gearbox. While the ideal solution may initially appear to be eliminating contaminants, that is easier said than done. Any plant responsible for

the processing of materials such as metal and wood will find that dust is an unavoidable consequence of production. This dust frequently enters the system oil, contaminating it and impacting machine performance. To prevent this from occurring, it is imperative that engineers remember to clean their systems before replacing machinery oil. The most efficient and effective way is to use a cleaning product to dissolve the deposits and neutralise any acidic contaminants. An effective system cleaning product, such as NCH Europe’s Flush & Clean, works by being allowed to run through the system during a brief period of operation. This separates the deposits from the system surface, leaving them suspended in the old oil so they are removed during the oil change.

THE RIGHT STUFF With the system flushed, the final step is the simple process of replacing the fluid with an effective gear oil. In order to choose an effective product, engineers must consider both the traits of the oil and the problems the application faces. For example, if the gearbox is prone to accumulating condensation and rusting, it is important that the oil can address this. In this instance, we would recommend our Top Blend CS product. Top Blend CS employs a higher percent of calcium-sulphonate technology that mops up acidity as a result of oxidation, it also contains demulsifiers that separate water from oil to keep gears properly and safely lubricated. Similarly, problems such as foaming and oil oxidation can also be addressed by choosing a product that contains anti-foam agents and oxidation inhibitors, respectively. It is important that maintenance engineers consider the operating environment and do not focus solely on the condition of the oil itself. Even if one gear oil is suited to a piece of equipment, it may not necessarily suit the operating environment. Several industries are subject to strict regulations that govern the products that can be used to maintain equipment and machinery, so engineers must ensure that products comply with the relevant standards. In the food sector, for example, there are a number of NSF categories for lubrication products. These categories denote what applications the product is suitable for, with NSF H1 certified gear oils safe for use in equipment where there is a chance of incidental food contact, while H2 indicates that a product cannot come into direct contact with food. Therefore, if a maintenance engineer is replacing the gear oil in a food conveyor system, they must use an effective food-grade oil with NSF H1 certification. It is also important to check the NSF rating of the other products used, such as the system cleaning product, to ensure regulatory compliance. Regardless of whether it is from a practical or a legal perspective, consideration must be paid at every step of the process to determine the best lubrication products for an application. This treatment should then be repeated for every subsequent refill. It might not need a 300-page explanation, but it is clear that oil changing is notthe simple process many consider it to be. With the right knowledge and solutions, boosting machine efficiency can be as easy as one plus one.

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HEALTH & SAFETY WASTEWATER TREATMENT MEETS TELEMETRY TECHNOLOGY Wastewater treatment dispensers now remotely monitored at NCH Europe headquarters. NCH Europe, global provider of biological wastewater treatments for the food and beverage, manufacturing and hospitality industries, has advanced its BioAmp 5000 by equipping it with telemetry monitoring. This high-tech system means NCH Europe has complete visibility of its customers’ wastewater treatment, allowing the company to investigate any changes or problems quicker than ever. The BioAmp 5000 is a microbial fermentation unit that dispenses 500 trillion active FreeFlow bacteria into the wastewater streams of businesses that want to reduce their effluent disposal fees. The bacteria digest fat, oil and grease (FOG), organic waste and suspended solids, transforming highly polluted water into an effluent that is acceptable to water utility operators. “We are continuously investing in our product range,” said Steve Martin, projects director of the wastewater and biologicals platform at NCH Europe. “This upgraded telemetry feature means we get alerted to all changes to our customers’ BioAmp 5000. The alerts are categorised into different levels of urgency, for example, opening the door of the unit will send us a low-level alert, but we’ll get a high level alert should there be a more serious problem with functionality. “By remotely monitoring our customers’ BioAmp 5000, we can fix issues incredibly quickly. With effluent constantly being pumped out in large scale industrial plants, there is no time to lose to ensure that the wastewater is being treated as effectively as possible. For example, if we are alerted that the temperature within the unit isn’t where it should be, we can be on-site to investigate why this is.” The upgraded BioAmp 5000 is also easier to install and has improved dispensing performance. For more information contact NCH UK, Bilston, West Midlands. Tel: +44 (0) 1902 510200 E-mail: customer.services@nch.com Web: www.ncheurope.com/en/nch-media

INDUSTRY 4.0 REQUIRES INTELLIGENT INTERLOCKS FORTRESS IS DELIVERING As we race towards 50 billion d e v i c e s connected to the internet by 2020, Industry 4.0 presents a huge challenge to manufacturers. Collaborative robots and the automation of tasks previously carried out by people is reducing the need for traditional machine guarding while increasing the need for smart interlocks. Malcolm Sharp, Managing Director of Fortress’ Australian operations, discusses how the company is facing these challenges head-on. “At Fortress, our focus has always been on mechanical strength and reliability - our interlocks are, after all, the strongest in the market. But we’re also building in additional functionality to help our customers with their processes. As the importance of data increases, we know that our products will be required to feedback through extensive, potentially global, data networks. “We are already moving in this direction, with recent installations utilising our network-enabled gate switches designed to operate on safety networks. These products are easy to configure and install and provide additional operational feedback, as well as carrying out their safety-critical task. “Two years ago Fortress launched an online configurator, enabling customers to create complex safety products from our wide range of modules and components. There are more than 4.9 billion potential configurations that could be created and since its introduction over 10,000 unique configurations have been created. Five years ago, such a configurator was unimaginable. “As industry evolves, our view remains unchanged - we need to protect people and productivity. It remains our massive transformative purpose in this digital age.” For more information contact Fortress Interlocks Ltd, Tel: +44 (0)1902 349000 Email: sales@fortressinterlocks.com Web: www.fortressinterlocks.com

ELFAB’S FLAME ARRESTERS & BREATHER VALVES OFFER SUPERIOR PERFORMANCE & SIGNIFICANT COST SAVINGS Elfab’s latest generation of flame arresters offer a brand new and patented construction concept for both deflagration-proof and detonation-proof designs. The

new concept contributes to better performance, easier maintenance (for 100% cleanliness) and easy assembling and disassembling without any risk of damage to the parts. Elfab’s Breather Valves comprise a completely new valve philosophy with the introduction of its unique modular design construction resulting in an increased number of configurations to fit various valve sizes reducing costs associated with oversizing and quantity of valves needed to fulfil the application requirements. The design offers better access to internal parts for improved maintenance, while due to the improved construction; less spare parts are needed. Further advantages can be achieved with the combination of Elfab’s breather valves together with its new generation of flame arresters. Both are fully approved and tested to the highest possible standards and all these benefits lead to a cost-effective, superior performance solution and industry best lead-times. To find out more about these product offerings contact Elfab Ltd, North Shields, Tyne & Wear Tel: +44 (0)191 293 1234 | E-mail sales@elfab.com | Web: www.elfab.com MAY 2017 - PROCESS INDUSTRY INFORMER

ASD FOCUS FOR PATOL AT FIREX Patol will be returning to Firex International1 with Aspirating Smoke Detection (ASD) and the wide range of applications for which it is ideally suited very much the focus of attention. Exhibiting on Stand C125 at the three day show, Patol will be highlighting the capabilities of the Securiton SecuriRAS range of ASD systems – developed in Switzerland and manufactured in Germany – for which Patol is the exclusive distributor in the UK. ASD is widely employed as a fire detection technology, providing fast and early detection of smoke particles to ensure it is employed in many different environments, from warehouses, museums, IT and data centre facilities to laboratories, clean rooms and cold stores. Kelvin Miller is Sales Director for Patol and recognises the recent successes achieved with SecuriRAS as providing an excellent platform from which to build – “The food industry has been an area in which we’ve been particularly active. In several applications, the particular challenges of cold stores and their low temperatures have been met through our ASD offering. By introducing heated sampling points which are automatically activated if the monitored airflow drops below a pre-determined level due to the build-up of ice crystals, we have been able to provide early fire detection in what is typically a challenging environment for fire detection. The SecuriRAS range is EN54-20 approved to class A, B & C and provides options for effective, scalable fire monitoring of small single premises through to much larger facilities. The ASD 535 detector is the flagship model and is one of the fastest growing ASD units in the world. Available in one or two-channel options it provides high sensitivity detection for areas up to 5,760 square metres. Alongside its ASD capabilities, Patol will also be showing the latest developments in its range of linear heat detection cable (LHDC) products, as well as discussing its specific expertise in application engineering and system design. This extends across several industries including heavy industry, power generation, underground rail, conveyors, escalators, waste recycling plants and petro-chemical and tank storage. For more information contact Patol Ltd, Reading, Berks. Tel: 01189701701| E-mail: info@patol.co.uk Web: www.patol.co.uk

NEW TIMERS AND CLOCKS: TIMING MADE SIMPLE IN HAZARDOUS & SAFE AREAS New BEKA Timers and Clocks simplify process timing in hazardous and safe areas. Able to display elapsed time between events, or control external devices, timing cycles can be repeated continuously or a specified number of times. As a Clock the instruments display local time in various formats. Two sizes of panel mounting instrument with IP66 front of panel protection and a rugged 316stainless steel instrument for applications in severe or marine environments. Field mounting instruments have IP66 impact resistant GRP enclosures suitable for harsh nvironments. Accessories include a backlight, pipe and panel mounting kits and a stainless steel legend plate that can be supplied with customer specified information. ATEX, IECEx and North American intrinsic safety gas and dust certification. For applications in Zone 2 or 22, Ex nA and Ex tc approval permits installation without the need for Zener barriers or galvanic isolators which significantly reduces the installation cost. For further information including datasheets and certificates please visit www.beka.co.uk/ timer_clocks.html or phone the BEKA sales office on 01462 438301. 11

FEATURED ARTICLE

GAMBICA The Trade Association for the Process Industries

By Sebastian Amos -GAMBICA – Sector Head, Process Instrumentation & Control The GAMBICA Association Ltd. is the Trade Association for Instrumentation, Control, Automation, Test and Measurement and Laboratory Technology in the UK. A Trade Association is a not for profit organisation that aims to give a voice to all their members on the issues of the day and into the future. GAMBICA’s sectors, defined above, include industry players across the board within the UK manufacturing space. A key activity is engagement with the development of standards and legislation that affects their operations within UK PLC and international markets. There are also activities through education and thought leadership where we open discussions concerning short, medium and long term developments of strategic importance. The size of each sector and their specific focus dictates the split that GAMBICA has provided and Process Industries continues to be a large group. There are many issues that affect all UK manufacturing but there are also many specific issues that affect the Process Industries.

HIGH PRIORITY NATIONAL ISSUES The national issue of the moment is Brexit. By the time this is published, the election should be over and a new government will be starting the negotiations. Government needs help with their strategy, and that is not a cynical poke, it is a positive recognition that government does not have all the answers and asks industry to assist in setting the agenda. Government does not want to dictate, it wants to affirm. There are two key issues under discussion: The first is the industry views on the recent Green Paper “Building our Industrial Strategy”. GAMBICA, along with other organisations has worked to develop a response to the contents through discussions with other trade bodies and of course, its members. This enables a structured and informed response. The green paper is laid out with many sections that include a precis on each question. GAMBICA took this document and developed a questionnaire which was circulated to all members. The answers are being collated and will have been sent to BEIS in April, along with a summary publication of the responses on our website. Whilst this green paper looks at many local UK issues, it also addresses exports and trade, especially with the EU. The second, which was actually started first, was an initial response to the Brexit vote and its effect on UK PLC. The graphs below summarise our member demographic who responded and key issues reported by members and no doubt will also appear in slightly different formats in the Green Paper response.

Our members provide predominantly process instrumentation, pressure, temperature, flow etc., and control equipment including Programmable Automation Controllers (PAC) and Distributed Control Systems (DCS). Services include configuration, installation, support and maintenance installation by these companies for their specific equipment. The following sections look at areas of work done on behalf of process sector companies.

MARKET REPORTS On an annual basis, we prepare and publish market reports for each type of equipment manufactured in the process sector in the UK. The data is produced by members under the strict guidelines of Competition Law. The key benefit of these reports is that they do not produce league tables like other “helicopter” reports that can be purchased, but provide information to participants concerning actual market size and trends. In order to receive these reports, a company must participate in the initial data gathering. Unlike a paper bag, you actually take out more than you put in. This year’s report was published in March and covered a UK market worth close to £600m. We produce two annual surveys around salaries. A Salary Intentions Survey collates data from members concerning the level of increase (or decrease) as a percentage they intend to make. We also collect actual salary data based on job descriptions. In most cases, the data comes directly from our members HR teams. Unlike surveys on the web where respondents will no doubt inflate their salaries, these reports are based on actual data.

STANDARDS Standards are key to the success of product development in a global market. It is unlikely that a company will develop products just for the UK market as they will always have an eye on exporting. Standards, and the UK input to them, especially as Brexit looms, remains high on the agenda, item 3 as shown on the above graph. GAMBICA is represented on 27 working groups at the BSI level that affect the development of over 100 standards for process instrumentation and control. Each working group, which is a mirror of European and International teams, is responsible for the standards that effect their area of expertise. Standards address specific issues and thus there is unlikely to be one standard against which to develop a product. For example, if you are developing a new product in the gas detector market, the BSI working group EXL/031/01 is responsible for this area. There are at least 12 specific standards that affect this area of design. These include amongst others; the EMC standards and the output from the LV directives, communications protocols if your equipment will be networked, and protection should

The full report is available on the GAMBICA website at: www.gambica.org.uk/resourceLibrary/gambica-survey-report---priorities-post-eu-referendum-pdf.html All our members have access to the cross-sector issues but we can now turn to the GAMBICA activities within the Process Sector.

GAMBICA PROCESS INSTRUMENTATION AND CONTROL SECTOR. Process is defined as equipment and services that are specifically sold into industries that manufacture chemicals, pharmaceuticals, food and beverage, oil and gas, water treatment and anywhere that three term control is required.

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your equipment be put in an explosive atmosphere. In most cases, standards are published Globally accepted with European and UK versions that remain close to the originals with minor changes in language, but not technical content. This is indicated by the initial letters of a standard e.g. ISO (Global) EN (European) BS (UK) 9001, most commonly referred to as ISO 9001 – Quality. Consequently, the work completed by GAMBICA involves us at the international level of standard development attending meetings and working groups with international partners. GAMBICA does not have engineers and scientists from its own staff on all these working groups. We can provide people from member companies who act as experts on behalf of ourselves and report back to all members. GAMBICA is placed second by BSI for the support provided to the standards markets. What are the benefits of using GAMBICA for representing the process industry on standards committees? Members have a voice, can comment and be able to plan and manage product development as requirements change as opposed to being reactive.

THOUGH LEADERSHIP AND INNOVATION Thought leadership can be used to spark lateral thinking. Innovation, often seen as ways to make changes pushes development. The process industries are lagging in innovative ideas in the fourth industrial revolution (4IR). This is a statement made on discussions and research over the last 12 months. However, process companies have been applying most of the technologies for probably 20 years based on DCS solutions and specific third party applications enabling integrated ERP, predictive control and asset management. Unfortunately, most of these tend to be bespoke and thus an end users becomes locked in to one major supplier and thus cannot benefit from the best of breed in specific areas. GAMBICA has been suggesting ideas that could improve uptake of the additional benefits of Industry 4.0. For all manufacturers, the questions they should be asking first is which, of the available directions identified in I4.0, should I invest my development budget in to bring the greatest uptake and return. For example, product or process. Should all my devices now support a communication protocol and if so which one or should my internal systems become automated within a supply chain cloud? Alternatively, what part of I4.0 should I invest in within my own organisation to gain the best returns for example, more robotics. Once these are identified, the next step can be taken in reviewing their own “digital readiness” for which there are several companies offering support and tools. GAMBICA reviews many strands of information which can be presented as papers and organise or support events that bring people together to discuss these ideas, something that on their own, they may not have the time or resources to review. Once identified, companies can access support, most notably, for the process sector,through the Centre for Process Innovation (CPI) in Wilton, the Catapult Centres and Innovate UK.

OTHER HOT TOPICS SKILLS This has been an issue for the last century and the UK has muddled through. However, it is now becoming critical as the technologies become more complex. We need well trained individuals in STEM subjects and apprenticeships across the board. GAMBICA works with companies, colleges and universities to develop approved curricula and delivery methods for this. We also work with companies to explain how they can recover some (or all) of the apprenticeship levy the government is now taking at source.

GENERAL AWARENESS There are many topics that do not receive high levels of publicity. These include areas including the Circular Economy, Conflict Minerals and understanding the customer’s barriers to adopting new automation amongst others. The key guidance for our investigation into these areas comes from our members. We address these at our board meetings that set the direction we follow, and the Process Council that extracts those directions relevant to everything process. Both these committees are run by and chaired by members.

SUMMARY GAMBICA is involved with a raft of issues affecting the Process Industries. Our key purpose is to improve the operational environment for the UK manufacturers. If you would like to find out more, please visit our website www.gambica.org.uk where our contact details are posted.

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HEAT TRANSFER & ENERGY HELIEX REINVENTS STEAM WITH THREE NEW TECHNOLOGIES Heliex Power, the East Kilbride-based innovative energy company, has launched three new products to help a variety of industries maximise their energy efficiency, by building on its existing unique steam technology.

The company, working with City, University of London, was the first to discover a way of harnessing “wet” steam – a ubiquitous, yet frequently untapped, energy source. Together they created the steam expander, Heliex’s core technology which harnesses the energy from standard industrial steam to generate mechanical power. Heliex’s first use of the expander was in the Heliex GenSet, launched in 2013, where it is used to drive a standard industrial generator, allowing businesses to produce electricity from the wet steam created in many of their processes. The company has now extended the use of the expander to drive a range of rotating equipment, such as pumps and blowers, with its Heliex SteamDrive. The expander can drive machinery more efficiently and cost effectively than an electrical motor. The company’s second new technology, the Heliex AirComp, uses a Heliex steam expander system to drive high-efficiency compressors, providing air. This is up to 18% more efficient than using an electrical motor, delivering savings in excess of £80,000 per year for a standard 100kW machine. Compressed air is employed in a variety of industrial applications, such as the running of control systems, cooling equipment, and drive components. The company’s third new technology, Heliex SteamComp, uses the original steam expander system in reverse. It allows plant operators to re-energise steam which has already been through a process, instead of having to condense and evaporate it again – an energy-intensive process. The technology is already being deployed by a packaging manufacturer on its production lines and has potential applications in industries such as pulp and paper, tyres, food processing, and chemicals. Chris Armitage, Chief Executive of Heliex Power, said: “The launch of these three new products demonstrates the level of commitment we have to innovation and R&D, as well as developing Heliex as a company. Steam is often seen as a technology consigned to the Victorian era, but it still has huge potential and enormous benefits to offer modern industry and society. For more information on Heliex Power please see www.heliexpower.com

COUNTER-CURRENT SCREW FOR HEATING LIQUID Subsidy makes faster development of groundbreaking innovation possible.

In the development of a new type of screw heat exchanger for liquids Van Beek has literally thought in the reverse direction. In this new screw heat exchanger the screw is in fact used to delay the movement of the product instead of conveying it. Under the trade name Celsius Van Beek already has wide experience with the construction of screw heat exchangers. These are used for cooling, heating and drying powders and granules. The company is now investigating whether a screw can also play an important part in a heating process with liquid. Slowing down product with a vertical screw “We were being asked increasingly often whether we could also heat liquids and so we starting thinking about this”, says Eric de Jong, Manager of Operations. The outcome is a vertically installed screw where the liquid is sprayed in from the bottom at around 10 bar. A shaftless screw rotates against the pressure to slow down the liquid. Fitted around the screw is a twin-walled tube through which heated oil or water flows. In this way the temperature in the screw can be regulated. Reverse shaft affects residence time The operator sets how much resistance the screw gives and affects how long the liquid remains in the screw. So it can be very accurately determined how warm the product is when it comes out of the screw. “We are the first to experiment with this technique in this way”, says De Jong. Counter-current screw attracts praise The first tests with this ‘rebel going against the flow’ are very promising. “A two metre high test machine has been used for one client who processes frozen fruit, for example, smoothies. The client is so satisfied that he wants another screw heat exchanger like this”, explains De Jong. De Jong expects that there will be a big demand for this unique screw heat exchanger not only in the food industry, but also in recycling (for example for sludge processing) and the chemical industry. Good cooperation with Kapp Van Beek has developed this heat exchanger with Kapp Nederland B.V. from Dordrecht, a trading and engineering firm specialising in industrial heat exchangers in the process industry. For more information contact Cynthia Meijer, E-mail: meijer@van-beek.nl Tel: +31(0)416 37 52 25 Web: www.van-beek.nl

SMART & SMALL POWER DISTRIBUTION FOR FIRST TIME Rittal, the leading global provider of solutions for industrial enclosures, power distribution, climate control, is offering manufacturers of small control panels and switchgear an innovative and tested power distribution system. The new RiLine Compact allows the user to mount different types of protective and switching devices onto a system, and then supply it with electrical power. Its standardised and standards-compliant technology means it is suitable for use in control panels in both the IEC and UL markets. The system consists of a base plate, onto which fully shock-hazard protected busbars are pre-installed. These busbars can be easily reached through a grid in the top cover. There are various adapters that makes connections easy and quick, which in turn helps installers to mount control and protective devices. In addition, there is an adapter to connect incoming round conductors, as well as a variety of slimline functional modules for motor and power control. The RiLine Compact System is quick to set up, saving time and costs. The base plates and all the system’s components can be easily and safely installed without tools. Added to which, the contact hazard protection means that the user is protected from live parts, right from the start - improving safety for users as well as the system itself. Further information at www.rittal.co.uk and www.friedhelm-loh-group.com or on twitter @rittal_ltd

FILTRATION TAKE THE STRAIN OUT OF CHOOSING THE RIGHT FILTER Filtration specialists, Axium Process, manufacture stainless steel filters that are customised to suit specific site or process requirements for applications ranging from pump and instrument protection to critical applications where filter failure or collapse is not an option.

Working closely with their customers, Axium Process’ engineers are able to help select the right filter from a comprehensive range of stainless steel wedge wire and sintered mesh designs that are tailored to suit a given application, flow rate and pressure. “Customers can have complete confidence that they are being supplied with the best solution for their application” states Axium’s Business Development Director, Derek Davies. “Axium’s filters are successfully used in a broad range of applications and the wedge wire design is excellent for products where smoothness and consistency are essential such as creams, emulsions, yoghurts, soft cheese and paints. All filter types are very easy and simple to maintain and do not require tools to dismantle. We have also fitted a 316 stainless steel safety clamp closure onto all our filters so that they can’t be knocked or accidentally opened in order to enhance plant safety. ” Delivering filtration levels between 5 micron up to 6000 micron as standard, Axium’s robust and versatile Pure-Screen and FineScreen filter ranges are in daily use throughout the pharmaceutical, food, beverage, dairy and chemical industries. Available as 90˚, in-line and straight thru designs, filters are fabricated in both standard and compact options with either 4” or 6” housings. All filters can be fully customised as jacketed, duplex, triplex or multiplex options and supplied with a stainless steel support frame when required. For further information please contact: Axium Process, Swansea. Tel: 01792 883 882 | Email: info@axiumprocess.com | Web: www.axiumprocess.com PROCESS INDUSTRY INFORMER - MAY 2017

FEATURED ARTICLE

OPENING THE ENVELOPE ON BEARING VIBRATION A sophisticated signal processing technique can help manufacturers in the process industry to pinpoint bearing failure at an early stage and keep machine downtime to a minimum. Chris Hansford, Managing Director at Hansford Sensors, reveals all.

xperienced operators can often tell if a machine is not working properly, on the basis that i simply does not ‘sound right’. The same principle can be applied – using modern electronics – to identify the exact cause of the problem. Sensitive accelerometers can detect and analyse the vibrations from industrial equipment, highlighting problems such as misalignment or bearing imbalance. The technique, known as vibration analysis, has become well established across the manufacturing sector. It can identify bearing failure in the very early stages, when there is a microscopic defect on the raceway, for example. The problem is that the identifying signal is usually drowned out in all the other noise emanating from the machine.

FILTERING DEVICE It is vital to catch these kind of defects as early as possible, to stop them developing into more serious problems. One way of homing in on the signal of interest – and filtering out the ‘noise’ – is to use a signal processing technique called acceleration enveloping. It works by progressively filtering out unwanted parts of the vibration spectrum until the signal of a bearing defect can clearly be seen – extracting low level, repetitive vibrations from the noise around it. The unfiltered waveform from a defective bearing is a mix of low and high frequencies, with no obvious pattern. The first step is to apply a band pass filter, which isolates only the frequencies in which the signal of interest is hiding. Some experience is needed in order to know how to choose the high- and low-pass frequencies. The filtered output will identify repeating, high frequency signals, though more steps are required to pinpoint the one specific to the bearing defect. First, the waveform is rectified – inverting the negative part to positive – and this is then enveloped (or demodulated) by tracing a line over the general shape of the rectified signal. This ‘envelope’ is now used as a true vibration signal – helping it to stand out from the noise. The envelope helps to contain regularly spaced signals, such as a single defect on a raceway. Other causes of noise, such as shaft rub, are random – so will not produce evenly spaced peaks.

MAY 2017 - PROCESS INDUSTRY INFORMER

ACCELERATION ENVELOPING IN ACTION THE TECHNIQUE Acceleration enveloping is most commonly used in roller bearing systems but can also be applied in areas such as electric motors and gearboxes. It is a key factor in the success of condition-based maintenance (CBM) programmes. While enveloping is most commonly used with signals in the acceleration spectrum it can be used to improve other measurements, such as a shock pulse. Once the signal has been filtered, the information can be collected from the accelerometer using a data collector, ready for review and interpretation by a specialist – who can decide whether or not maintenance work is required immediately or can be planned as part of routine schedules. While acceleration enveloping may seem to be the definitive answer to detecting bearing failure, it cannot be universally applied to any machine. The technique detects faults involving repetitive, metalto- metal interactions. Anything that masks this, such as gaskets or dampers, may put a machine outside its scope of use.

ACCELERATION ENVELOPING SUCCESS FACTORS If an application is suitable for enveloping, several factors will help to ensure better results. Firstly, accelerometers to measure the low level signal should be selected carefully – in the proper frequency range – to suit the needs of the particular machine or application. Secondly, accelerometers should then be correctly mounted – close to the component being monitored, on a flat, clean surface to guarantee consistent results. Poor mounting can reduce reliability and often make collected data redundant. Once accelerometers have been installed and calibrated, data readings should then be taken at regular intervals over a period of time to allow accurate trend analyses to be produced. This allows a steadily deteriorating condition to be identified, for example. It is important to understand that the information provided is not a simple ‘yes/no’ answer – and requires some skill and experience to interpret: the amplitude of a worsening condition can actually reduce over time, for example, as the imperfection becomes slightly smoother. The potential benefits of acceleration enveloping are clear, but it would be unwise to rely on the technique alone. Implementing it as part of a wider monitoring and analysis regime can be far more effective – helping plant engineers to safeguard the health, performance and productivity of all the assets under their care.

Although wear tends to be gradual rather than catastrophic, it can nonetheless lead to expensive repairs that, in terms of downtime, cost far more than just the cost of a replacement bearing or gear unit would have. Regular vibration monitoring can prevent these issues occurring. The complexity of some machines used in manufacturing, however, can present a challenge for vibration monitoring. For example, gearboxes and generators can often have many rolling element bearings installed, while gearboxes can incorporate a series of stages, each with multiple gears. These components generate unique vibration signatures, with different amplitudes and frequencies, which can be difficult to isolate from each other and that can be masked by noise from surrounding systems. This is where a technique such as acceleration enveloping can play a crucial role, enabling vibration analysts and maintenance engineers to separate vibration signatures and identify the changes in signal conditions, which can indicate increasing wear. To be effective, acceleration enveloping requires the use of multiple accelerometers, fitted to all key rotating parts. These include the main bearings, planetary, intermediate and high speed gear stages, the generator (inboard and outboard bearings) and ideally the nacelle traverse and axial movements. In each case, there are several critical factors that must be considered. In particular, each accelerometer must be mounted securely on a clean and solid base, and as close to the component being monitored as possible. It is also important to collect data consistently; this ensures any change in operating conditions or trends over time can be accurately identified at the earliest possible stage. The latest hand held data collectors feature software capable of automatically calculating acceleration enveloping, or software can be transmitted to a remote monitoring centre for subsequent analysis. 15

FEATURED ARTICLE

THE DIGITALIZATION OF

FOOD PALLETIZING New technologies are changing the face of food packaging

The technological and social revolutions of the past few decades have completely reshaped industry. The food packaging and palletizing industry is no exception. In fact, the last ten years alone has seen the adoption of advanced technologies at an unprecedented rate. Here, Alan Spreckley, robotics food and beverage segment manager and palletizing robotics expert at ABB, explains how digitalization is repackaging the future of food palletizing.

he last two decades have seen a decline in the nuclear family and a global rise in the number of private households with only a single occupier. In 2014, the UK office of national statistics (ONS) conducted a study that found 28 per cent of UK households had only one inhabitant. Likewise, the labour force survey (LFS) showed that one-third of European households are single person, while the US has been experiencing a significant increase of single person households since the 1920s. This growing trend places a higher demand for single-portion servings of pre-prepared and pre-packaged food on the food industry, which makes the packaging and palletizing processes less linear than they have previously been. Similarly, the unstable economy of recent years has nurtured a generation of savvy customers, eager for the special offers and deals that retailers regularly provide, further complicating the palletizing process. This leads to scenarios where manufacturers will be required to change palletizing patterns quickly and cost efficiently to deliver this. To keep pace with this changing demand, plant managers and process engineers must ensure that the palletizing process is as efficient and effective as possible. This means keeping systems maintained and palletizing patterns up-to- date, while minimizing any risk of downtime or hindered performance.

To make these processes easier to manage, plant managers have been increasingly turning to new technological solutions; solutions that are a step beyond the traditional automation systems or machines that have previously improved industrial performance. In the twenty-first century, digital technologies and software are proving to be the unconventional ally of the modern plant manager.

VIRTUAL COMMISSIONING Robots have been a staple of the food industry since the 1980s, with most businesses using at least one robotic system for some part of the production line. Palletizing robots have proven particularly popular among plant engineers as they increase productivity, improve working conditions and can be easily integrated into existing production systems. However, the process of integrating palletizing robots has traditionally relied on computer assisted design (CAD) drawings and involved a lot of estimation. Food plant managers provide approximate dimensions to robot manufacturers for the robot and leave the rest in the hands of the manufacturer, who tests the product in its own facility before finalizing and installing onsite. While this approach is sufficient for some businesses, it can open up several performance problems. For example, CAD drawings alone do not necessarily provide an accurate representation of the operating environment and the robots still need to be programmed after installation. This lengthens periods of unproductive downtime to accommodate the placement and programming of a new robot. To minimize unproductive downtime, the process of virtual commissioning is becoming increasingly popular among plant managers, often using ABB’s innovative suite of virtual commissioning tools. Instead of using CAD drawings and developing robots in an external environment, the process is modelled in 3D which provides an accurate visualization of a factory layout. This allows plant engineers to see a digital representation of how the robot will integrate and move within the process, and allows them to discover and resolve any potential technical issues before they become a reality, reducing commissioning time by up to 25 per cent. For example, one of the most common causes of damage to palletizing robots is collision with a cell’s support pillar during operation. By using a virtual commissioning platform, such as ABB’s RobotStudio® these instances of collision can be fully discovered and resolved in a time and cost efficient manner on the computer.

This helps minimize the actual, physical commissioning.

REMOTE CONDITION MONITORING Once commissioned, robots are machines like any other and they are susceptible to component wear over time. As such, regular maintenance is required to ensure that everything is functioning effectively and safely. This doesn’t pose much of a problem for plants that are ahead of the curve and running on an Industrial Internet of Things (IIoT) network. IIoT allows engineers to assess cloud data to assess the performance of machinery remotely and schedule maintenance work accordingly. ABB has put together a suite of connected services that provides services that are available 24/7. These include condition monitoring and diagnostics, backup management, remote access, fleet assessment, and asset optimization. This level of information provides plant engineers with advance notice when service is or unproductive downtime occurs.

REAL-TIME OFFLINE PROGRAMMING While virtual commissioning and remote monitoring technologies both keep factories running, it is the development of offline programming software that yields efficiency benefits for plant managers. This is software that allows the remote programming of palletizing robots without interrupting production. For example, if a retailer usually asks for four-packs of tinned soup but decides to offer a 50 per cent-extra- free offer for a period of time, the palletizing robot will be required to change palletizing patterns accordingly. Failure to do this effectively could result in businesses being unable to supply a sufficient amount of product to retailers, which leads to lost contracts and the risk of heavy supplier fines. Plant managers can prevent this by digitally reprogramming palletizing robots using offline software such as ABB’s RobotStudio, which can be accessed using a standard PC to change palletizing patterns. This reduces the time taken to change over and boosts overall productivity to ensure that demands are met. In the nineteenth and twentieth centuries, the automotive sector was one of the most technologically advanced and adaptive industries. If the past decade is anything to go by, the food industry is quickly building a similar reputation. By thinking more about digital solutions to production problems, plant managers can ensure that food processing becomes the automotive industry of the modern age, easily coping with the demands of the nuclear family and single occupier households.

PROCESS INDUSTRY INFORMER - MAY 2017

MAY 2017

Here we are with the second edition of the‘new’ BPMA PUMP INDUSTRY NEWS and it’s good to report that the first edition has been extremely well received, so we thought we would do it all over again, hopefully, you will find this issue just as interesting and helpful. As with all associations news vehicles, we would like your comments and suggestions for more material, not only from members of the BPMA but also from the readers of PII,

after all the ’News’ is importantly geared to that the BPMA members offer, it is certainly you as well. Please send your suggestion to worth checking, not only the MEMBERS s.smith@bpma.org.uk DIRECTORY but also find out more about how the BPMA itself, you might be truely Currently, the BPMA has 74 members, not all surprised... Why not log on to www.BPMA.org. of which are pump providers, some provide uk or perhaps give a call on 0121 601 6350 or services that relate to, and with the working E-mail: enquiry@bpma.org.uk. activities that pumps utilize in a variety of industries. Perhaps you work with a company that might benefit by joining the BPMA, or alternately could benefit from the services

HEADLINES FOR THIS ISSUE * After the success in February we have another Q & A .

*Engagement with Brexit

* In February we promoted the Pump Awards – now it’s the winners

* News about BPMA staff * GDP growth forecasts

The path to a greener future... Efficiency l Strength l Reliability Since January 2017, EU MEPS have stipulated that any new motors on the market ranging from 0.75 kW to 375 kW power output have to meet the IE3 efficiency standard or IE2 efficiency standard if used with an inverter drive. Our inverter drives will work with new and existing motors to help you reduce energy consumption and meet legislation when used with an IE2 motor.

For a greener future www.weg.net

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

FOREWORD

training

Welcome to the Spring Edition of the BPMA Pump Industry News. Since our last edition we now have UK General election on the horizon with political parties not only highlighting their usual policies but now also offering their version of a solution to BREXIT. One thing is for sure BREXIT will offer opportunities for BPMA members but I am sure there will also be threats. With this in regard BPMA staff and Council members are currently focusing on this important subject to identify areas of concern and will hopefully have an industry position in the coming months that we can take to the appropriate government departments to achieve our goals.

BPMA LECTURE BASED TRAINING

Regards Peter Reynolds BPMA President

BREXIT & The Pump Industry – Get Involved! Our exit from the European Community and the Government’s introduction of the Great Repeal Bill – dismantling the tie to EU laws. What does this mean for the UK Pump Industry? In this article, Shaun Hampson, Chairman of the BPMA Marketing Committee, encourages pump sector engagement in order to meet both the challenges and the opportunities. At the moment nobody really knows for sure what Brexit means for the UK, but it is our time to come together to capture the opportunities whilst managing the threats, through unified lobbying of Government. A vast amount of UK legislation contains references to EU Treaties, and the Government will be seeking to stabilize UK law and regulations as fast as possible. These regulations, laws and directives contain material which can directly tip the buoyancy of our UK pump industry. Basic practises like CE Marking and Declaration of Conformity, for example, will need to be reviewed for inclusion into UK legislation. Other legal directives which we all take for granted may also be reviewed with respect to Import & Export Compliance, movement of employed staff, transfer of machinery, cash pooling, trade-barrier taxation, along with hundreds more. How many of us have non-UK EU citizens working in critical roles within our businesses – will they decide to go home, and why? What about the paperwork needed to import a simple gasket from France? Let’s not even discuss the implications with exotic alloys and PTFE which have dual use! On the flip-side, there are ‘once-in-a-lifetime’ opportunities which could outstrip the threats; with examples being a wider global market, boosted domestic manufacturing & production, elevated skills & talent pools, plus the good old British motivation. Much of these will be the product of Apprenticeship schemes and easy access to technically-driven education. Hedging the threats and capturing the opportunities, however, is heavily dependent upon the eventual deal agreed between our Government’s single seated negotiator versus a twentyseven strong seated opposition. At what point will the pumping

industry be discussed - before or after the automotive, banking and military sectors? Will it ever get any specific consideration? Now is our time to find the common thread amongst the UK pump industry and its front-line supply chain. It is vital that we fight to preserve beneficial laws, eradicate other bureaucratic nonsense, and forge strong apprenticeship schemes. Right now – at the very early stages - BPMA is working for the good of our UK Pump Industry through member engagement. The aim of the BPMA is to construct an agenda of “go” and “no-go” aspects of forthcoming legislation, while demanding the re-balance of skills, and ultimately voicing our unified position LOUDLY with appropriate Governmental Bodies. Not many pump companies will escape some form of change to their business model after BREXIT has finally matured. If you have unanswered questions about future legislation, and would like be included within the BPMA escalation discussions, you are encouraged to engage with the BPMA in the not-too-distant future. Recently, the BPMA has been collecting thoughts and prescriptions from its membership through a simple questionnaire. This is a critical path to ensure that we cover every angle on this topic without leaving any business - small or large – marooned and exposed. If you are a member and have not completed this short assessment, please give it the benefit of your Team’s vast experience. Non-members, who understand that this subject will affect their Company, and/or distributor network, should contact Steve Schofield - Director of the BPMA at s.schofield@bpma.org.uk. By doing this, we can all work together to guard against threats and identify opportunities for our pump companies.

Five courses are presented by an experienced tutor in a modular form, each taking no longer than a day. These are all stand-alone courses, however, BPMA recommends that delegates take the Pumping Fundamentals course before then selecting any one of the othe courses to best enhance their knowledge The next BPMA Lecture Based Courses to be held at the offices of the BPMA in West Bromwich will be:

PUMPING FUNDAMENTALS

Monday 5th June £300.00 +vat per delegate –member discounts apply Aimed at those purchasing and operating pumps this course introduces delegates to the role of pumps and pumping and the effects of liquid qualities.

PUMP TESTING

Tuesday 6th June £300.00 per delegate –member discounts apply Performance indicators are identified and test methods reviewed to include flow, pressure, speed, noise, and vibration. Designed to enable individuals to enhance their knowledge and skills in the practice of pump testing

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

CPSA (Certified Pump System Auditor) - an industry specific professional qualification developed by the BPMA (British Pump Manufacturers Association Limited) which is already an established 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&#39; for individuals assessing the performance of a pumping system. A second course has been scheduled between Monday 20 th November and Thursday 23 rd October 2017. This will take place at The Park Inn, Birmingham West and includes 3 nights B &amp; B accommodation at the same hotel. 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 a BPMA Training Guide

BPMA NEWS

FLOTRONIC PUMPS TAKES ADVANTAGE OF NEW DIRECTIVES ADVISORY SERVICE

The first audit under the BPMA’s new Advisory Service offers thumbs up. Not being legally compliant when placing products onto the UK or European market can lead to large fines for the company. But worse still, if a non- compliant product leads to injury or death, it can result in prosecution or even imprisonment for company executives. The BPMA has for many years provided generic information to its members on EU Directives which specifically affect the pump industry, either through guidance documents, position papers or more general information given out at meetings. Building on this important ‘information transfer’ yet further, the BPMA now offers an ‘advisory service’ which is designed to help suppliers of liquid pumps achieve and maintain the correct compliance procedures and documentation. Comprising a site visit, a full appraisal of a company’s Technical File, CE Marking, Declaration of Conformity and other certification requirements, along with the provision of a detailed information folder, a follow-up written report is then submitted. One company that has already taken advantage of this advisory service is AODD Pump manufacturer, Flotronic Pumps Ltd. With its comprehensive range of pumps serving a broad application base, from acids to adhesives, paints to petrochemicals and pharmaceuticals to food &amp; drink, the company was keen to ensure that its compliance obligations were being thoroughly met. The review was initiated by Peter Wheal, Flotronic Pumps’ Chief Engineer, who considered the use of the BPMA Advisory Scheme to have been beneficial in explaining pump industry practices, and how applicable directives and standards might develop going forward. He said, “Awareness of possible additional requirements as pump products encompass more control and hazard prevention capabilities had been a useful discussion point for us.” He continued, “Guidance on when directives will change helps to save cost on printing, but the BPMA advice may also avoid the need, and additional cost, for external support from Notified Bodies and The CE Marking Association.” John Bower, who carried out the BPMA Advisory Scheme audit at Flotronic Pumps’ facility in Bolney, West Sussex last month (February) was delighted to state that, “Flotronic had diligently followed compliance processes, in particular with Technical Dossiers, Hazard Assessment, Testing, Product Safety and IoMs.” The BPMA actively promotes a “Buy with confidence from BPMA members” ethos and this new service aims to fully support and enhance that approach. If you are interested in this service please contact Steve Smith at BPMA on 0121 601 6691 or e-mail s.smith@bpma.org.uk

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VapourView™ Non-intrusive instrumentation that uses ultrasonics to detect the presence of gas in a liquid from outside the confines of the pump. Secondary Containment Options to enhance even further the environmental, health & safety attributes of sealless pumps.

With new derivatives including vertical, high-pressure, low-flow, multi-stage, even extended sump versions, there is a Sundyne HMD Kontro sealless pump that is perfect for your next project. Enquire today.

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QUESTION & ANSWER

SOLUTION

YOUR PUMPING QUE Demystifying IE standards By Patrick O’ Neil, Managing Director, WEG UK Global population growth and economic development have generated significant energy demand around the world, resulting in increased use of fossil fuels and greater levels of pollution in our atmosphere. The European Union has targets to reduce CO2 emissions by 40 percent before 2030 through the creation of renewable energy sources, as well as improved energy efficiency. Given this ambitious target, the EU has placed a high priority on increasing the efficient use of energy consumed. Industry is by far the most significant consumer of energy, with some studies suggesting that almost alf of global energy consumption comes from industry. Electric motors account for almost 70 percent of the energy consumption of industrial users, representing around a third of total global energy consumption, and yet, the vast majority of installed motors are old, outdated andconsequently inefficient. From January 2015, European Commission Regulation 640/2009 stipulates that electric motors for sale with a rated output of 7.5 to 375 kW must meet the IE3 efficiency class (or the IE2 efficiency class if equipped with a variable speed drive). In the next phase, from January 2017, the rated output range was extended to between 0.75 and 375 kW.

maintain their own persistent magnetic fields. Mounted on, or embedded into, th rotor, they couple with the motor’s current-induced, internal fields, generated by electrical input to the stator. Its electromagnetic coil is attracted to the permanent magnet, causing the motor to rotate. When electrical input is removed, the wire loses its magnetic qualities and the motor stops. In this way, rotation can be managed by a motor driver that controls when electricity is applied to the coil, and for how long. Unlike asynchronous induction motors, where the rotor has a lower rotational frequency than the magnetic field driving it, PM motors are synchronous, meaning the rotor spins at the same speed as the motor’s internal rotating magnetic field. This enables more precise speed control, higher efficiency particularly at lower speeds, and higher power factor. PM motors eliminate rotor conductor losses, have lower Joule losses in the stator (due to lower current), and exhibit flatter efficiency curves. They also run cooler than induction motors, with lower rotor/bearing temperatures resulting in longer insulation and bearing lifetimes, as well as longer bearing greasing intervals (bearing failure is a major cause of motor outage). And importantly, they provide more torque for the same size package (or the same torque in a smaller package). PM motors are suitable for variable or constant-torque applications, where the drive and application parameters dictate to the motor how much torque to produce at any given speed. This flexibility also makes them ideal for variable-speed operation, requiring ultra-high motor efficiency.

SYNCHRONOUS RELUCTANCE MOTORS

Whilst the requirements are clearly stated above, some motor manufacturers are already offering, as standard, superior premium efficiency motors that comply with, or even exceed, the forthcoming IE4 classification. The benefits of this are clear, with a reduction in energy losses ranging from 10% to 24%, as compared to IE3. However, IE4 is typically the highest level of efficiency that can be achieved with a standard squirrel caged motor.

TAKING EFFICIENCIES TO THE NEXT LEVEL The next step in the evolution of motor performance energy efficiency is to offer motors that are IE5 compliant, and some manufacturers are already actively designing, and even producing products that offer this classification. This is being driven by customers who want to achieve the maximum possible efficiencies, as the return in terms of reduced energy usage, and therefore cost savings, cannot be underestimated. Over the lifetime of most applications, energy costs far outweigh motor purchase and maintenance costs. However, if industry requires the ‘ultra-efficiency’ of IE5, then new technologies in terms of motor design, beyond the squirrel caged motor, must be considered. The goal here is to reduce losses further by some additional 20 percent relative to IE4. There are a number of technologies that offer the potential to achieve greater efficiencies and we will take a closer look at two, namely permanent magnet and synchronous reluctance motors:

PERMANENT MAGNET MOTORS Permanent magnet (PM) motors are brushless electric motors that use permanent magnets in the rotor. As opposed to those magnetised by an electric field, permanent magnets, made from rare earth metals,

Synchronous reluctance motors (SynRMs) induce non-permanent magnetic poles on a ferromagnetic rotor, which does not have any windings, and torque is generated through the phenomenon of magnetic reluctance. The stator’s poles are wrapped with windings that are energised, while the rotor’s magnetically permeable steel projections act as salient poles that store magnetic energy — leveraging the tendency of magnetic flux to follow the path of least magnetic reluctance in order to repeatedly align the rotor and stator poles. Until fairly recently, the use of SynRMs has been limited by the complexity of designing and controlling them. But these challenges are now starting to be overcome by advances in the theory and the use of sophisticated computer design tools.

FOR MAXIMUM EFFICIENCY, REVIEW THE WHOLE DRIVE CHAIN SYSTEM Selecting motors that have been designed with energy efficiency as a priority will increase productivity and cost-effectiveness, but there are other important steps to consider and take in achieving the most energy efficient set-up throughout the entire drive chain. The most significant of these is motor control. Optimising motor control using an inverter enables energy savings of up to 60% to be realised. Implementing helical or helical-bevel gearings rather than worm or spiral gears can also have a major impact, and allowing energy efficiencies of 15-40% to be achieved. However, identifying the most significant change an engineer can make to improve the energy efficiency of the drive chain system depends on the application. In a fan or pump application, for example, the most important factor will usually be fitting a variable speed drive inverter. But in conveyor applications, the belt might be the most significant aspect to review, and replacing conventional V-belts with synchronous belts will enable the user to make maximum energy and cost savings.

CONCLUSION The drive for energy efficiency across industries isn’t going to go away; indeed we are likely to see governments continue to impose ever tighter rules and restrictions, in order to protect our environment. As outlined in this article, selecting motors with energy efficient ratings is imperative, but it is only one part of the puzzle. System engineers have to take a deeper holistic dive into the whole drive train system, and look beyond just the motor to realise continued efficiency improvements.

QUESTION & ANSWER

NS FORUM

ESTIONS ANSWERED Is The Motor Efficiency Really The Best Way to Improve Pumping Efficiency? By Julijana Ristov - UK Business Manager LD – Products– Siemens plc Using a high efficiency motor is certainly one way to improve the efficiency of the pump and the motor pump system. However, looking into the overall drive system and the most suitable solutions for an efficient system for the application is always necessary. When a solution is developed for a pump application you need to look into how the pump will be operated. For example, will the pump be required for usage direct on line constantly or will you be looking into using a variable speed drive? If the efficiency of the solution is the driver, you need to be aware of the legal requirements and existing efficiency standards required such as IE3 IE4 efficiency classes. In addition, you need to be aware about future requirements and standards for drives systems i.e motors and drives. At Siemens we have developed products which are perfectly integrated and have been developed so they work together effectively as a system. Working with Integrated Drive Systems, Siemens supplies the only real complete solution for overall drive systems worldwide. All components of the drive train are integrated to create an efficient, complete solution – an integrated drive system, which sets itself apart as a result of its triple integration:

THIS IS A NEW POTENTIAL FOR THE COMPLETE LIFECYCLE EFFICIENCY - especially for

pumps, fans and compressors, Siemens has developed integrated drive systems, where the motor, drive and coupling are optimally harmonised and coordinated with one another. Individuals and businesses all face a number of challenges and one major challenge is climate change and therefore, the sustainable use of energy. With this in mind, a number of initiatives have been brought into the industrial environment to play a part in addressing this challenge. For example, various standards and legislation have been introduced, including efficiency standards / legislation for electric AC motors.

HOWEVER, IF YOU LOOK INTO THE STATISTICS, THE DRIVE SYSTEMS use around 70%

of industrial power. Currently, there are standards and regulations that define the efficiency classes of DOL motors as explained previously. However, there are also future definitions of efficiency classes for converters and systems in the various standards and later, in the appropriate regulations. The new EN 50598 standard defines ecodesign requirements for drive systems used in an electrically driven machine. It is based on the ErP Directive of the EU, which defines minimum standards for products that consume energy in private households, the service sector, as wellas the industrial environment. All products that use an appreciable amount of electrical energy must be evaluated relating to the efficiency and/or the losses. The new standard is based on the concept of the ‘extended product approach’, where the mode of operation of products is taken into consideration when considering their efficiency. This standard was drawn up by the technical committee of the European CENELEC standards organisation of Europump, the Association of European Pump Manufacturers, as well as machine OEMs and motor and drive manufacturers. The objective was not only to address pumps, but all types of driven machines. As a consequence, the new standard contains all of the relevant parameters relating to the energy demand of an electrically driven machine.

With EN 50598, the focus moves away from individual components to the overall system. The energy efficiency requirements have been extended from the individual drive components to include the system, as well as the driven loads. The standard comprises three parts, where the second part is especially relevant in this regard. It specifies indicators to evaluate the energy efficiency of drive and motor systems, and also defines how the losses are to be determined. To keep the associated costs within reasonable limits, a total of eight operating points have been defined. Manufacturers should determine the losses at these eight operating points and document them. Furthermore, components and systems are classified according to specificefficiency classes so, their energy efficiency can be compared. Drives are classified according to IE 0, IE 1 and IE 2 – and drive systems according to IES 0, IES 1 and IES 2. The new standard allows the power losses of inverters and drives to be determined at a reasonable cost under reproducible conditions. This allows users to be able to appropriately compare products. They apply to AC/AC drives not capable of energy recovery and motors with integrated drive in the power range extending from 0.12 up to 1,000 kW and supply voltages from 100 up to 1,000 V. Optionally, the standard can also be applied to AC/AC drives, AC/DC and DC/AC drives capable of energy recovery and a combination of drives and motors. The straightforward, standard system configuration even reduces engineering time and costs, interaction of all of the drive components results in a higher energy efficiency and lower noise levels. Drive train condition monitoring as optional service plays a role in achieving outstanding plant availability across the board.

FURTHERMORE, DIGITALISATION SPARKS A QUIET REVOLUTION in the pump industry

which, could be discussed in the next edition, but it is all about the use of data. How it is monitored, stored and processed across the whole industry from the creation of the pump to its installation and lifecycle of operation. Its impact is potentially profound but, pump manufacturers are still coming to terms with the implications. At Siemens, digital management has become completely integrated into its key oil and gas and water markets with the goal being to maximise performance, efficiency, lifespan and safety through remote monitoring, pre-emptive maintenance and simulated training. Working closely with our clients and pump OEMs, it is clear that, unlike traditional manufacturing where a product is developed and manufactured to meet as many applications as possible at considerable cost in terms of time and money, using digital technology means bespoke solutions can be applied to specific situations if necessary. By continually building data, greater efficiencies can be applied across the board with experience gained from every new project through ongoing development of applications. The potential for digitalisation is seemingly limitless. It allows for the collection of vast amounts of data to be applied to even an individual pump or to create bespoke solutions for specific areas of operation. The future will no doubt provide further breakthroughs in service and efficiency as the quiet revolution continues.

This was the 17th year of the Pump Industry Awards and it was considered by many to have been the best ever. Whether it’s recognising companies and individuals who go the extra mile or acting as a motivator to encourage more companies to fulfil their potential, the core values of the awards have not changed over the years. This year’s Pump Industry Awards Gala Dinner was held on March 23rd at the splendid Crowne Plaza Hotel, Heythrop Park on the fringe of the Cotswolds, for the second consecutive time. The awards ceremony was the feature of the evening, hosted by the delightful TV & Radio Presenter, Anna Williamson and held in association with the BPMA and sponsored by Process Industry Informer, KSB, SPP Pumps, WEG, Siemens, Tomlinson Hall and World Pumps. The eight delighted winners were presented with their trophies & certificates to the cheers & jeers’ whilst the finalists also were awarded their certificates on the stage. The after dinner entertainment was from the fantastic young ladies who comprised the Siren String Quartet, the raving cheers and lasting applause said it all. Finally, there was the usual Charity Raffle to raise money for WaterAid, which raised a magnificent £3100. For further information about the Pump Awards & view the photo gallery please visit www.pumpindustryawards.com. If you are interested in sponsoring, nominating and/or attending the 2018 event contact Andrew Castle at Andrew@touchwavemedia.co.uk

MEET THE WINNERS

The awards focus on key areas of manufacture and supply, including innovation and achievement, energy saving, engineering excellence, customer care and employee motivation. On the night, six companies and two individuals were awarded, and a fantastic night was had by all!! TECHNICAL INNOVATION – PRODUCTS SPONSORED BY: PROCESS INDUSTRY INFORMER WINNER: SUNDYNE HMD KONTRO VAPOURVIEW®

VapourView® is a revolutionary condition monitoring instrument that broadens the scope of sealless pump technology extending its economic and environmental benefits to wider applications. Hazardous area certified, VapourView® can be applied where sensitivity to vapourisation is critical (e.g. hydrocarbon pumping). Non-invasive, VapourView® provides a real time ‘window’ on the pumped medium, signalling any significant gas content in the liquid. Subsequent remedial system changes eliminate safety risk, maximise up-time and extend the life of capital equipment. TECHNICAL INNOVATION – PROJECTS SPONSORED BY: KSB WINNER: TRIARK AODD PUMP USED IN FOAM CONCRETE APPLICATION By using an AODD pump at its heart, Triark developed a pneumatic ‘foam generator’ that was able to produce the same sort of foam that Celcon use in the factory production of its building blocks, but in a more liquid form to enable onsite mixing and pouring of lightweight foam concrete to fill landfill sink holes. Attached to the side of the cement mixer, allowing use of the on-board compressor and water tanks, appropriate volumes of water and foaming agent are drawn separately into the integral AODD Pump, which mixes them in the correct ratio to produce the pre-foaming solution. ENVIRONMENTAL CONTRIBUTION OF THE YEAR SPONSORED BY: SPP PUMPS WINNER: SIEMENS INSTALLATION OF VARIABLE SPEED DRIVES ON MARCHWOOD POWER STATION MAIN COOLING WATER PUMPS Marchwood Power Station is located near Southampton on the Solent estuary and in 2015, they contracted Siemens DF& PD to convert three mechanically throttled pump systems on the plant cooling water intake system to variable speed flow control. On completion of the project, the power station has seen significant energy savings and a dramatically improved station power output (more MW’s for the same fuel usage) based upon optimised cooling.

MANUFACTURER OF THE YEAR SPONSORED BY: SIEMENS WINNER: NEPTUNO PUMPS World-class designer and manufacturer with over 44 years of experience delivering custom engineered, innovative and sustainable pumping solutions for highly abrasive and corrosive applications. Recognised by the World Economic Forum as a pioneer in the circular economy, Neptuno Pumps has adapted its capabilities to reduce, reuse adn recycle its customer’s waste through remanufacturing and redesigning as well as reducing their CO2 emissions through energy efficient pumping solutions, redefining the relationship between end-user and manufacturer.

DISTRIBUTOR OF THE YEAR SPONSORED BY: WEG WINNER: TOMLINSON HALL & CO. Founded in 1919 Tomlinson Hall’s extensive engineering expertise ensures they provided full service solutions to customer’s challenges. 2016 saw the firm at the forefront of offering innovative new services to industry, including Pump Energy Check reports in partnership with Grundfos Pumps, whilst also continuing to invest heavily in staff training. As a manufacturer of its own pump “Liquivac” in addition to global distribution for other brands, Tomlinson Hall understands technical challenges from a manufacturer’s perspective, which greatly strengthens the service offer to end users. ENGINEER OF THE YEAR SPONSORED BY: WORLD PUMPS WINNER: JAMIE MILLS XYLEM WATER SOLUTIONS Jamie, Systems Engineer at Xylem Water Solutions is a dedicated member of the BIM4Water steering group who specifically explores water industry information exchange and standard product data template creation. With a strong interest in emerging technologies he pioneered techniques of additive manufacturing in hydraulic pump modelling. In 2015 Jamie proposed a concept which aims to predict the optimum time to service or replace pumps by mathematically predicting their performance degradation.

SUPPLIER OF THE YEAR SPONSORED BY: TOMLINSON HALL & CO WINNER: ABB As a supplier to the pump industry, ABB goes the extra mile to deliver innovation and value to its organisation and customers. This goes far beyond providing the consistently high levels of technical innovation, environmental awareness, market penetration and growth are the company’s objectives. With its focus on delivering best practice and leading-edge ideas, ABB continues to push the boundaries of technological achievement, with particular emphasis on helping its customers to explore and unlock the opportunities offered by industry 4.0. 06

training THE LIFETIME ACHIEVEMENT AWARD AT THE PUMP INDUSTRY AWARDS – A MAN OF DETERMINATION Brian Huxley is a qualified Training Officer, whose career started in the early 1960’s as a commercial apprentice with GLYNWED. He went on to hold several training positions, before leaving the company in 1974 to become Group Training Officer for METCOM – a Federation of Mechanical and Engineering Trades. He held that position until 1978 when he was promoted to Regional Manager. From his humble beginnings at METCOM he progressed to Regional General Manager, then Assistant Director, then Director and eventually to take on the role of Managing Director. In 1993, amongst his other roles within METCOM, Brian was also asked to take on a Trade Association which was at that time operating with a part time General Secretary and a part time Technical officer. It was from there that our recipient began the restructuring of the BPMA. As a Director of the BPMA, he has been responsible for introducing and creating many of the services that are available to members today, such as the Buyers Guide, Newsletters, BPMA Training and the World Pump Report. In 1998 he insisted that the BPMA employed a full time Technical Director, to oversee and further develop that important aspect of the Association’s service offering. Under his Directorship the BPMA became one of the first Trade Associations to have a website and to offer membership to suppliers of the industry, something that has been copied by many others since. In 2009, in order to safeguard the interests of both members and staff, he instigated the BPMA’s transition to a limited company. Over the years, he stabilised the finances and developed a healthy balance sheet, enabling the role of BPMA Director to be passed onto his successor, Steve Schofield, in 2013. An accomplished diplomat, well known for his calm and measured approach, he is recognised throughout the UK and Europe as a true Ambassador for the UK Pump Industry. In view of this outstanding dedication, Brian is a worthy winner of this year’s PIA Lifetime Achievement Award.

VAPOURVIEW® WINS INNOVATION ACCOLADE SUNDYNE HMD KONTRO COLLECTS PRESTIGIOUS PUMP INDUSTRY AWARD VapourView ® from Sundyne HMD Kontro has won a prestigious accolade for innovation at the British Pump Industry Awards 2017. Defying stiff competition, VapourView ® , the company’s revolutionary sealless pump condition monitoring instrument, won the coveted award for Technical Innovation of the Year (Product). Martin Stuart, Product Development Manager, was delighted to collect the award on behalf of Sundyne HMD Kontro Sealless Pumps at the ceremony: Whilst our technical team foresaw that the development of VapourView® would broaden the scope of sealless pump technology, we did not envisage the honour of winning this internationally renowned award for innovation. “Gaining such a prestigious accolade has confirmed VapourView® as a groundbreaking gas detection device. We look forward to further introducing sealless magnetic drive pumps to new audiences who can now benefit from lower maintenance costs, enhanced health and environmental safety, leak-free operation and long life durability.” Developed by HMD Kontro and launched with cUL harzardous area certification in mid-2016, VapourView ® provides vital information to the end-user on the presence of gas in a pump’s internal flow regime and forewarns of adverse conditions likely to affect bearing lubrication or magnetic coupling cooling in a sealless magnetic drive pump. Non-invasive, VapourView ® , provides a real time ‘window’ on the pumped medium, signalling any significant gas content in the liquid. This information permits remedial system changes to be made, eliminating safety risk, maximising up-time and extending the life of capital equipment. Founded by the British Pump Manufacturers Association (BPMA) in 2000, the importance of the Pump Industry Awards programme has grown steadily to become the recognised platform for celebrating significant industry achievement. For further details about VapourView ® and the Sundyne HMD Kontro sealless pump range, please visit www.sundyne.com/hmdkontro.

THE ENGINEER BEHIND THE ACCOLADE As part of a series of interviews with individuals who have chosen career in the Pump industry, here we talk to Jamie Mills, winner of the ‘Engineer of the Year Award’ at the recent 2017 Pump Industry Awards. Q1. EDUCATION: When did you first become aware that you wanted to be an engineer and how did you approach this career path (University, Apprenticeship, other)? From an early age I’ve always had a keen interest in science technology and engineering, to some degree I think my father, who is a physicist, may have influenced this. After leaving school I worked on the tools as a kitchen fitter and carpenter. I really enjoyed my time on site but felt the wear on the body would get the better of me in later life so I made the decision to retrain as an engineer, taking a full time degree at Aston University in electromechanical engineering. Q2. CAREER CHOICE: When and how did you decide on a career in Pumps? My first encounter with pumps and turbomachinery was at university on the fluid dynamics module. I had a very keen interest in fluid systems and the way in which we can mathematically predict the behaviour of pumps within a system. Whist studying I took a placement with Xylem working with the Flygt brand, which allowed me to pursue a ‘final year project’ measuring pump flow rates using LASER technology. Having enjoyed this I returned to Xylem as a Trainee Systems Engineer. Q3A. WORK Is there an average day for you and if so what does that involve? My primary job function is to support the Xylem UK sales team on complex pumping and pump system issues. The jobs I get involved in can range from studying rising main profiles and developing system curves to in depth energy analysis. Alongside this I also look after Xylem’s interests in building information modelling (BIM) where I also chair the BIM4Water Standard Libraries Group; we are specifically looking at data exchange within the water industry and how we can facilitate this for our clients going forward. Q3B. What do you enjoy most about this industry and your role in it The water industry forms a key part of the day to day life. I feel at this present time we are on the verge of a technological leap forward with lots present time we are on the verge of a technological leap forward with lots of intelligent new systems and products. This is very exciting and presents great opportunities for engineers. Q4. PIA What was it that you think, made you a finalist in this year’s Awards and how did it feel to win? Over the past couple of years I have been working hard to ensure Xylem and other manufacturers within the water industry can deliver the correct information required by owner operators and members across the supply chain to make BIM happen. For us all to see the benefits of good information management someone needed to carry this forward, and with support from my management team, I have been pushing this vision hard. Other involvements that I’m particularly proud of include my work with emerging technologies and additive manufacturing for pumps. Winning the award was a very proud moment for me! Better still, I got to share the achievement with my grandfather who sadly passed away shortly afterwards. He too was an engineer and a great inspiration to me. 5. CPSA You are CPSA accredited, has this helped you in your work or contribute to any aspects of your work? Yes very much so, I will regularly look at a machine’s energy characteristics - efficiency and unitisation when making pump selections. Having a practical working knowledge of pump performance and their understanding pump performance testing in accordance with ISO14414allows me to capture data with confidence and deliver a qualified energyanalysis. But of course more importantly it gets me out of the office for onsite testing; something I enjoy from my days on the tools. Jamie Mills is a Systems Engineer with BPMA member company, Xylem Water Solutions.

training

industry news

LET BPMA HELP WITH YOUR PUMP SELECTION

THE WEEE2 DIRECTIVE (WASTE ELECTRICAL & ELECTRONIC EQUIPMENT 2012/19/EU) WILL COME INTO FORCE IN THE UK IN AUGUST 2018

Old pumps not only consume too much energy, they are also prone to failure which can adversely affect your maintenance budget and in turn your business. By replacing them with new, correctly sized, energy-efficient pumps, you will enjoy reliable, low-cost pump operation. As a way of helping to undertake that all-important pump selection the BPMA has developed a Pump Search Engine, which is available for anyone to use. This easy to use online search facility can be readily accessed via the existing BPMA website www.bpma.org.uk.

Under the existing WEEE Directive, pumps (other than garden pumps) have NOT been included within scope. However, this first revision of the Directive has now brought into play many products that were previously out of scope, including pumps. Following a meeting between BPMA, BEIS (Business, Energy & Industrial Strategy) and the Environment Agency in July 2016, which was convened to clarify whether ‘pumps’ should be within the scope of WEEE2, it was agreed that the BPMA would produce and submit its own ‘position paper’. This course of action was determined primarily because BEIS had been overwhelmed with the amount of items that required clarification, but also because BPMA was best placed of draft such a document, given its in depth knowledge of the subject matter. As such, and having formed a dedicated Working Group to fully assess the Commission Guidance documents for both domestic and non-domestic pumps, the BPMA produced and submitted its proposals. Unfortunately, due to a number of factors, the initial draft of the ‘position paper’ was rejected by BEIS & the Environment Agency and so the BPMA were asked to revisit certain aspects and re-submit a second draft in due course. This was duly done but our revised position paper was not accepted at a further meeting in December 2016 and neither the UK Government or Environmental Agency would give a blanket exclusion on pumps for WEEE2. They recognised some of our statements such as fixed installations and professional installers may be used on some types of pumps but said these statement could not be used across all pumps. Many topics were discussed such as ; · pumps with couplings and pumps without couplings · domestic pumps & industrial pumps . who places the finished product on the market? . bare shaft pumps . motors and who is responsible for the motor The conclusion was that the pump industry needed to come up with a set of principles/scenarios And then have groups of pumps which will be in WEEW2 and out of WEEE2. Both BEIS and the manufacturers. They needed something that was simple that could be used by all. Accordingly the BPMA Working Group met again and produced amongst other things a Flow Chart to assist in clarifying compliance.... Regrettably at a further meeting in May 217 the BPMA proposals were again rejected and accordingly further guidance from Government is now awaited.

HOW TO USE THE PUMP SEARCH

There are two ways to search for your perfect pump and its supplier: Search One: You know the type of pump you need If you know the type of pump you are looking for, you just need to click on the Pump Type drop-down menu, select your Pump Type then click Show Results. This will offer you a list of BPMA members who will be able to supply this type of pump. Search Two: You know the application, but not the pump type If you are not sure of your Pump Type, but know what it will be used for, simply click on the Pump Application drop-down menu, select your application and then click Show Results. This will offer you a list of BPMA members who can supply pumps suitable for that particular application. If your initial search delivers a large number of potential suppliers, it can be further refined by selecting extra parameters from the options available in the left hand column. Only BPMA members are displayed on this search engine and all BPMA members have agreed to adhere to the BPMA Code of Conduct, so you are assured of high quality, fully compliant, energy efficient pumps on every selection. You can now use the Pump Search to easily find the correct pump for your requirements and then knowingly “Buy with Confidence” from a BPMA Member.

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

economic update ECONOMIC VIEWPOINT – GLOBAL AND UK (MAY 2017) Oxford Economics We have raised our world GDP growth forecasts by a percentage point to 2.7% for 2017 and 3.0% in 2018. Similarly, we have lifted our inflation forecast for this year to 3.1%. Surveys continue to suggest buoyant global manufacturing activity. The global manufacturing PMI slipped slightly In April, but remains near three-year highs. Encouragingly, all main product groups - consumer, intermediate and capital goods – have registered solid increases. Indeed, the acceleration in intermediate goods production could signal stronger growth in the months ahead further down to the supply chain. In addition to a buoyant PMI reading, our own monthly export indicator shows another acceleration in March, which points to further support for manufacturing activity. But there are reasons for caution given there are still underlying factors holding back demand. Large uncertainties around our central forecast persist given the unpredictability of President Trump’s policies, and markets have tempered their initial enthusiasm regarding the success of ‘Trumponomics’. The Eurozone economy remains resilient amid key elections in the Netherlands, France, and Germany. Our view remains that populist fears are overstated, which is only reinforced by the victory of Emmanuel Macron in the second round of the French presidential election. Many emerging markets have started 2017 with positive momentum, but caution remains the name of the game as the Fed prepares to raise rates faster than previously expected and the future of US trade policy remains uncertain. In the UK, we have nudged down our forecast for 2017 GDP growth from 1.9% to 1.8% following a disappointingly weak outturn for Q1. After displaying a surprising degree of resilience last year, consumers now appear to be retrenching in the face of higher inflation, while other sectors of the economy have thus far struggled to fill the void. UK business investment faltered badly in 2016, falling by 1.5% for the year overall after growing 5.1% in 2015. Although the corporate sector continues to enjoy a strong financial position, Brexit-related uncertainty is likely to persist with some firms set to postpone capital spending until the UK’s future trading relationship with the EU becomes clearer. Capital spending is likely to expand just 0.4% this year and 1.6% in 2018. Markets reacted favourably to the announcement of a snap election on June 8, reasoning that a large Conservative majority would make it easier for May to win parliamentary support for the final Brexit deal and offer her greater flexibility to make the concessions required to agree a deal with the EU. We concur with this view and it has strengthened our conviction that the most likely Brexit outcome will be a three-year transitional arrangement followed by a free-trade agreement.

industry compliance As part of the UK leaving the EU, the Government will introduce the so- alled “Great Repeal Bill” which will repeal the European Communities Act 1972 and transpose European Union law into domestic law, where practical. The estimates are 63,000 pieces EU law will need to be reviewed . This is needed because some types of EU legislation have never had to be formally written into UK law before. In other cases, EU legislation has been transposed into UK legislation either by statutory instruments or primary legislation. A vast amount of UK legislation therefore contains references to the EU Treaties, other EU bodies with regulatory functions. The government will also be able to consider opportunities for regulatory flexibility once the UK leaves mnthe EU. Government must work to ensure as much stability and comparability on regulation and standards as possible post Brexit is achieved. We still awaite clarity on what will replace the existing CE mark in the UK that is currently placed on products . The BPMA Currently advise members on specific changes with the following EU Directives; 1. Directives ; ◦ ATEX 2014/34/EU 2. ◦ Pressure Equipment 2014/68/EU 3. ◦ Machinery 2006/42/EC 4. ◦ Outdoor Noise 2005/88/EC 5.◦ EMC 2014/30/EU 6. ◦ EMF 2013/35/EU 7. ◦ Low Voltage 2014/35/EU 8. ◦ Drinking Water 98/83/EC 9. ◦ Chemical (Reach) 2016/217/EU 10 ◦ WEEE 2012/19/EU ◦ ROHS 2011/65/EU 11. ◦ IPPC 96/61/EC 12. ◦ ErP (Energy Related Product) 2009/125/EC 13. ◦ Energy Labelling Directive 2010/30/EU 14◦ Energy Efficiency Directive 2012/27/EU 15. ◦ Energy Performance of Buildings 2010/31/EU 16. ◦ Construction Products Regulation 305/2011Whilst there is no imminent actions required we advise the following updates received from the European Commission. Whilst there is no imminent actions required we advise the updates received from the European Commission. For more informatuon contact Steve Smith at BPMA on Tel: 0121601 6691 or e-mail s.smith@bpma.org.uk

bpma news KSB TO SUPPLY PUMPS & VALVES FOR NEW HINKLEY POINT C NUCLEAR POWER STATION The KSB Group has received orders amounting to just under € 30 million to supply pumps and valves for the new Hinkley Point C nuclear power station. The power station on the Severn Estuary in South West England involves the construction of two new units equipped with EPR reactors and is due to be completed by 2025. The German pump manufacturer will supply four vertical, multistage barrel pull-out pumps of the RVM 80-265 series, including motors and further accessories as well as a spare parts package by 2020. Crucial for winning this order was the tight cooperation between the German- based KSB AG and the Chinese joint venture SEC-KSB. These specialist pumps are being constructed for handling water for the primary cooling circuits in each reactor. KSB’s Luxembourg-based subsidiary SISTO Armaturen S.A. will supply some 6,000 SISTO-20NA and SISTO-KRVNA diaphragm valves and vent valves by the end of 2019. Receiving the go-ahead for this contract was largely due to the good experience the operators have enjoyed with these valves in the three other EPR reactors. Furthermore, KSB S.A.S. France and the KSB Aktiengesellschaft factory in Pegnitz, Germany will also deliver numerous lowpressure and lift check valves by the end of 2021. The overall cost for the extension of the Hinkley Point nuclear power station is estimated to amount to more than € 20 billion. The two new reactors are scheduled to go online in 2025 and have a planned service life of 60 years. The aim is for the power station to cover seven percent of the UK’s power requirements. For more information contact KSB Ltd, Tel: +44 (0) 1509 231 872 E-mail: sales@ksb.com Web; www.ksb.com

BUY WITH CONFIDENCE – AND ENJOY PEACE OF MIND The UK pump industry, through the auspices of the British Pump Manufacturers Association (BPMA), has over recent years been working closely with the UK Government and the European Commission, along legislative programmes dealing with product safety, environmental impact and energy reduction. The BPMA continues to invest in this activity for the benefit of the sector, its customers and most importantly, pump users. In support of this work and the massive investment manufacturers have made in this area, the BPMA created a ‘Code of Conduct’ for its members, where compliance with all relevant European and/or UK legislation is a major requirement. Therefore, by choosing to deal with BPMA members, you are assured that the products and services supplied are fully compliant across all the given parameters. Many people may not be aware that it is not just the manufacturer who is responsible for compliance, but that suppliers and installers of pumps and pump systems must also play a part when placing products onto the UK market. This especially applies if the products supplied are ‘own branded’ or ‘packaged’. In view of the tremendous cost burden placed on the pump sector through implementing the legislative programmes, the BPMA, on behalf of its members, are keen to ensure that every product placed on the market in the UK is fully compliant. As such, we are already working with the UK Market Surveillance Authorities to ensure that this is the case. The BPMA, and its members, will take every action required (and available to them), to stop non-compliant products entering or being placed on the UK market. The BPMA is proud to promote the “Buy with Confidence” from a BPMA member ethos and indeed its new Advisory Service, which seeks to assist companies in achieving appropriate compliance with current legislation.

bpma news HEAVY DUTY CHOPPER PUMPS FOR INDUSTRIAL PROCESS APPLICATIONS With T-T’s 57 years’ experience they have vast knowledge on the challenging fluid handling problems in the process industry. T-T’s range of heavy duty chopper pumps have been designed to tackle the tough industrial processes. The ETO, ETV and PTS range of heavy duty chopper pumps have a double chopping anti-clogging performance. The first chopping system consists of two chrome steel blades secured on the body inlet, acting in contrast to a spiral conveyor made from high grade cast iron and fitted to the motor shaft. The second chopping system consists of a shear cutting plate in special high grade cast iron, the cutting edges of the high grade impeller maximise the cutting action against the cutting plate. With a maximum speed of 2900 rpm, this is the only chopping system that operates at over 170 cuts per second! Each pump in the range is ideal for particularly heavy applications that require a preliminary chopping of the solid material suspended in the liquid being pumped. The PTS range is a submersible heavy duty chopper pump. The ETO is an electric horizontal version which is mounted on a frame and coupled with a standard starter electric motor by a flexible coupling, and the ETV is a vertical option of the chopper pump range. The ETO, ETV and PTS range of heavy duty chopper pumps are available in a Nitec anti-corrosive coating for protection against aggressive liquids, making them the ideal choice for industrial applications. For more information visit Web: www.ttpumps.com or call Tel: 01630 647200.

STUART TURNER INTRODUCE FLOMATE IBOOST, THE ULTIMATE SOLUTION TO LOW MAINS WATER PRESSURE Flomate iBoost has been developed to boost the mains supply to larger properties with multiple bathrooms, using high flow combination boilers or an unvented cylinder system, where higher pressure and flow are required. This fully integrated system combines a 200 litre cold water break tank which overcomes restricted mains water flow with a high performance multi-stage pump to dramatically boost pressure. Flomate iBoost is capable of delivering water up to 4.5 bar and flow rates in excess of 100 ltrs/min and is designed to sit alongside other appliances within a kitchen or utility room or can be concealed within any standard 600mm kitchen larder cabinet. For more information contact Stuart Turner Ltd, Tel: 0141 637 7141 E-mail: info@spumps.co.uk Web: www.stuart-turner.co.uk

BPMA NEWS

BPMA STAFF ROLES ANNOUNCEMENT

GET YOUR PUMPS HEALTH CHECKED

After 24 years as a Director of the BPMA Brian Huxley has decided to retire on the 30th June 2017 . When Brian took over in 1993 the association was run by part time staff. From 1994 -1998 he rebuilt the association moving from 1 part time to 3 full time staff with new services and resources to ensure the BPMA would continue to grow . I am sure you will all join me in wishing Brian a long and healthy retirement As part of a restructure within BPMA Steve Smith will be promoted to Assistant Director commencing 1st July 2017 . All existing contracted external resources that support our Brian Huxley Training, Web, Marketing, Economic, PR and Accounting functions will be maintained, and the Board will continue to work with Steve Schofield and his team to ensure that optimum levels of service are maintained to members during the changeover and beyond. We are sure that you will welcome the changes and join me in congratulating Steve Smith in his new position

Steve Schofield Peter Reynolds BPMA President

Steve Smith

Older pumps not only consume too much energy, they are also prone to failure that can adversely affect your business and your maintenance budget. By replacing them with new, energy-efficient pumps, you get reliable, low-cost pump operation. This is what a large office building in central London did when they replaced obsolete pumps with new, energy-efficient models following a Grundfos Energy Check. The pumps now operate to meet the actual demand, and the new pumps are delivering a saving 318,000 kWh per year after they followed through on recommendations they received having undertaken a Grundfos Energy Check. This amounts to a massive saving of ÂŁ30k p.a., a large reduction in CO 2 emissions and a payback of just 2.8 years. Grundfos are typically able to achieve savings of 30-50% for customers with an Energy Check. As they point the way towards the optimal pump replacement that provide great energy savings. In addition, you will achieve reliable operation, reduced downtime and reduced repair costs. The result: greatly improved system reliability. Visit www.grundfos.co.uk to learn more.

BPMA NEWS

QDOS PUMP REPLACES THREE DIAPHRAGM PUMPS AT MAJOR WATER TREATMENT PLANT · Qdos 30 pump proves ideal for dosing phosphorous coagulant iron III chloride · Maintenance time and spare parts reductions help deliver rapid ROI · More Qdos applications now planned at this plant and others in the company The water treatment plant at Riepe, in the East Frisia region of Lower Saxony, has replaced three diaphragm pumps with a Qdos series peristaltic pump fromWatson-Marlow Fluid Technology Group (WMFTG). Dosing phosphorous coagulant iron III chloride for over a year, the Qdos 30 pump has not only cut capital equipment costs, but introduced significantly reduced maintenance and repair costs. The Oldenburgisch-Ostfriesischer Wasserverband (OOWV) is a regional water association in the East Frisia region of Germany that not only supplies clean drinking water, but purifies the waste water from more than 500,000 people through 46 water treatment plants. “Besides household waste water, we also have a relatively large amount of waste water from industrial areas,” explains Plant Manager Klaus Janssen. “For this reason, the phosphorous levels in the inflow water are relatively high, at around 15 mg/l on average. However, our prescribed phosphorous limit at the point of entry is 2.0 mg/l, although we are in fact striving to not exceed the target limit of 0.5 mg/l.” DIAPHRAGM PUMP ISSUES In order to achieve this reduction, the waste water facility uses chemical coagulation, which converts the phosphate solution in the water into insoluble phosphate compounds that can then be isolated. At Riepe, one diaphragm pump supplied the coagulant

from underground storage containers into the holding tank, with the actual dosing handled by two further diaphragm pumps – one in constant use and one in standby mode in the event of a failure. Indeed, failure was an increasingly common outcome as the pump diaphragms were often corroded by the chemical coagulants, making replacement necessary. “The diaphragm pumps also produce a strongly pulsating flow which, after some time, would lead to signs of wear and tear on the fittings and valves,” says Mr Janssen. “The maintenance work started amounting to several hours per month; moreover, we had to hold a whole range of spare parts in stock, including diaphragms and valves.” A further problem with the diaphragm pumps was suction. Air would be drawn in, which could jam the valves meaning that the diaphragm pumps were unable to prime and pump. As a result, the phosphorous limits discharged from the plant increased and, in the worst case, meant that the relevant authorities had to be notified. To avoid this, emergency operations at night or during the weekend were becoming more frequent. The problem occurred most often whenever the stock of coagulant was replenished. Here, the chemical dosing lines had to be manually flooded with water to enable the diaphragm pumps to operate. HIGH PHOSPHATE LEVELS? NO PROBLEM The new Qdos 30 peristaltic pump at this site doses at 150ml/ min, although it offers a maximum flow rate of 500ml/min – more than enough for occasions when there are high phosphate levels in the water. The single Qdos pump is able to draw the iron III chloride directly from the storage tank, which means

that a holding pump, the standby pump and, the holding tank, plus associated float switches and electronics, are no longer necessary “While the accuracy of the diaphragm pumps declined over time as the diaphragms became corroded and worn, the Qdos pump is extremely accurate, so we’ve able to reduce the frequency of recalibration.” COMPLETE RELIABILITY In total, Mr Janssen estimates that the Qdos pump has led to an impressive time saving of between two and five hours per month. “By relieving us of this workload and the saving on spare parts, the investment has paid off very quickly.” For more information please contact Watson-Marlow Fluid Technology Group, Falmouth, Cornwall. Tel: 01326 370370 E-mail: info@wmftg.co.uk Web: www.wmftg.com

BPMA NEWS

Albany Pumps

INTRODUCING THE FIDC™ SEAL – THE NEXT GENERATION OF HIGH PERFORMANCE SEALING SOLUTIONS Developed using the basis of the proven CDSA™ cartridge double mechanical seal, AESSEAL® are pleased to announce the availability of the FIDC™ (Flow Induced Dual Cartridge) seal. The FIDC™ boasts improved barrier fluid flow through a unique integral pumping device. This is designed to increase and direct barrier fluid towards the seal faces keeping them cool, therefore leading to even further improvement on reliability in the process. Available in a range of different materials from standard stainless steel to other exotic alloy materials, this makes the FIDC™ compatible with a whole host of process fluids including the special demands of corrosive fluid containment. Additionally, the FIDC™ has self-aligning seal faces keeping them square to the shaft whilst also being hydraulically pressure balanced to ensure excellent sealing. With its modular design, the FIDC™ is easy to install and can be easily adapted to different applications. AESSEAL® is one of the worlds leading specialists in the design and manufacture of mechanical seals, bearing protectors, seal support systems and gland packing. AESSEAL® has 230 locations worldwide, supplying customers in 104 countries, and employs a global network of sales engineers and technical support specialists. For more information, visit our website www.aesseal.com or call 01925 741111

ITT GOULDS PUMPS – INNOVATORS FOR OVER 160 YEARS INTRODUCES i-ALERT2 The i-ALERT Equipment Health Monitor is a Bluetooth Smartenabled machine health Monitor that allows customers to identify potential equipment problems before they become costly failures. ITT’s ALERT2 tracks vibration, temperature and run-time hours and wirelessly syncs the date with smartphone or tablet through the i-ALERT2 mobile app. This condition monitor combines the latest in Bluetooth low-energy and sensor technologies commonly used in the newest consumer health and fitness trackers and smart watches. It is the first condition monitor to successfully integrate these technologies into an industrial package in a small footprint for [2.24 in. (L) by 1.54 in. (W) by 1.40 in. (H] which is half the size of a credit card. It is engineered and rated for use in a wide range of industrial environments. It is chemical resistant, rated for extreme temperatures (40 to 183 F) and is rated to operate in environments with explosive gases, dust and fibres. With 24/7 monitoring, a wireless range of up to 100 ft and the abitlity to scan multiple i-ALERT2 devices at once with a mobile device, customers will be able to quickly and safely inspect multiple pieces of equipment and be alerted of potential problems before they become critical failures. Through mobile app, customers can now view real-time and historical data, diagnostic information and machines records. This provides them with the data necessary to make informed decisions. Customers can now spend less time collecting data and more time saving problems. The i-ALERT2 is fitted as standard to Goulds ANSI and ISO process pumps and comes with a 5 year warranty.

For more information contact: Tel: 01297 639100 www.gouldspumps.com www.ittproservices.com

A N E M P LOY E E O W N E D CO M PA N Y

A fresh approach from Albany Pumps

Albany Pumps makes a wide range of reliable and robust standard, customised and specialised positive displacement pumps. If you require an external gear pump, a twin screw pump or an internal lobe pump, we think you’ve found the right place: • 100+ years of experience and British manufacture • Employee ownership with a Trust to guarantee longevity • CNC production plant in Lydney, Gloucestershire • Service and repair centre in Bradford, West Yorkshire • Standards for every industry ATEX, CE, BSI, VdS and API • 100+ countries sold to worldwide • Over 10,000 proven application stories NEW

BROCHURE

NEW

WEBSITE

NEW

ONLINE QUICK PUMP GUIDE

NEW

CONFIGURE A PUMP SERVICE

Download your essential guide to Albany Pumps now: www.albany-pumps.co.uk

Contact Sales on +44 (0) 1594 842 275 sales@albany-pumps.co.uk www.albany-pumps.co.uk 13

BPMA NEWS

THE ESSENTIALS FOR POWERFUL PUMPS Pumps are absolutely central to minerals processing, transporting the process liquid through the entire wet cycle. Therefore, choosing the right pump for the job is essential to avoid unnecessary and costly interruptions to the process. Harvinder Bhabra, Pumps Senior Product Manager at Weir Minerals Europe, discusses how the latest generation of pumps is achieving a longer lifespan alongside ease of maintenance and enhanced efficiency.

Whatever the application for your pump may be – whether it is mining or quarrying – reliability, ease of maintenance and efficiency are all essential. In general, the process of mining is delving deeper, which necessitates more powerful pumps. The type of pumps used may change from single-stage centrifugal models to configurations of up to six or seven pumps in order to move liquid across greater distances and increasingly higher heads. Another factor to consider is the strict regulation surrounding various processes. In the minerals processing industry, for example, the drive to recycle water and reduce waste has introduced additional stages into the process, to ensure maximum water conservation. Such regulations have intensified the focus on keeping the process and all equipment functioning correctly and efficiently. Weir Minerals has responded by developing pumps that are more efficient, easier to service and operate longer between repairs. Employing the latest computer-aided design and simulation techniques and advanced engineering methods, Weir Minerals is rising to the challenge of fulfilling these requirements.

REINVENTING THE WHEEL

NEW AND IMPROVED

It is necessary for manufacturers to examine their existing designs and update their most widely used models. Using state-of- the-art techniques, Weir Minerals research and development teams are committed to designing new pumps that will out-perform their predecessors in terms of wear lifespan, safety, ease of maintenance and efficiency. Weir Minerals used Computational Fluid Dynamics (CFD) software to create 3D performance analysis models that helped refine the impeller and volute design of the Warman® AH TM pump. This technology identified areas that would normally experience excessive wear and enabled the team to design features to combat this issue and improve performance as a whole. The engineers who designed the pump took into account the full range of slurry mixtures them new pump would be expected to handle, while also analysing its energy consumption data. In trials, performance of the new product – the Warman® WBH® pump – was found to be vastly superior to the previous design, the Warman® AH™ pump. Wear life, ease of maintenance and energy consumption were studied in a variety of applications, with the new model exceeding every expectation. One field trial was conducted on an aggressive china clay application in the UK. On average, the existing Warman® AH™ pump lasted around 2,200 hours before requiring a complete overhaul of the wet end – not an unreasonable figure for this type of application. However, the Warman® WBH® pump achieved 6,700 hours before worn parts required replacement, more than three times the duration, with no noticeable loss of efficiency and minimal ongoing maintenance. Another field test saw the Warman® WBH® pump used on a cyclone feed application in the sand and aggregates sector. Again, it outlasted the existing pump by a compelling margin whilst consuming approximately 15 percent less energy.

Weir Minerals’ latest generation of pumps boasts a number of unique features that offer improved performance, including an adjustable throatbush, which addresses one of the most common wear areas within slurry pumps. Adjustment of the gap between the throatbush and impeller is one of the most regular maintenance operations, to reduce slurry recirculation which accelerates component wear. The development of a single point adjustment feature that is quick and easy to use without disruption to pump operation is a significant asset. Other improvements include a four-vane impeller that offers superior slurry guidance and a smoother flow through the pump, which in turn leads to improved wear life and better efficiency. Evolving existing pump designs and materials looks set to continue, alongside an emphasi on regular condition monitoring, to ensure equipment is able to deal with increasinglyrigorous demands without costly stoppages or consuming too much energy.

THE CASE FOR AN UPGRADE Weir Minerals’ latest generation of pumps has been created in response to a need for operators to get the very best performance out of their pumps. In the mining industry in particular, where the reliability and stability of the process is central to delivering the profit margin, operators need to think carefully whether to upgrade to the latest process equipment. The case to upgrade is a compelling one when a more reliable, modern pump might allow them to run their process harder and longer, more efficiently and, as a result, more profitably.

For more information contact Harvinder Bhabra, Weir Minerals Europe Ltd, Todmorden, Lancashire. Tel: 01706 814251 E-mail: sales.uk@weirminerals.com

NEW SERIES OF CIRCUIT BREAKERS FROM WEG PROTECTS EQUIPMENT AND PREVENTS DOWNTIME WEG, a leading global manufacturer of motor and drive technology, has launched the DWB series of modular circuit breakers that can reliably interrupt shortcircuit currents up to 80 kA at 415 V to protect plant, equipment, cables and wiring, as well as motors and generators. The circuit breakers are ideal for a wide range of industrial applications and feature compact design, robustness and reliability, so engineers benefit from maximum operational reliability and uptime under the most demanding conditions as well as space-saving installation. The DWB moulded case circuit breakers are designed with rated operating voltages up to 690 V AC or 250 V DC and are available in three-pole and four-pole versions in six case sizes with rated operating currents from 16 to 1,600 A. The circuit breakers and associated

equipment and components can be switched on and off remotely with related accessories. The whole range features the same accessories including auxiliary switch blocks,undervoltage and shunt opening releases, and phase separators so engineers can reduce the required diversity of parts stock. That has a positive impact on stock management, type selection and detail engineering. The modular design of the DWB series allows the complexity of the circuit breakers to be adapted to the requirements of each application. For example, the needs of simple costsensitive applications can be met using circuit breakers with fixed overload and short-circuit tripping mechanisms based on the thermal-magnetic operating principle. By contrast, circuit breakers with adjustable overload and short-circuit tripping mechanisms can be deployed in more sophisticated solutions. Additionally, power disconnectors are available for effective interruption of power circuits. For more information on WEG’s energy efficient automation solutions visit www.weg.net/uk or call Tel: +44 (0) 1527 513800 or E-mail; wuk-sales@weg.net

BPMA NEWS

THE GRUNDFOS SP - A HIDDEN GEM

The Grundfos SP reached a significant milestone this year when it celebrated its 50 th birthday. This durable, reliable, efficient submersible pump family has benefited from the addition of some advanced engineering improvements and a number of line additions in the interim, but fundamentally, the original construction is unchanged. These pumps were the world’s first submersible pump to be made entirely from stainless steel and their innovation was recognised early on when they won a prestigious design award in recognition of the fact that they delivered an engineering balance between technology, function and form. Today, the SP family is still a mainstay of the Grundfos portfolio and their flexibility can be seen in the many applications they support including delivering groundwater supplies, irrigation as well as supporting new digital solutions that offer farmers the additional opportunity for remote control and monitoring. Their robust nature makes them suitable for use in harsh environments such as mining. Since their launch, a staggering 4 million of these units have rolled off the production line and today millions of people all around the world depend on these submersible pumps to deliver their groundwater. Their continued success lies in the fact that they can be relied upon to work away, hidden from view and they are very, very good at doing this. Visit www.grundfos.co.uk to find out more.

AXFLOW INTRODUCES COMPRESSOR VAPOUR RECOVERY SYSTEM FOR TANK EMPTYING AxFlow is now offering a compressor system as an alternative to centrifugal pumps for emptying liquefied gas from storage tanks, vessels and mobile tankers. Unlike pumps, which can only unload around 85% of the liquefied gas, the compressor system will easily transfer over 99% thereby enabling users to recover this potentially expensive liquid heel. The compressor system also eliminates the problem of liquefied gases boiling when centrifugal pumps are used. AxFlow’s VRS is a simple framemounted unit which can be used for intermittent and continuous duties. Available in mobile and static formats, the VRS is divided into two stages, liquid transfer and vapour recovery. The function of the compressor is to push the liquid from inside the tanker into the storage vessel using pressurised vapour from the storage vessel. Following this, the compressor connections are reversed using a 4-way valve to suck out any remaining vapour in the tanker and transfer it to the storage vessel. Designed specifically for liquefied gas transfer duties, the vertical piston compressor comes in single or two stage versions with air or water-cooling. Engineered to meet customer’s specific requirements the VRS enables liquid transfer or gas evacuation down to pressures of 50 millibar absolute, and is suitable for displacements of up to 212 m3/h and system pressures up to 42 bar. For more information contact AxFlow Ltd, Ealing, London. Tel: 0208 579 2111 E-mail; info@axflow.co.uk Web: www.axflow.co.uk

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves A FULL HYGIENIC OFFER FROM DIXON Over the last 30 years Dixon has significantly extended its range of Valves, Fittings and Couplings for the Hygienic markets through product development and acquisition.

Dixon offers a full range of stainless steel hygienic fittings and valves for use in the food, dairy, beverage, brewery, cosmetic, chemical and pharmaceutical industries. Of particular note is Dixon’s range of high quality process valves which include ball, butterfly, diaphragm, seat, sample, and mix-proof valves which can be actuated to customer specifications and fitted with a range of stocked accessories that includes limit switches, solenoids and positioners. Here in the UK, Dixon offers, specialised support and bespoke engineered solutions from concept, to design, through to installation. Dixon’s onsite manufacturing and engineering department means that new designs, animations and 3D modelling can rapidly be produced to support customer’s requirements. As a result, Dixon Europe are pleased to be launching a new product, the Dixon Hygienic THE GREEN PERISTALTIC Breakaway Check Valve, which is proving to be ‘the right connection’, potentially saving companies thousands. At a recent trade show, an engineer from a well-known UK dairy company explained how a milk tanker had driven away from the loading bay before disconnecting the delivery hose costing thousands in replacement piping and install cost. Dixon’s Hygienic Breakaway coupling is a solution to this problem. In such instance the coupling will break in two, separating the tanker from the loading bay. The 13kN break load bolts are the only items that will need replacing. The new Dixon Breakaway Check Valve is an innovative solution that is designed to eliminate product loss too. It incorporates the Breakaway Coupling and a Hygienic Check Valve. It acts as a single unit that has a diverted breaking point which will break at a determined break-load. Then the check valve will close protecting the loading bay pipe system AND avoiding product spillage. Designed with hygienic processing in mind, you can be assured that the breakaway conforms to FDA standards and is CIP capable; but, without the intricate workings and associated cost of similar products on the market. Also available from Dixon’s inhouse production capabilities are full hygienic fabrications and custom made hose assemblies for the hygienic market. Our range includes but is not limited to San hygienic Rubber, Silicone, Metallic, PTFE lined, and general PVC suction and delivery hoses. This means that whatever hygienic special you require and whatever industry you serve to, Dixon can help. For more information contact Dixon Group Europe Ltd, Tel: +44 (0) 1772 323529 E-mail: enquiries@dixoneurope. co.uk Web: www.dixoneurope.co.uk

PUMP

NEW

VERDERFLEX VANTAGE 5000

The Next Generation Peristaltic Cased Pump with Intuitive Touch-Screen Technology

www.vantage5000.com

MAY 2017 - PROCESS INDUSTRY INFORMER

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves HYDRA-CELL… RUN-DRY PUMPS HANDLE AGGRESSIVE CHEMICALS Pumps failing through running dry, or becoming damaged due to pumping corrosive liquids are not uncommon problems. However, Wanner International claims that using Hydra-Cell seal-less diaphragm pumps can eliminate both these costly issues. Pumps with dynamic seals rely on seepage of the pumped liquid for seal lubrication. Dry running at best, causes the seals to wear and could result in seizure and catastrophic pump failure. Seepage of corrosive and noxious liquids through seals is a further problem for conventional rotary pumps. Hydra-Cell pumps have no dynamic seals and can run dry indefinitely without problem. Seal maintenance is eliminated and being totally leak free, they provide 100% containment of all pumped liquids, removing any possibility of dangerous liquids or vapours leaking to atmosphere. An extensive range of ‘liquid end’ materials, including Hastelloy, Duplex and Super Duplex steels and Kynar® PvDF, ensures Hydra-Cell pumps can handle virtually any liquid, reliably and efficiently and because the pumps are seal-less they can pump liquids containing abrasive particles and even slurries with ease. Exceeding the performance requirements of API 675 in terms of repeatability, linearity and steady state accuracy, the Hydra-Cell pump’s multi-diaphragm configuration generates virtually pulseless flow, removing the need for pulsation dampeners in most applications. For more information contact Wanner International, Tel +44 (0)1252 816847 Email: NHerrington@wannerint.com | Web: www.hydra-cell.eu

ASCO NUMATICS 580 SERIES ELECTRONICS PLATFORM Emerson have expanded the ASCO Numatics 580 Series fieldbus electronics platform with the introduction of an IO-Link® communication option. For use with the ASCO Numatics 500 Series valve islands, the new IOLink module will allow machine automation designers a convenient, cost effective and reliable solution for solenoid valve control through direct digital data communication with the machine controller plus the ability for event-based and I/O mapped diagnostics – both important predictive maintenance requirements for Industry 4.0. The 580 Series IO-Link is compatible with the full range of 501, 502 and 503 Series valve islands which offer from 400 to 1400 l/min flow rates in valve sizes of 11, 18 and 26 mm. Now available with base-plates that allow two pressure sizes to be combined in one convenient assembly, simplifying installation and allowing valve piloting and pneumatic systems from the same island. A comprehensive range of options are available for complete application flexibility. IO-Link is gaining increased popularity for automation systems, offering an internationally standardised I/O technology (IEC 61131-9) for communication at the sensor/actuator level in machine control. The ASCO Numatics 580 Series IO-Link module offers many advantages such as simple commissioning with unshielded 3-wire comms connection and 4- or 5-pin industry standard M12 connectors for power and communications. When used with the 500 Series valve islands and a compatible IO-Link master, a modular distributed I/O topology is easily achieved for up to 32 solenoid outputs per master in addition to third-party sensors, relays and other field level components. IO-Link is independent of upper level fieldbus systems and is available for almost all major fieldbus protocols available today.. For more information about ASCO products, visit www.asconumatics.eu

IMI PRECISION ENGINEERING EXCELS WITH THE NEW EXCELON® PLUS AIR PREPARATION UNITS

CSF centrifugal pumps are quick-strip, easy-clean and reliable…perfect for food, brewing, pharmaceutical and other ‘sensitive’ applications. ● Can handle capacities from 1 to 550 m3/hour at heads up to 155 metres ● AISI 316L stainless steel for all wetted parts ● Quick strip, easy-to-clean and designed for CIP(clean-in-place)

Pick the perfect pump – from Pump Engineering

AB13-613

TEL: 01903 730900 sales@pumpeng.co.uk www.pumpeng.co.uk

IMI Precision Engineering has advanced its portfolio of air preparation products with the introduction of the lighter and smaller IMI Norgren Excelon® Plus. The latest generation of air preparation equipment, Excelon® Plus is a modular Filter, Regulator, Lubricator (FRL) range suitable for all industrial applications. Designed with safety in mind, it combines great performance and is compact and lightweight. Tamper resistant features come as standard and include: • Padlock features on the shut-off valves and regulator • A rotating safety shut-off valve, which makes it easy to isolate the system with no reduction in performance • A unique double safety bowl lock with an audible bowl clip – a safety detent which when pressurised makes it impossible to remove the bowl when in use. The new filter maintenance system allows the filter element assembly to be removed with the bowl, enabling faster and cleaner servicing. It features a Quikclamp system, which acts as a bracket and locks Excelon® Plus modules together. Excelon® Plus can be used on stand-alone or modular assemblies and allows for installation and removal of units without breaking a pipe connection. David Whelan, Global Product Director, said: “Excelon® Plus is a result of our inventiveness, imagination and innovation.” For further information, please visit: www.mostmarvellousmachines.com/

PROCESS INDUSTRY INFORMER - MAY 2017

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves SEALLESS, SELF-PRIMING MAG-DRIVE PUMPS FOR LEAK-FREE PUMPING Reliable, leak-free, low-maintenance pumping has always been essential in many process applications, particularly when ‘challenging’ liquids like corrosives need to be transferred safely and efficiently. Magnetically driven pumps are ideal for these types of duty as they have no rotating seals to fail so the risks of downtime and lost production are minimised, as are the problems of cross contamination, or wastage of the pumped fluid. A good example of this type of pump is the Finish Thompson SP series of magnetic drive, self-priming centrifugal pumps, available from MICHAEL SMITH ENGINEERS. The SP Series are well proven in many demanding applications as they offer a fast, reliable and powerful performance with corrosion-resistant materials for harsh environments. The range consists of four models which provide maximum flow rates up to 45 m3/hr and maximum differential heads to 37 metres. SP self-priming pumps combine deep lift capabilities (dry lift pumping up to 7.6 metres) and fast priming (5.5 metres in 90 seconds) with the important advantages of magnetic drive technology; no seals to replace and zero leakage.. The pumps are available in a choice of Polypropylene or PVDF which results in a tough and durable, corrosion resistant pump. Maximum operating temperatures are 82°C for the polypropylene version and 104°C for the PVDF version. They are reliable with low maintenance and safe operation is assured thanks to the SP Series magnetic technology. Typical applications include sump emptying, transferring from underground storage tanks and tanker trucks, pumping in systems that are liable to have trapped or entrained air or in process systems where run-dry protection is needed. For more information contact Michael Smith Engineers Ltd, www.michael-smithengineers.co.uk Michael Smith Engineers Ltd, Tel: 0800 316 7891. Email: Info@michael-smithengineers.co.uk MAY 2017 - PROCESS INDUSTRY INFORMER

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves

ALBANY PUMPS LAUNCHES ONLINE PUMP CONFIGURATOR TOOL Albany Pumps has launched an online Pump Configurator tool – which can be used to critical effect in understanding the company’s new product portfolio and specifying a pump more quickly. Designed with flexibility mind, this tool will help customers, agents & distributors to build their perfect pump solution through a series of key questions. As Phil Dykes, Managing Director of Albany Pumps explains, the new ‘Configure a Pump’ service is part of a major improvement programme to offer an easier and faster way for customers to access the impressive services from this 100-year old company: “We are proud to be investing in a new online resource for our customers. When creating our new website, we drew inspiration from customer feedback and as a result, we’ve created a really impressive online resource for all sorts of useful tools and data including application databases and case studies. In particular, we have built a Pump Configurator that will allow users to create their specification relevant to particular needs such as market sectors, or liquid to be pumped, or pump construction materials. Our dedicated sales team will then work to make your pump solution a reality. We believe our tool is bringing innovation to the positive displacement pump industry, and we’re thrilled to be offering such a helpful aid.” For more information on Albany Pumps and its range of pump products, please call Albany Pumps direct on +44 (0) 1594 842275 or visit www.albany-pumps.co.uk.

Your Right Connection For Hygienic Process Systems Valves

Fittings

Hose

Engineered Products

Fabrication

Tel: +44 (0)1772 323529 Email: sales@dixoneurope.co.uk www.dixoneurope.co.uk 36

PROCESS INDUSTRY INFORMER - MAY 2017

FEATURED ARTICLE

AODD PUMPS:

CORRECT CONFIGURATION IS KEY Air-Operated Double Diaphragm (AODD) pumps are reliable and cost-effective, but only if they are configured correctly.

In a variety of applications across a number of industries, Air-Operated Double Diaphragm (AODD) pumps provide reliable, high performance pumping. They have come to be known as the “work horse” of industry, when it comes to handling and transferring fluids at relatively low flows and pressures. Above ground or below ground, on land or on sea, in normal or extreme conditions, the versatility of AODD pumps ensures that processes keep moving.

ey to safe and reliable operation of an AODD pump is correct configuration. This involves taking fluid characteristics into consideration, such as pH levels, abrasiveness, temperature and fluid density. Also important is to check chemical compatibility: manufacturers often provide guides on their websites to ensure pump materials are suitable for the fluid being transferred. These same websites often feature online pump selector tools to assist in configuring a pump in a matter of minutes and with a few clicks of the mouse. However, some of these configuration tools can appear overwhelming at first, especially considering the vast number of alternative materials that can be specified for pump components. Making the right choice can significantly reduce the overall cost of the pump – while making the wrong choice can give you a pump that is too expensive for your requirements. This article identifies and recommends popular ball, seat and diaphragm materials (internal pump components) and pump fluid sections (pump bodies) to perform in applications with varying fluid characteristics. These are general guidelines and points to consider when specifying the correct configuration. In parallel with these recommendations, it’s always advisable to check the manufacturer’s specifications and chemical compatibility guides.

WHAT TEMPERATURE? The first guideline is to remember to identify the temperature limits of all components in the pump. The internal pump components may be rated to an extremely low or high temperature, but that does not imply that the pump body material is rated to the same level, and vice versa. When configuring an AODD pump, it’s important to identify temperature ratings of all components, by referring closely to the manufacturer’s product specifications. Increasing the working temperature has a significant consequence on material selection. For example, plastic pump bodies are not recommended because cold flow and creep can lead to leaking. As temperatures rise above 80°C, the choice of compatible internal

MAY 2017 - PROCESS INDUSTRY INFORMER

components further decreases. At these elevated temperatures, materials such as ethylene propylene diene monomer rubber (EPDM), polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF) and fluoroelastomer (FKM or Viton®) are preferred. FKM and EPDM have the highest heat resistance, rated to 160°C and 135°C respectively. Next in line are PVDF and PTFE, rated to 107°C and 100°C respectively. At the other end of the thermometer, glycol transfer pumps are required to withstand cold environments down to -20°C, thus requiring aluminum, stainless steel, EPDM, FKM and Santoprene.

KEY TAKEAWAYS:

- For high temperature applications: Stainless steel or aluminium pumps with FKM, EPDM, PTFE or PVDF wetted materials. - For low temperature applications: Stainless steel or aluminium pumps with EPDM, FKM or Santoprene wetted materials.

CORROSIVE ENVIRONMENT? If you want your AODD pump to handle corrosive chemicals or fluids with fluctuating concentrations and/or pH levels, then it’s vital to make the proper selection of pump bodies and internal pump components to avoid pump corrosion, ensure compatibility, and reduce maintenance requirements. For such applications, plastic pump bodies such as polypropylene, PVDF, Kynar® and PTFE are often chosen on account of their chemical inertness. The highest chemical compatibility is offered by PTFE, which can generally be safely used with the most basic chemicals to the most acidic acids. It could be, however, that PTFE is an over-specification. Other materials such as polypropylene or PVDF may suffice. It therefore makes sense to refer to the manufacturer’s chemical compatibility guides for guidance as to which are the optimal pump materials nto use for the chemical or fluid you are working with.

KEY TAKEAWAY: - Check manufacturer’s chemical compatibility guide.

WHAT’S THE FLUID DENSITY? Surprisingly, when configuring a diaphragm pump the most frequently overlooked specification is fluid density. It’s an important factor to consider because diaphragm pumps utilize ball checks that rise and fall as pressure changes occur within the fluid chambers of the pump. Ball checks come in a whole range of metal and elastomer configurations. Each of these materials has a different weight, or specific gravity. Understanding how this weight relates to the fluid has an influence on the material specified. If a low-viscosity fluid is being transferred, the weight of the ball is not of critical importance because the fluid is not restrictive during the ball seating process. A 30% slurry, on the other hand, has a higher viscosity and therefore requires a heavier ball to move through the slurry so the ball seats properly. If the ball is too light, it will hang up in the slurry and will not seat, leading to poor pump performance that includes priming issues and cavitation. A rule of thumb is the denser the fluid, the heavier the ball check.

KEY TAKEAWAY:

- Neoprene, stainless steel and PTFE ball checks have the highest specific gravity, or weight, allowing ball checks to seat reliably through high-viscosity fluids.

WANT TO MINIMIZE WEAR? For abrasive fluids, metal pump bodies are generally recommended. The most commonly used materials are aluminium, stainless steel, and Hastelloy®. Santoprene® and Geolast® are good for internal pump components as they provide longevity and resistance to destructive abrasives. Applications with petroleum-based fluids, such as waste oil, are best paired with Geolast ball, seat and diaphragm materials. Santoprene, one of the most versatile elastomers, offers good chemical compatibility and excellent abrasive resistance. PTFE offers a high level of chemical inertness and compatibility in high- temperature applications, but it is often incorrectly specified in abrasive applications, such as chemical slurries. Again, it’s important to check chemical compatibility of all these materials.

KEY TAKEAWAY:

- Stainless steel pumps with Santoprene or Geolast wetted materials

LOOKING TO REDUCE COSTS? When configuring a cost-effective pump, aluminium, polypropylene, Geolast, TPE and EPDM need to be high on your shopping list. As variables such as temperature or abrasives become more challenging, using an ultra-high molecular weight polyethylene (UHMWPE), neoprene or nitrile may be required, but this is going to increase the pump’s cost. Other materials that will add to the cost of the configured pump are specialty materials intended to handle the most extreme fluids. These materials include PTFE, PVDF, FKM, Hastelloy and stainless steel. A useful tip is to be open to using a different material when your pump has to be repaired. It might not be necessary to re-order exactly the same material. Consulting a chemical compatibility guide might help identify other materials that are perfectly suited for the same fluid but at a lower cost.

KEY TAKEAWAYS: - The most cost-effective materials: Polypropylene, Geolast, EPDM, TPE and aluminium. - Midrange materials: UHMWPE, neoprene and nitrile. - Higher price range: PTFE, PVDF, FKM and stainless steel.

MORE INFORMATION Graco offers a broad range of air operated diaphragm pumps, which can be configured with an online selector tool at graco. com/husky-selector- tool. If you have further questions relating to the configuration of an AODD pump, email Walter Leeten at walter.leeten@graco.com. 37

FEATURED ARTICLE

WINDS OF CHANGE FOR LEVEL MEASUREMENT IN THE

WATER & ENVIRONMENTAL SECTORS ?

HOW THE LATEST RADAR LEVEL TECHNOLOGY, WITH NEW LEVELS OF AFFORDABILITY AND BLUETOOTH COMMUNICATIONS CAN BENEFIT THESE SECTORS By Doug Anderson, Marketing Manager VEGA UK Comments from Jürgen Skowaisa, Product Manager - Radar and Ultrasonic VEGA Germany

price competitive to incumbent technologies.

PROCESS CHALLENGES Across the world, there are tens of thousands of sewage treatment plants and billions of litres of sewage is treated every day

yriad measuring instruments monitor and measure water or sewage for level, flow, pressure and water quality, as well as controlling increasingly complex biological processes at the treatment facilities themselves. Level is one of the most common measurements - for example, flow in open channels, flumes and weirs, controlling screening systems, emergency overflows, flood monitoring, settling ponds, sludge, solids handling and dosing systems …along with countless other tasks. Until recently, continuous level measurements in the water processing and monitoring industries mainly relied on non-contact ultrasonic level sensors, particularly on effluent, due to the large amounts of solid material, and submersible pressure transmitters used mainly on the cleaner, water supply side. Now, a still relatively new contactless level option is using radar technology. It’s already well-established in many process industries, yet water utilities still have comparatively little experience with it, partly due perceived higher cost and perceived complexity, making them a ‘specialist’ solution. Now, thanks to new developments in technology and cost, radar can be considered as a first choice. Why choose radar? Mainly due to less influences from process or environment, the excellent reflectivity of water to radar signals, inherent accuracy and repeatability and a more robust measurement technique. at a

Jürgen Skowaisa is Product Manager for both radar and ultrasonic technology for a market leading level company. From experience, he considers contactless radar level technology as the future for the water, environmental and sewage sectors, primarily because of its robustness in the face of process and weather influences. He has direct experience of condensation, turbulence, vapours, wind, fog or rain impairing ultrasonic sensors, as well as temperature influence (solar gain) from solar radiation. Velocity changes of ultrasonic signals are related to temperature changes (1.6% per 10 ‘degrees’ Kelvin). For instance, on an ultrasonic sensor a temperature sensor inside the transducer does the compensation “As long as it’s cloudy, you get reliable values” explains Skowaisa “But during longer periods of direct sun, temperature on the transducer increases, and the sensor temperature can become much higher than the ambient temperature, thus causing an error “One solution is a solar shield, or additional temperature sensor, but it doesn’t always mitigate errors, as temperature variations in the air between sensor and liquid surface can’t always be measured and corrected for. This was demonstrated in a test by an environment agency, who installed a radar alongside an ultrasonic sensor (fitted with a temperature sensor and a solar shield) on small bridge. The data showed the ultrasonic sensor still produced noticeable errors, or drift, in certain weather conditions, while the radar device output remained accurate. Turbulence, waves or foam can also affect ultrasonic sensor performance, reflection signals can scatter and if in the open, wind can take the signal away completely . Radar microwave signals are unaffected – with millions of pulses emitted and the output updated twice each second – which means they can even measure wave height. With surface foam, latest radar sensors also have the focusing and dynamic sensitivity to carry on working and measuring. Radar delivers accurate, reliable level data even with sensor face

condensation or vapours and gases in the vessel. The proliferation of Anaerobic Digestion (AD) units for energy generation and sludge handling plants typically present these environments for level controls. Also, new designs of ‘sealed’ waste treatment plants - to reduce odour in urban areas and facilitate harvesting of gases for energy generation - provide greater potential of these issues arising in future.

WHAT CAPABILITIES DO THE SENSORS TYPICALLY HAVE? A compact 2-wire, (4-20mA) loop-powered ‘water’ radar will typically have an accuracy in the region of 2mm or 5mm, (bulk solids versions level available) with encapsulated antennas with a 10° beam angle (3° options), ranges from around 8 to 15 metres (variants up to 120m), they can feature Bluetooth, Profibus, FF and HART communications for set up and/or data transmission with ATEX and IEC hazardous area approvals along with SIL 2 conformance. Some resist submersion with flood-proof housings (IP68 to 2 Bar). Basic devices can handle process pressures up to 3 bar, temperatures up to 80 °C – normally ample for most water/environmental sectors (alternatives are capable of 400 Bar and 400°C!). There are tens of thousands of radar based devices already installed in the water industry worldwide, and the adoption looks set to accelerate. “The technology boasts higher precision in general, it is very easy to use and can offer a great performance alternative to ultrasonic instruments” explains Jürgen.

SO WHAT ABOUT THE PRICE? “The price differential between ultrasonic and radar measurement technology used to be very high. Today, the cost of radar technology is the same, even lower, depending on the application, so it is actually turning out to be a better all round solution”. It means customers can now choose based purely on best technology, rather than on price.

PROCESS INDUSTRY INFORMER - MAY 2017

APPLICATION ORIENTED Like any industry-oriented device, application based set up helps with both quality and speed of commissioning. “Users in this industry require quick, easy selection for applications such as pumping stations, sludge reception and handling tanks, digesters, flow-rate measurement in open channels and other similar applications typical of this sector. Even flow curves can be programmed into the sensor itself for open channel flow measurement.” A variety of mounting and communication options are available to make the sensors easy to integrate into existing infrastructures. Straightforward, userfriendly operation and handling, like Bluetooth Apps and PC comms. delivers fast simple set up and diagnostics. Jürgen adds, “The measurement data can be transmitted either directly to an existing control unit or to a SCADA system (4 … 20 mA, Profibus PA even Foundation Fieldbus), so this makes the technology a true all rounder.” he concluded. When it comes to approvals, as well as hazardous area certifications, there is a European norm for Level Probing Radar (LPR) level sensors for open air use. Devices must conform to this standard to be used outside. Reliable data in demanding applications: The following examples show the advantages the new sensors have in daily use in the water sector. Precision open channel flow measurement: In flow rate measurement in open channels, accuracy is key due to the exponential flow calculations, which can amplify the small errors. According to Jürgen, many users don’t realise that ultrasonic technology can deliver inaccurate results. “Users simply trust that the values stated in the manual are correct, but in reality, these only apply under ideal measuring conditions.” Regulators charge businesses for effluent discharge quantities on the basis of these values. Radar technology can deliver better measurement data for all parties involved.

MCERTS APPROVED RADAR FOR OPEN CHANNEL FLOW MEASUREMENT Recently the first radar based system for open channel flow measurement was approved under the MCERTS scheme - overseen by the Environment Agency in the UK. It was assessed for performance, accuracy and quality of manufacture. Radar technology is a perfect choice for this application, unaffected by temperature changes, reliable in all weathers, even with condensation on the sensor face, delivering precision level data for computation into flow. It is now certified for this application under the scheme and offers great advantages for versatility, capability and flow measurement accuracy .

Storage of chemicals: some chemicals used for sewerage or water treatment and cleaning give off fumes, condensate and vapours. They require secure, safe handling and measurement when used so close to the water courses and plants. Radar works with fumes or vapours present and has the great advantage that it can be mounted above/outside a plastic or GRP vessel looking down through the top to provide a reliable, accurate monitoring for inventory. An ideal solution for plastic mobile IBC containers, no fitting required.

Water radar (at left of picture) at work on a on a deep pumping shaft focused on the water level, ignoring the many obstructions around Pumping stations, wet wells and shafts: Radar offers excellent performance, pump shafts are often narrow and filled with many pipes, fixtures and fittings, the pumps themselves are sometimes located directly in the shaft, build up solids is prevalent. Reliability is achieved with focused beam and the very high reflectivity of water to radar signals. On very deep shafts, seen on large-scale schemes, an alternative sensor can be used with only a 3 degree beam angle with ranges up to 120m. Open waterways Flood risk is increasing, as the result of more concentrated heavy rainfall in some areas and urbanisation in others. In turn, so is flood level monitoring, gauging of rivers, waterways, and estuaries. Non-contact radar sensors, with their immunity to sun, wind, rain and fog etc. really come in useful. They can be mounted anywhere, quickly and easily, out ‘in the open’ without still wells or sounding tubes, of or under bridges and retrofit to existing installations.

Radar mounted off a bridge over a river, simple to install with two fixings. No effects from high winds or temperature gradients, no conduits or silting either. 12m range, powered by battery logger mounted in a discreet, robust tube. Measuring every 15 minutes, working for over 3 years on same battery. User reports zero maintenance, 100% accurate data in all conditions.

Storm overflow chambers - radar has no blocking distance, therefore its ideal in confined spaces, mounted horizontally with a 45 reflector plate increases the range of measurement Storm water overflows and sewer flows: SWO or CSO chambers are often sited underground and users can benefit greatly from the technology. “Because radar technology has no blocking distance, measurement can continue even to very high water levels, and the immunity to condensation on the sensor face also helps reduce misreads or lost readings”. Jürgen mentions another advantage, “Even flooding is no problem, because radar sensors have IP68 protection options. Millimetre measuring precision under all conditions can monitor ‘spill’ more accurately, too.”

Chemical storage tanks; radar can be mounted completely outside a plastic vessel. It adds to safety, ease of installation and operation, while simplifying change over if using an IBC

MAY 2017 - PROCESS INDUSTRY INFORMER

THE OUTLOOK With its contradictions of scarcity and deluge, the monitoring of water and flood levels, supply and sewage treatment will continue to grow in the future and it will always place new challenges on technologies. Meeting these needs in different environmental markets is a challenge in itself: In Europe - upgrades for existing plants, looking for latest technology to automate etc. while in countries like China and Brazil, new sewage plants with latest field bus communications are being built ‘almost daily’. New technology level devices with improved reliability and performance, application based set up, Bluetooth set up, as well as price competitiveness - offer a real alternative to legacy sensors with a choice based on the technology, not just price. “Future market and environmental requirements can be quickly met with such a capable core technology concludes” Skowaisa, “I am convinced radar instruments will play a major role in achieving this.”

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KNOW YOUR PUMP WITH ABRASIVE & CORROSIVE MEDIA Pumping abrasive and corrosive media can be a real challenge if you’re not using the right kind of pump, argues Rens Zwart, Group Industrial Sectors Business Development Manager, at Watson-Marlow Fluid Technology Group (WMFTG). test facility was built to determine the viscosity of the ash slurry, as well as measure the pressure Q. HOW IS IT BEST TO SPECIFY A PUMP FOR ABRASIVE SLURRY TRANSFER? A. Let the experts at pump manufacturers provide assistance. Abrasive slurries have many drop of the pipes at a given water percentage, so that pumps and pipe runs could be dimensioned different parameters that can impact on pump selection. These include particle size and distribution (percentage of small particles in the slurry), particle shape, concentration of solids and density of solids. Ultimately, slurry types will behave differently depending on particle size and transport speed, so correct pump specification is important.

appropriately. At Dong Energy, fly ash is mixed with 35% water and fed to the dosing tanks (each with a recirculation line) in the pellet mills through a 650 metre long pipeline. Here, Bredel hose pumps are deployed to avoid settlement. In total, 21 such pumps are now in use at the plant, delivering an optimised solution that has resulted in huge financial savings: fly ash is traditionally handled by large doubleacting hydraulic pumps costing circa £500,000 each.

Q. WHAT ARE REAL COSTS OF USING PERISTALTIC PUMPS FOR ABRASIVE MEDIA? A. While the initial purchase cost can be slightly higher than other types of positive displacement Q. HOW MUCH DOWNTIME CAN BE SAVED IN ABRASIVE PUMPING/OPERATIONS? (PD) pumps, a quick assessment of associated lifecycle costs quickly tips the balance in favour of A. Another example. An APEX 35 hose pump from WMFTG was put to the test in a process- critical peristaltic hose pumps. For instance, there are no expensive seals, ball valves, rotors or stators to wear and replace, while hose/tube replacement usually takes only a few minutes. Furthermore, the low cost hose or tube can be replaced in-situ without the need for special tools or skills, making the process extremely economical in comparison with conventional PD pumps where replacement parts can cost up to 75% of the pump’s initial purchase price and take several hours to fit.

Q. HOW LONG DO HOSES LAST? A. All hose elements have a serviceable life before fatigue demands replacement; predominantly dependent on the pump speed, but not influenced by the abrasiveness of the fluid being pumped. Depending on the duty and the economics of using a larger and consequently higher flow pump and slowing it down its RPM, operating costs can be much reduced in terms of energy efficiency, hose life and pump maintenance costs. High quality hose pump manufacturers produce hoses within tight tolerances. They also utilise adjustable shoes to set the perfect compression force for specific process conditions such as suction and delivery pressure and pipework.

abrasive slurry mixing operation at freight carriage component manufacturer, Amsted Rail. The trial showed that in comparison with previously deployed AOD pumps, the APEX pump could extend the time between scheduled maintenance dramatically. While the AO pumps need to be maintained every two weeks, the APEX pump ran continuously for 10 weeks before maintenance was needed. Furthermore, when maintenance of the APEX pump is required, additional savings are apparent as it takes less than 50% of the time needed to reinstate the AOD pump to operational condition. The same pump model also proved successful at EEW Saarbrücken GmbH, a producer of energy from waste. Here, not only did the APEX 35 pump run for a much longer period when pumping abrasive brine (salt slurry), but the time taken and cost of replacement parts was reduced greatly. EEW had been using a progressive cavity pump to feed the centrifuge for approximately 1.5 hours every 3-4 hours in a 24/7 operation. However, the abrasive nature of the brine demanded the repair of the PC pump stator or rotor every month, along with occasional replacement of the linings. Furthermore, not only would it take a minimum of four hours to perform the repairs (using expensive replacement consumables), but the pump would also have to be removed from the process line.

Q. HOW COMPLICATED IS INSTALLATION? Q . ARE THERE ANY EXAMPLES OF COST SAVINGS? A. Peristaltic pumps do not require the ancillary equipment commonly used with other positive A. Many companies achieve wide-scale savings when switching to peristaltic hose pump technology. displacement pumps in abrasive applications, such as double mechanical seals, seal water flush The combined heat and power (CHP) plant of Dong Energy in Studstrup, Denmark, is a case in point when it recently sought to switch from coal to biomass. This unusual application involved pumping highly abrasive fly ash slurry and required an ‘engineered’ solution to help maximise hose life. A

systems, run-dry protection systems, and in-line check valves. Not only does this reduce operating costs, but it also makes installation and maintenance remarkably simple and fast.

TEST & MEASUREMENT COMPLETE PACELINE CLP RANGE FROM HBM REACHES THE PARTS OTHER LOAD WASHERS CAN’T REACH!

HBM – a market leader in the field of test and measurement – is pleased to announce the launch of three new piezoelectric miniature force washers, which enable force to be measured at locations where standard force sensors cannot be installed. Available in three new capacities, (3 kN, 14 kN and 36 kN) the latest additions complete the innovative PACEline CLP range from HBM and are available for instant integration into existing set ups using all industry-standard screw connections from M2.5 to M14. Featuring a compact design the latest additions to the PACEline CLP range can be easily installed in very small sets ups, without the need to resize or adapt the screw or bolt connections, offering substantial time savings. Piezoelectric force washers use a measurement principle whereby the sensitivity does not depend on the nominal force, which makes the PACEline CLP range ideal for measurements in partial load ranges, where greater resolution is required. All products in the PACEline CLP range feature a symmetrical design to give good linearity and have very minimal displacement, which results in very high stiffness and excellent dynamic properties. Suitable for machine monitoring applications and laboratory experiments, the PACEline CLP range of piezoelectric load washers feature a minimal height of typically four millimetres, which is particularly suitable for when space is constrained. Available in seven different versions ranging from 3 kN to 80 kN and manufactured from stainless steel, all washers in the PACEline CLP range are RoHS compliant and come complete with an integrated cable of either 0.5 or one meter long. The PACEline range is suitable for use in force and strain measurement technology and is based on the piezoelectric effect. HBM offers a growing range of piezoelectric test and measuring equipment under the PACEline brand to complete the standard range of force sensors based on strain gauge technology. For further information, contact HBM on Tel:+44 (0) 20 8515 6000 or via Email: info@uk.hbm.co.uk or visit the HBM website at Web: www.hbm.com MAY 2017 - PROCESS INDUSTRY INFORMER

HBM EXHIBIT AT OFFSHORE WIND ENERGY 2017 Stand: N-A14 HBM – a leader in the field of test and measurement – will once again be exhibiting its latest range of revolutionarily measurement systems, at this year’s Offshore Wind Energy 2017 exhibition, which takes place on the 6-8th June at London ExCeL. HBM is able to design, manufacture, install and support robust measurement systems for offshore wind turbines. For validation purposes and longterm condition monitoring, HBM uses either resistive or fibre-optical strain gauge arrays, together with other sensors and a comprehensive DAQ package for SCADA interface or stand-alone operation. To demonstrate HBM’s capabilities in the structural health monitoring market, guests are invited to visit stand N-A14 where HBM will be showcasing its leading-edge wind turbine model, which is fitted with a QuantumX cX22W data recorder for high performance testing or monitoring and Catman software to measure, visualise and analyse saved data. The QuantumX CX22B-W Data Recorder seamlessly integrates with the universal QuantumX series. Regardless of whether mechanical, electrical or thermal measurement qualities or signals provided by the vehicle bus, camera, wheel force sensors or GPS are acquired, CX22B-W conveniently collects, analyses and stores the acquired data in the device, without a PC connection and with total sample rates up to 5 MS/s. Used with Catman software, easy analysis can be achieved. Catman simplifies the parameterisation, acquisition and visualisation of measurement data. Guests will also have the opportunity to take a closer look at the range of HBM sensors, transducers and data acquisition systems applicable for condition monitoring and renewable energy industries. HBM measurement technology helps to identify mechanical stress on wind turbine components at an early stage, during research and development testing and during operation minimising downtime, extending life cycle and improving safety. Co-organised by Wind SALES | TRAINING Europe and Renewable CALIBRATION | HIRE UK, Offshore Wind Energy 2017 – the world’s largest offshore wind energy gathering – enables key players in the offshore wind energy sector the opportunity to exchange ideas, establish partnerships and further advance the tremendous gains made by this industry in recent years. For further information, contact HBM on Tel:+44 (0) 20 85156000 or via Email: info@uk.hbm. co.uk or visit the HBM website at Web: www.hbm.com

TEST INSTRUMENT CENTRES South: 01622 690 187 North: 01942 886 993 Wales & West: 01633 853 803 www.alpha-electronics.com

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HOW TO TELL WHEN YOUR INSTRUMENTS ARE IN NEED OF A HEALTHCHECK By Dr Jonathan Farrington, Technical Manager – Service, ABB Measurement & Analytics

It is easy to take the efficiency of your installed instrumentation for granted. After all, if it’s measuring, it must obviously be working. Yet the reality is that this assumption could actually be losing you money. Not only could you be losing potential revenue through impaired or lost production, but the cost of rectifying an instrument problem could often end up costing you more than if you had simply serviced the device throughout its lifetime. Moreover, an impaired measurement could also affect your ability to comply with environmental and safety legislation, exposing your organisation and its representatives to legal action and potentially ruinous financial penalties.

HOW TO START Constraints on costs, limited in-house technical resources, a lack of technical expertise or installations being located in hard to reach areas are just some of the common factors that can lead to instruments not being maintained in accordance with a manufacturer’s guidelines. Where sites have had multiple owners or frequent changes in maintenance teams, for example, it is also not unknown for documents for specific instruments to be lost, or for users to lose track of where devices are installed. The following are some suggested pointers to help you assess whether an instrument may be in need of a health check, which may highlight the need for servicing, upgrading or replacement with a better alternative.

CALIBRATION – ARE YOU DOING IT PROPERLY? Correct instrument calibration is vital for accurate and repeatable measurement performance. Instruments such as pressure and temperature sensors and transmitters and flowmeters will all

have been calibrated when they were manufactured to check their performance under a known set of operating conditions. Although this calibration will be valid when the instrument is first installed, it cannot be assumed that it will remain so indefinitely. Arduous processes especially will cause instruments to drift, such that a failure to routinely take a device out of service and calibrate it could lead to a measurement error. Drift is also more common on older instruments compared to the new generation of instruments, which feature improved electronics, with self-checking routines builtin, and a more robust mechanical design. Even these devices will still need to be checked, as their electrical components can be affected by small chemical and / or physical changes with time, resulting in unavoidable long term drift. The calibration of an instrument can also often be compromised as soon as it is installed. In most cases, installers will calibrate a device to the installation using their own devices, effectively over- riding the original factory calibration. The resulting new calibration will only be as good as the devices they are calibrating against, which may themselves not be properly calibrated. It is important to be aware that any of these factors could affect a manufacturer’s guidelines when it comes to calibration frequency. Even where a manufacturer recommends a longer period between calibration checks, the installation environment can impact on the performance of the transmitter and/or primary sensing element. In such applications, more frequent calibrations, or at least inspections, may be necessary. Standards such as section 7.6 of ISO 9001:2015 oblige companies to maintain and calibrate their measurement instruments on a regular basis, the frequency of which should be dictated by the specific requirements and demands of the application. Additional requirements include the need for instruments to be clearly labelled with information including calibration status, the date when the next calibration is needed, and the need for protection against accidental damage and deliberate interference. Instruments must also have been calibrated by a qualified testing and calibration laboratory. ISO/IEC 17025 stipulates key management and technical requirements for ensuring that laboratories are operating the correct quality management systems and that any tests and calibrations are performed to the correct accuracy and reliability. Where multiple instruments are used, for example for redundancy in safety critical processes, it is also advisable to check the calibration of each instrument and recalibrate if necessary, with the frequency of checking being determined by the characteristics and operating requirements of the application. This will avoid measurement discrepancies between each instrument and ensure that each instrument is operating accurately and safely. Depending on the type of instrument and the nature of the production process in which it is being used, it can be desirable to be able to check and adjust its calibration without having to remove it

from the line. This not only prevents disruption caused by removing and replacing the instrument, but also helps to avoid the introduction of any external factors that could affect its calibration. While the calibration of many types of instruments can be verified in-situ, it should be emphasised that verification is not the same as calibration, and should never be considered as a replacement. If the verification reveals that an instrument’s calibration has wandered significantly, then it must either be returned to the manufacturer for recalibration or replaced.

ARE YOUR INSTRUMENTS GIVING YOU THE DATA YOU NEED? Another area to look at is whether your installed instruments are delivering the right information. A study by the ARC Advisory Group estimates that global process industry losses due to unscheduled downtime and poor quality are in the order of $20 billion, or five percent of annual production. Of these losses, almost 80 percent are avoidable and 40 percent are attributable to operator error. ABB’s own studies highlight that as many as 35 percent of trips into the field are for routine checks, 28 percent are for non-existent problems, 20 percent are for calibration shifts, six percent are fo ‘zero off’ issues and six percent for plugged lines. Only four percent are actually for failed instruments. From these figures, it is easy to get an idea of the potential savings that could be achieved by equipping engineers with the knowledge and equipment they need in advance, rather than having to visit one or more devices to diagnose a problem. One way that this can be achieved is through the use of smart instrumentation. Developments in communications technologies present new possibilities for gaining quick and easy access to an expanded range of instrument data. In particular, the latest generation of smart instruments offer a range of capabilities that were not previously possible in conventional 4-20 mA analogue devices. Foremost amongst these is the ability to obtain a clearer picture of what is happening in a process. The ability to convey a greater range of data from a device at faster speeds over a digital network enables real or near real-time data to be obtained which can be used to identify areas for possible improvement. When connected to a process visualisation system, smart instrumentation can provide an immediate overview of conditions, making it easier to make informed decisions about areas for greater efficiency. Another benefit of smart instruments is their self-diagnostic capabilities. By assessing every aspect of the instrument’s performance and pinpointing potential issues before they develop, this technology can help enable improved deployment of engineering resources. It is true that the added time and effort needed to

PROCESS INDUSTRY INFORMER - MAY 2017

PROCESS MEASUREMENT

& INSTRUMENTATION

LOW POWER 800-SERIES FLOWMETER FOR BATTERY OPERATED EQUIPMENT

configure and connect smart instruments to fieldbus systems means that they can cost comparatively more to install than their analogue counterparts. It is therefore necessary to understand in advance the potential scale of savings that could be achieved by using smart instruments, which can then be weighed against the cost of installing them.

COULD YOUR MEASUREMENT DEVICES BE CAUSING YOU PROBLEMS ELSEWHERE? Frequent or unexplained plant breakdowns can often be symptomatic of a measurement problem. Although an instrument may appear to be in good working order, it may actually be generating spurious information that can impact on equipment or processes further down the line. This can be avoided through performing regular inspections, particularly where the measurements are critical to a production process. These inspections should include both a physical examination of the instruments themselves, and also any recorded data that can be used to check for deteriorating measurement performance. In installations using older instruments, it may also be advisable to either upgrade or replace them with the latest technology. Equally, problems with instrumentation may also be due to the characteristics of the installation environment. High vibration, extreme ambient temperatures and continuous exposure to the weather, can all impact on instrument performance.

Titan Enterprises has introduced a new version of its popular 800 series turbine flow meter that enables integration with battery powered or portable equipment.

Designed to operate with minimal power input, this competitively priced, low power 800 series flowmeter maintains high performance over 6 flow ranges from 0.05 to 15 litres per minute. Totally non-metallic wetted components, including a moulded PVDF body and Viton ‘O’ seals, makes the lower 800 series flowmeter the ideal choice for the metering of even aggressive chemicals. The standard inlet tubes are barbed to accept a hose size of 8mm although for OEM use - alternatives are available. At the heart of the low power 800 series flowmeter is a precision turbine that rotates freely on robust sapphire bearings. The turbine contains fully moulded-in magnets that are detected through the chamber wall by an extremely low drag, low power detector. The output for the low power 800 series flowmeter is a stream of pulses that are readily interfaced with most electronic displays or recording devices. This combination of materials and technology ensures a long life, high performance product with continuous reliable operation. For further information visit www.flowmeters.co.uk or contact Titan Enterprises on

Tel: +44-1935-812790 or Email: sales@flowmeters.com.uk.

ARE YOUR DEVICES AS ACCURATE AS THEY COULD BE? In the same way as calibration, the long-term accuracy of a measurement instrument cannot be taken for granted. One way is to check the current performance against the original specified accuracy. Referring to the original specification and/or historical data collected from the device can help to pinpoint any divergences in measurement performance, which can then be addressed if necessary. This may include recalibrating it, or, where the problem is due to wearing or failure of components, repairing or replacing it. Another way is to verify a device by comparing it against a device with a known accuracy. This may be a device specifically for verification, or an identical ‘mirror’ device that can be set up to temporarily measure the same process, with the readings being compared to the device under test.

Innovative level-measurement technologies

ARE YOU COMPLYING WITH THE LATEST LEGISLATION AND STANDARDS? Ensuring compliance with the latest legislation is essential in order to avoid the risk of financial penalties, plant shutdown and, in extreme cases, criminal prosecution. Typical areas to look at when assessing the capability of instrumentation to meet legislation include: – Is the equipment fit for purpose? – Is the equipment considered as a best available technique? – Is the equipment suitably certified for use in the application? – Are there any special requirements relating to operation and/or maintenance of the equipment? – Is the equipment covered by a documented maintenance strategy, stipulating the frequency of maintenance, the persons responsible and the scope and limits of any maintenance work? – Is there a maintenance history for the installed instruments, detailing the frequency and nature of any work carried out? – Does the measurement data need to be collected for reporting purposes? – Is there a requirement for redundant measurement? By considering each of these areas in turn, a health check strategy can be formulated to help ensure compliance. Po

UWT - The Level Measurement Expert

Mononivo® Compact vibration probe     

Connection thread from 1" All-Rounder for all industries Very light bulk material >20g/l Universal voltage No calibration necessary

SUMMARY With cost pressures and a shortage of sufficient skilled staff to carry out regular maintenance and inspection, it can be difficult to give every installed device the attention it needs. Turning to the instrument supplier or manufacturer for help can often provide the answer. Their in-depth understanding of their equipment and the conditions under which it can be used, coupled with their expertise and knowledge of the latest standards and legislation, means they are well-placed to help you find ways to optimise the efficiency of your measurement devices. In conjunction with other organizations, ABB offers a broad range of health check and life cycle services to help you get the most from your installed instruments and analysers.

MAY 2017 - PROCESS INDUSTRY INFORMER

UWT (UK) Ltd Tel: +44 (0) 1743 718883 sales@uwtuk.com www.uwtuk.com

CALIBRATION

INSPECTION & VISION SYSTEMS

DIGITAL FUEL TURBINE METER - NEW FOR 2017 Tuthill is pleased to announce a game-changer in the in-line meter market. Tuthill has introduced an all new, 100% made in the USA, in-line digital meter that has +/- 1% accuracy, global certifications and simple, preset calibrations making it the clear winner in the most sought after customer wants for this meter category.

These new digital meters have many advantages over competing brands. First, they are accurate to +/- 1%, whereas many other brands are only accurate to +/- 5%. Second, they come out of the box with 18 factory calibration presets making it fast and easy to setup for first use. Plus, it measures in gallons, litres, quarts, pints and ounces. It also has global certifications including UL for US and Canada, ATEX, IECEx and CE. These certifications are on the entire meter, not just the electronics. The meter is designed for use in-line or at the end of the hose so users can easily install it where it is most convenient. It has simple, four button operation and a rubber boot to help protect it from impact should you accidentally drop it. Plus, it has replaceable AA batteries. There is no need to order expensive, special batteries from the manufacturer. The all new in-line digital meter is available in three models to handle a wide variety of fluids and in both 1” NPT and BSPP threads. The Aluminium model (TT10AN) is designed for gasoline, diesel and other fuels. The nickel plated model (TT10ANC) is for bio-diesel to B100 and ethanol blends to E85. The polymer model (TT10PN) is for diesel exhaust fluid, anti-freeze and other chemicals. For more information, visit www.bellflowsystems.co.uk or contact the sales team on 01280 817304.

LOMA LAUNCHES IQ4 - PROBABLY THE MOST FUTURE PROOF METAL DETECTOR SERIES IN THE WORLD

New IQ4 offers improved sensitivity, ‘beyond’ IP69K washdown rating, larger 7” touch screen across all IQ4 model and variable frequency for pipeline & VF models. Further underlining its position at the forefront of high performance inspection equipment for the global food and pharmaceutical markets, LOMA SYSTEMS® (www. loma.com) has launched its revolutionary new IQ4 series of next generation metal detection systems. With the combination of enhanced Auto Learn functionality, improved product screening and more sophisticated signal processing, the IQ4 provides significant improvements in detection performance. In fact, compared to previous generation LOMA IQ3+ST Metal Detectors, the IQ4 can provide up to a 35% improvement in detection sensitivity with tough to handle metallised film products and achieves this without having to result to complex or expensive simultaneous frequency technologies. The IQ4 technology has enabled LOMA to introduce true Variable Frequency to its Pipeline, Waferthin and Vertical Fall metal detectors for the first time. Operating between 31-882 kHz, all metal detectors in the IQ4 range are capable of automatically selecting correct operating frequency so changes in products or packaging that necessitate an alteration in frequency no longer require costly and inconvenient operator intervention. In an industry first, all models in the IQ4 Metal Detectors boast a newly designed 7” colour touchscreen with a modernised and more intuitive interface that has been developed to simplify operation, deliver instant clarity to inspection status and provide straight forward access to a host of advanced functionality. Toby Kemp, LOMA’s Global Marketing Manager comments: “The IQ4 series is the culmination of 50 years of working closely with our global customers, major retailers and organisations like the BRC to truly understand current and future inspection challenges. As a result, we truly believe that the IQ4 is the last generation metal detector the industry is likely to need. “It is probably the most future proof system we have ever built and we are confident that the IQ4 is the best all round metal detector range currently available on the market,” he concludes. For product enquiries please contact: Anita Miault, Tel: +44 (0)1252 893300 Email: enquires@loma.com Web: www.loma.com PROCESS INDUSTRY INFORMER - MAY 2017

FEATURED ARTICLE

IS YOUR SMART GRID SECURED? By Patrick Le Fèvre – Chief Marketing and Communication Officer, Powerbox

nvolved in early days projects to add communication and intelligence to power supplies, which became the so called “Digital Power” I have been frequently asked about software security and how the power supplies industry was prepared to address such issues? If it is for sure, there is very little risk a hacker reaches a single Digital-POL at board level, the risk increases exponentially as we move upward in the value chain and, in that chain, the Smart Grid is probably the highest and the most exposed to attacks (Figure 01). At time the number of renewable power sources are growing, smart meters deploying and many others connected to the Smart Grid, what is the situation in terms of security? Are we safe?

RISK ESCALATION From the 2007, when the US government demonstrated, in the Aurora Generator Test, with only 21 lines of codes, how hackers could take control of a power plant and physically destroy a generator; to April 2016 when a water and electricity authority in the State of Michigan, after been victim of a ransomware attack was forced to keep IT systems locked down for a week, the number of cases reported to security authorities is rapidly increasing. The Florida International University estimated that, during the first six months of 2015, more than 100 cyber incidents have affected infrastructure in the US and the energy sector had the largest number of attacks. Cyber-attacks toward Smart Grid is a global threat and all countries exposed to high risk, motivating power experts and networks managers to consider global response and methodology to prevent any damages. February 2016, the US Department of Homeland Security (DHS) issued an alert (IR-ALERT-H-16-056-01), reporting on a case that happened on December 2015 in Ukraine, lifting the information to a high level of attention to Smart Grid Operators, motivating them to accelerate protections mechanisms and to develop preventive actions policies. The Ukrainian case combines multiple elements in the attack, including physical sabotage though the sophistication of the part related to the cyber-attack reached a new level of intrusion, motivating the Smart Grid community to strengthen cooperation and efforts to accelerate sustainable security within the Smart Grid.

BLACK CHRISTMAS FOR UKRAINIANS! December 23rd 2015 at 04:00 PM, the Ukrainian’s region Ivano-Frankivsk was plunged into darkness for several hours and more than 220.000 customers lose power and, the IT and communications systems of the electricity companies severely damaged by the attackers. In this case, the attackers combined a large number of attacking tools, spreading phishing e-mail containing a variant of the BlackEnergy 3 and KillDisk malwares, exploiting MS Office documents security holes to get into the IT network of the electricity companies and inhibited most of the security agent in firewall (figure 02). At the same time they managed to break credential codes to access deeper level of the system, controlling industrial communication busses such as the ones interconnecting Uninterruptible Power Systems (UPS) and to the Supervisory Control and Data Acquisition (SCADA) systems. SCADA systems are basically Process Control Systems (PCS) that are used for monitoring, gathering, an analyzing real-time environmental data. PCSs are designed to automate electronic systems based on a predetermined set of conditions, such as traffic control or power grid management. For the ones used to lower energy and board power systems, it’s a super Software Define Power Architecture, which, considering the strategic role it plays, requires an extremely high level of security. Managing to control the SCADA systems, the

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hackers accessed the electricity network, with possibility to shut down and severely damage equipment. The Ukrainian’s case is considered as “real life example” of what could happen to larger networks and lessons to learn from that case part of the ongoing Smart Grid security standardization projects run in USA, Europe and Japan.

MAKING SMART GRID SAFER! Smart Grid is an extremely complex architecture with a lot of areas for intrusions and attacks. Especially when operating a Smart Grid has moved from managing electricity distribution to a supper Information and Communication Technology machinery. Michael McElfresh, Adjunct Professor of Electrical Engineering at Santa Clara University, very well summarized the situation, saying: “Technological advances in grid operation have made the power grid increasingly vulnerable to cyberattacks, writes The growth of the smart grid has created many more access points for penetrating grid computer systems – the “internet of things” will only make this worse.” All over the world, governmental, consortiums and group of experts are engaged in an amazing race to deploy security methods and protocols to make the Smart Grid safer. In USA, the set of Critical Infrastructure Protection (CIP) standards issued by the North American Electric Reliability Corporation (NERC) became mandatory in 2007 for owners, operators and users of the Bulk Electric System (BES) to ensure that certain assets on the grid critical to reliable operation are protected from both a cybersecurity and physical security standpoint, is going through a wave of new revisions, moving from CIP V3 to CIP V5, skipping V4, and accelerating V6! That situation reflects the situation faced by the standardization organization developing security standards in a fast evolving world of threats. In Europe, despite a number of initiatives within the European network and information security community to establish frameworks and standard operating procedures, the EUlevel response to cyber incidents lacks consistency though projects such the EU-funded Smart Grid Protection Against Cyber Attacks (SPARKS) are showing very good signs of progresses. Step by step, the worldwide Smart Grid is getting stronger and safer though the potential of threats remains high.

IN CONCLUSION Because of the complexity and the variety of connected devices to the Smart Grid (figure 03), power supplies manufacturers will have to consider the security aspect when their products integrated within a Smart Grid. As I introduced at APEC 2015 Software Defined Power Architecture is deploying fast in the ICT industry and some systems, already installed in data-centers, are connected to the Smart Grid and communicating through the SCADA system. To close the loop, if there is little risk a hacker to send a command to a POL blasting local core processor, the risk for UPS and even frontend rectifier to receive a fatal command is not excluded. The Ukrainian’s case trigged the alarm ON and for all of us involved in developing power systems connected to the Smart Grid a signal that we should never forget about the final application and to be Smart Security Innovators to power Smart Grid with excellence.

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