Process Industry Informer April 2016 by Process Industry Informer

www.processindustryinformer.com

APRIL 2016 Volume 12 No.2

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

FOOD INDUSTRY SPECIAL -The right line to success

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

CONTENTS. 4-5 News & Events

38 Spectrometers

6-7 Applications

38 Network &

9 Welding

Communications

9 Enclosures

38 Filtration

11-12 Process Control

38 Compressors

12-16 Food Special Focus

39 Products & Services

17 Lapping & Polishing

Suppliers Directory

INSTRUMENTATION IS THE KEY TO CHPQA BENEFITS

OPTIMISING CUSTOMER SERVICE

BIO-THERMIC DIGESTERS A NEW APPROACH

PROCESS SAFETY DATA: IS YOUR DATA VALID?

Systems 17 Infrared Cameras 19-25 Fluids & Liquids Handling (incl. Pumps & Valves) 28-29 Process Measurement &

Instrumentation 33-34 Health & Safety

COMBATTING COMPRESSORS: FOOD PROCESSING SECTOR

36 Centrifugal Sifters 36 Heat Transfer & Energy

STEPPING UP THE FIGHT AGAINST FOOD CONTAMINATION

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

HOW CHANGES IN THE RETAIL WATER SUPPLY MARKET MIGHT CUT COSTS

REPAIR OR REPLACE

INNOVATIVE LOAD CELLS OFFER A FRESH START TO FOOD PRODUCTION

THE ROAD TO PRODUCTIVITY PRODUCTION

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

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NEWS & EVENTS JWF GROUP MAKE A MOVE JWF Group, the UK’s leading Instrumentation solution provider has moved premises to an all new state of the art facility at Seaward Street, Glasgow. The new HQ significantly increases both office and warehousing space and provides support to JWF’s other offices in Aberdeen and Teesside. Following the £1m investment in the new premises, JWF are laying the foundations for further growth across their four areas of business. • JWF Process Solutions • JWF Instrumentation • JWF Metering • JWF Service One of the many improvements has been the development of a new training facility which includes a live instrumentation rig. This allows our engineers to provide training in Flow, Pressure, Temperature and Level instruments using various technologies from ABB, WIKA, Flexim and Canalta. For more information contact JWF Group, Glasgow Aberdeen Teesside. Tel : 0141 880 7455 E-mail: sales@jwfltd.com Web: www.jwfltd.com

FIRST UK ORDER FOR ABB YuMi® Sony UK Technology (UKTEC), the leading manufacturer of broadcast and professional cameras and camera systems will be the first in the UK to order ABB’s YuMi

Ideal for use in small parts assembly, Sony UK Technology will use ABB’s dual arm robot solution to pick and place circuit board parts. Primarily used in research and development, YuMi will help Sony UK Technology to better understand the benefits of collaborative robotics in its high volume circuit board application. Having recently been awarded the prestigious Production Centre President Award for Best Performance, Sony UK Technology will use YuMi to help improve assembly techniques, specifically the manufacture of circuit boards.

Kevin Edwards, General Manager and Head of Engineering for Sony UK Technology Centre explains: “The innovative

design and forward-thinking capabilities of YuMi will complement our culture of doing something better today than yesterday. We consistently strive to produce the highest quality products with the highest reliability and we pride ourselves on using the latest state of the art manufacturing techniques that enable us to respond quickly to customers’ needs.” YuMi’s safe design, 2-finger grippers, accurate vision and sensitive force control lends itself well to the proposed application and presents Sony UK TEC with the opportunity to readily adapt YuMi’s programming to match any changes in its assembly process. Furthermore, YuMi’s flexible software allows staff to use lead-through programming to effectively teach the robot how to handle each part, reducing set-up time and allowing team members to play a significant role in the robot’s operation. Kevin Edwards adds: “YuMi creates value-added opportunities for our employees to utilise their skill sets. We look forward to discovering the further benefits that this collaborative robot will bring and appreciate how the local engineering support provided by ABB will allow us to remain competitive within the 3C industry.” Colin Dullaghan, Product Manager at ABB Robotics continues, “YuMi, short for you and me, will open up more

opportunities for UK businesses like Sony UK TEC to improve their productivity. Task sharing between humans and robots is great way to accelerate production with lead through programming making the programming stage achievable for staff at all levels in a minimal amount of time.” For more information please contact: ABB Robotics Tel: 01908 350 300 E-mail: michelle.jocelyn@gb.abb.com

HBM ANNOUNCES WEBINAR WEEK DEDICATED TO QUANTUMX

GAS ANALYZER MANUFACTURER ACQUIRES UK’S QUANTITECH LTD

HBM – a market leader in the field of test and measurement – is pleased to announce the dates for its dedicated webinar week on QuantumX data acquisition systems, which takes place 17th – 20th May 2016.

The Gasmet Technologies Oy (Helsinki, Finland), one of the world’s leading manufacturers of gas monitoring equipment, has, on April 4th, announced the acquisition of Quantitech Limited (Milton Keynes, UK). Gasmet’s

Being held over 4 days, each hour long webinar has been designed to fit in with challenging time constraints which can often make attending relevant training courses difficult, and will provide valuable information on QuantumX, the leading data acquisition system, from HBM. The QuantumX dedicated webinar week starts with ‘Minimising the Measurement Uncertainty of your Force Measurement Chain’, which will look at what factors impact measurement uncertainty on force measurement chains. It will also explain what characteristics have a particularly high influence and how to enhance the measuring chains accuracy. As one of the key requirements of any DAQ equipment is its ability to successfully capture and record all relevant data, often in the field, ‘Mobile Data Acquisition Made Easy’, on 18th May, explains how to achieve successful mobile data acquisition, regardless of the operational conditions. On day three, users can receive practical tips on ‘Measuring temperatures and voltages on high electrical potential’ followed by ‘Ask me anything on QuantumX’ on 20th May. Each webinar, which normally takes a maximum of one hour, can be easily accessed at a later date or simply used as a refresher course. As an added benefit, all registered attendees will receive a link to the webinar, via email, after the presentation. All HBM webinars are free of charge and open to anyone. Spaces are limited and available on a first come, first served basis. Please reserve your spot by booking at the link http://www.hbm.com/en/3157/webinars/ The QuantumX data acquisition system is the perfect tool for all your test and measurement needs. For reliable data acquisition of signals from different measurement quantities and sensor technologies, the QuantumX offers the ideal solution. For further information, contact HBM on Tel: +44 (0) 20 8515 6000 or via Email: info@uk.hbm.co.uk or visit www.hbm.com

products are employed globally in regulatory monitoring, process control and environmental/safety applications, and Quantitech has been its sales and service partner in the UK and Ireland since 1995. Mikko Ahro, CEO Gasmet Technologies Oy. “Quantitech has an excellent reputation and has established a comprehensive customer base, and with the retirement of the current owner, this acquisition is designed to secure the long-term future of the business and to exploit the growth opportunities that we see in the UK market,” Established in 1983, Quantitech represents a small number of leading global manufacturers including Gasmet. Providing advanced environmental and process monitoring instrumentation in the UK and Ireland, the company’s success is built upon the quality of the products and customised systems that it is able to offer, coupled with outstanding levels of service. Following the acquisition, Quantitech will remain at their Milton Keynes location, trading under the same name and continuing to supply the same range of products. Looking forward, Mikko Ahro says: “We believe there are significant growth opportunities for FTIR analyzers in the UK, so it is our intention to strengthen the resources at Quantitech to further improve the experience and expertise that drive the company’s high levels of customer support.” For more information contact Gasmet Technologies Oy, FI-00880 Helsinki, Finland Tel: +358 9 7590 0400 Email: contact@gasmet.fi Web: www.gasmet.com

PROCESS INDUSTRY INFORMER March - April 2016

NEWS & EVENTS MOODY DIRECT APPOINTED AUTHORISED INTEGRATOR BY ALFA LAVAL Alfa Laval – a world leader in heat transfer, centrifugal separation and fluid handling - is pleased to announce the appointment of Moody Direct as Authorized Integrator for the UK. This appointment represents a significant business opportunity for both organisations, providing customers with a dedicated channel for design and integration services across a range of industries, including dairy, food, brewery and beverage, home and personal care, pharmaceutical and chemical industries. Moody Direct offers peace of mind as the ‘emergency service for the process industry’. Providing emergency engineering services, scheduled service visits and preventative maintenance contracts 24hrs a day, 7 days a week, 365 days a year.With a team of directly employed specialist engineers, Moody Direct have a wealth of knowledge and experience. Imran Rashid, Divisional Manager for Alfa Laval’s Equipment Division commented: “The appointment of Moody Direct as Alfa Laval’s Authorized Integrator for our process industry products here in the UK is a great opportunity for us both. The appointment will increase our exposure to the market, offering customers full integration, maintenance and service packages. I’m very much looking forward to working with and supporting Moody Direct on this new journey.” Ken Wild (Director), Moody Direct Ltd said: “We are delighted to be involved in this new partnership with Alfa Laval. As a result of this agreement, we are looking forward to providing our customers with exciting new and innovative products. It will also enable us to provide a superior service for existing and potential new customers. We look forward to a long and effective partnership for both Moody Direct and Alfa Laval.”

For more information contact Alfa Laval Ltd, Tel: +44 (0)1276 63383 E-mail: general.uk@alfalaval.com http://www.alfalaval.com / www.moodydirect.co.uk

FLUID POWER SOLUTIONS TEAM MARKS 15TH ANNIVERSARY After notching up more than 600 years of industry experience across more than 20 technical and product specialists, Brammer’s Fluid Power Solutions team is celebrating another major milestone in 2016, marking 15 years since its inception. Led by National Technical Manager Terry Davis, who alone has dedicated more than 25 years of his career to Brammer, the Fluid Power Solutions team partners with the world’s leading manufacturers of pneumatics and hydraulics to offer an added-value service to customers in sectors as diverse as food and drink, aggregates, automotive and rail. With expertise in product specification, energy efficiency standards, preventative maintenance and health & safety, the team also manages an industry-leading portfolio of more than 22,000 product lines. Terry Davis explained: “When customers purchase a product from Brammer, they’re not just buying a pump, actuator, filter or hose. They gain access to one of the industry’s most experienced technical specialist teams, who are able to support them throughout – from initial specification and installation to retrofits, troubleshooting, repair and maintenance. Our aim is always to reduce total acquisition cost, improve production efficiency and reduce working capital – whether we’re dealing with the most complex hydraulic or pneumatic instrumentation or a seemingly simple hose or fitting.” Brammer is an authorised distributor of fluid power products from more than 1,500 of the world’s leading manufacturers, including global brands such as Festo, IMI Precision Engineering, SMC, Parker Hannifin and Bosch Rexroth. Able to offer audit, improvement, monitoring and refurbishment of existing systems as well as the ability to spec out and product-manage the design and commissioning of bespoke systems, Brammer’s service is backed by full manufacturer warranty and technical support. Brammer is the largest distributor of fluid power products to UK manufacturers, holding more than 7,000 fluid power products in UK stock with additional overnight access to more than 1.1m more, covering process, instrumentation, pneumatics, vacuum and hydraulics.

For further information please visit www.brammeruk.com

IMI CRITICAL ENGINEERING ANNOUNCE THE APPOINTMENT OF IT’S PETROCHEMIQUES ACTIVITIES IMI Critical Engineering, a global provider of critical flow control solutions, has appointed Andrea Forzi to head its pétrochimiques activities, which initially will be based at the headquarters at IMI Critical Lakeside (Birmingham) where he will use his experience over 25 years in industrial engineering to drive the growth plan within the division.

Andrea was previously CEO of Weir Gabbioneta, customized technical Pump skate manufacturer for the oil and gas sector. Andrea is a graduate in Mechanical Engineering and speaks five languages, an asset that will prove very valuable in light of the overall supply IMI. Metin Gerceker d’IMI Z & J Germany, Simon Lawrie d’IMI Z & J Houston, Andreas Zerfass IMI Th Jansen and Luca Mambrini d’IMI Remosa, who supervise the respective activities, report directly to Andrea. “The skills Andrea brings to the company are invaluable and appreciated. He has extensive experience as a spearhead of a strong commercial growth and an ability to get the best out of the teams he leads,“ said Roy Twite, CEO of Critical IMI Engineering Division.

For more information, visit www.imi-critical.com .

PROCESS INDUSTRY INFORMER March - April 2016

SPIROFLOW’S SAFE HANDLING SOLUTIONS TAKE CENTRE STAGE AT FOODEX, April 18-20, NEC Birmingham, Stand P276

Award-winning Spiroflow will be showcasing its latest state-of-the-art bulk handling and conveying solutions for shifting food ingredients during the Foodex Show at the NEC in Birmingham (April 18-20).

Transferring food powders, flakes and granules from one area of a factory to another for processing, packaging and distribution requires a system that is fast, easy to route, has few moving parts, empties the system of product with minimum residue and provides a dust-tight operation -– essential when dealing with potentially combustible material. As well as providing a comprehensive range of equipment and testing facilities, an outstanding level of customer service is part and parcel of Spiroflow’s ATEX approved conveying and bulk handling systems, which really makes the company a cut above the rest. Foodex attendees can see for themselves how Spiroflow’s equipment can make a difference. In addition to demonstrating working models of a Bulk Bag Discharger and Flexible Screw Conveyor, Spiroflow’s team will be on hand to discuss the range of flexible and totally secure solutions for food materials where the most rigid standards in hygiene and containment need to be met and maintained. Spiroflow’s bulk bag discharger along with the flexible screw conveyor are ideal for the totally hygienic discharging and distribution of food ingredients, including sugar, flour and spices, within a factory environment. This exceptional equipment fulfils the very highest levels of hygiene and dust control, whatever strict operating parameters are in place. The Model T2 bulk bag discharger is a market leader, installed by major food processors world-wide for dust-free and controlled discharge of ingredients. Options include loss-in-weight product feed, patented massage systems to promote flow from bags, hygienic bag spout sealing device, integral hoist and other features to ensure hygienic emptying of 1-2 tonne bags. The main advantage of Spiroflow’s flexible screw conveyor is its simplicity, which results in short installation times and low maintenance – the whole system can be stripped down for cleaning in minutes. It can transport powdered, granular and flaked materials with a bulk density up to 2.5kg/1 and carry material to a maximum distance of 20 metres, although multiple units can extend to greater distances as required. Food manufacturers and processors visiting Foodex - possibly agonising over which conveyor not only best suits their product but also meets the stringent regulatory safety requirements need look no further than Spiroflow’s stand P276. Finding the right conveyor will depend a lot on finding the right supplier. The key for food companies is to source a conveyor provider that understands your business, proves it can meet your requirements and who will give a performance guarantee – just like Spiroflow. Visitors to Foodex at the NEC in Birmingham on April 18-20 will be able to see for themselves some of the high-quality conveying and bulk handling equipment on offer from Spiroflow on stand P276. However, if you can’t get there and would like more information on the company’s products and services please visit www.spiroflow.com or call +44 (0) 1200 422525.

APPLICATIONS PLASTICS MANUFACTURER CUTS ENERGY COSTS BY 15 PERCENT WITH MOTOR-DRIVE PACKAGE A manufacturer of sheet plastics has cut energy costs on a blown film extruder by up to 15 percent per tonne by installing an ABB variable-speed drive and motor.

Capital Valley Plastics produces gas barriers, damp proof membrane and damp proof course at its plant near Pontypool in South Wales. The company uses several blown film extruders, which it was keen to make more efficient and productive. Richard Haigh, Capital Valley’s project manager, says:

“Some of our extrusion lines are between 20 and 30 years old and we wanted to improve their output and efficiency without committing to a large investment. Making these improvements would mean we could cut our production cost per tonne and be more competitive.” The blown film extruders use DC motors, which are becoming increasingly expensive and difficult to replace and maintain as they become less common. “The DC motors for these machines are bespoke and cost around £30,000 to replace, with a lead time of around 12 weeks,” says Haigh. Maintenance was also a problem, with the carbon brushes of the DC motors needing to be replaced every year at £1,000 a time. Over the years, the blown film extruders suffered wear and tear on parts, which reduced the output. One particular machine had been fitted with a new barrel and screw. To make the most of these improvements, Capital Valley also decided to replace the machine’s existing DC motor with a new AC motor. Capital Valley’s electrical maintenance contractor Lesco recommended ABB’s Authorised Value Provider, APDS. “APDS came to the site to assess what we needed on the blown film extruder. We found them very good to work with and very knowledgeable. They instilled a lot of confidence in us that they would provide the solution we needed,” says Haigh. APDS recommended an ABB 200 kW IE3 motor together with an ACS880 variable-speed drive. “The new drive and motor are much more efficient,” says Haigh. “Also, because we’re getting live readings of our power usage from the drive, we can see how this changes with different products. This helps us quote a more accurate selling price for our products because we have better information on what it costs to produce them.” Together with the new barrel and screw, the ABB drive and motor are saving Capital Valley Plastics between 10 and 15 percent on power use per tonne on the refurbished machine. Capital Valley Plastics had used an ABB drive and motor on a previous extruder project. In that case, replacing a blown DC motor with an AC motor and variable-speed drive increased productivity by 30 percent. Capital Valley intends to work with APDS again to replace the DC motors on two other blown film extruders with ABB drives and motors. For more information contact ABB Ltd, Daresbury, Warrington Tel: 01925 741111 E-mail: info@gb.abb.com Web: www.abb.com

ABB BEARINGS CUT MAINTENANCE COSTS FOR CARROT GROWER Maintenance intervals are increased from four weeks to over six months by replacing standard bearings with ABB Dodge ISN bearings, on an industrial vegetable peeling machine. The ABB Dodge ISN bearings can take increased load and are more resistant to wear and moisture. This has resulted in a vast increase in the interval between replacements. MH Poskitts Ltd produce 50,000 tonnes of carrots and other root vegetables a year from its farms. Grown for distribution to major supermarkets, the carrots are washed and peeled at a facility in Yorkshire, using several rotating drums. Each drum contains 18 rotating cylinders. Surfaced with carburundum, the cylinders abrade the carrots and peel them, whilst water washes away the dirt and peelings. The resultant abrasive fluids are constantly sprayed over the entire machine including the bearings. Poskitts were faced with a major maintenance problem with two of the peelers, in that the bearings of the peeling cylinders were lasting up to four weeks before needing to be replaced. The company called in specialist bearing supplier Castleford Bearings, an ABB distributor, to assess the problem. Working with ABB, Castleford Bearings found that the length of the peeling cylinders was causing the problem. Both the drums and the peeling cylinders are 3.5 metres in length. Supported only at either end, the shafts of the peeling cylinders were constantly flexing. This meant that the standard ball bearings used on the cylinders were suffering from a dynamic loading that they could not handle. This load was cracking the inner ring of the bearing, letting in water and contamination, which rapidly lead to the bearings failing. The decision was taken to replace the bearings with ABB Dodge ISN bearings for a trial period on a single peeling cylinder . These spherical roller bearings can handle the dynamic load induced by the shaft and move to take account of the misalignment. The Trident seals, which are standard on these bearings, are extremely effective for dirty environments, low to medium speeds and normal ambient conditions. They comprise a nitrile triple-lip rubbing seal plus metal flinger, which maintains full seal contact even when misaligned. To accommodate the ISN bearings, Castleford Bearings re-machined the two original housings on the peeling cylinder. The two ISN bearings on trial have been operating since April 2015 without needing to be replaced. As a result, ABB and Castleford Bearings are now in the process of replacing all of the original bearings on the two, 3.5 metre peeler machines with ISN units, a total of 72 bearings. To find out more about the Dodge® line of bearings, gearing and power transmission components, please go to: http://new.abb.com/mechanical-power-transmission

For more information please contact: ABB Ltd, Daresbury, Warrington Tel: 01925 741572/ 07773 814511 Enquiries.mpt@gb.abb.com / Web: www.abb.co.uk

ARCELORMITTAL IMPROVES SAFETY AND REDUCES COSTS WITH SMART KEY MANAGER RFID-based system only releases keys to authorised personnel ArcelorMittal, the world’s leading steel and mining company, has improved safety and reduced costs at its Fos-sur-Mer site in southern France with the Smart Key Manager from SERV Trayvou Interverrouillage (STI).

Before introducing the Smart Key Manager, ArcelorMittal relied on a twin-key system to grant workers access to fork lift trucks and radio controls for overhead cranes. Staff presented their fork lift licence or permit and were given a specially-numbered key. By inserting this key into one side of a two-key lock and turning it, they freed the other key, which then allowed them access to their desired piece of machinery. Over the years, lost, stolen or forgotten keys had to be replaced, while some employees retained their key without holding the necessary licence or authorisation. To improve this situation, the steel manufacturer installed three RFID-based Smart Key Managers. Staff now tap a personal code into the unit’s keypad to retrieve the key or keys to which management has given them access online. Management can deny access online to any driver who has failed to pass their latest fork lift licence test, which drivers have to sit every five years. As a result, keys are always available in the right place and all key movements, whether live or historical, can be traced online. The Smart Key Manager’s webserver interface allows the system to be checked and managed in real-time via a web browser from a PC, tablet or smartphone; no software needs to be installed. The system indicates which keys are present in or absent from the cabinet, and who has taken each key and when. Via email, managers can remain informed of key movement, inform others and monitor several levels of administrators.

For more information contact SERV Trayvou Interverrouillage S.A.S. Tel : +33 (0)1 48 18 15 15 Email: pr@servtrayvou.com Web: www.servtrayvou.com

RILEY SURFACE WORLD APPOINTED TO MANAGE SALE & DECOMMISSION OF POWDER COATING & PAINTING FACILITY Riley Surface World has been appointed to handle the sale and decommissioning of a large Würster powder coating and painting facility formerly used by JCB Vibromax in northern Germany.

JCB Vibromax was a manufacturer of road rollers and soil compactors in Germany. Following the restructuring of its manufacturing operations, the powder coating and painting plant and the building in which it is housed, are now available as a going concern or for relocation to other similar organisations around the world. Würster, which is also based in Germany, is one of the world’s leading producers of powder coating and painting plant and machinery. The facility, which is housed in a purpose-designed building, was manufactured and installed in 2008. It consists of a pre-treatment line, drying and curing ovens, twin down flow powder booths with extraction and recovery, waste water treatment plant, an extensive conveyor installation and a Siemens control system. In addition to the process plant, the building is also available to lease subject to negotiations with the landlord. Riley Surface World was appointed to handle the sale due to its specialist knowledge of the surface treatment and coating industries, its global marketing capabilities and its experience of handling similar projects for other national and multinational companies. The company will be featuring this plant and other substantial surface finishing facilities at forthcoming exhibitions in Mexico, Germany and the USA during the remainder of 2016.

For full details, visit www.rileysurfaceworld.co.uk For technical and product information contact: Helen Wilkinson, Riley Surface World Tel: +44 (0) 1922 45 8000, Email: helen@rileysurfaceworld.co.uk

PROCESS INDUSTRY INFORMER March - April 2016

APPLICATIONS BLACKMER SLIDING VANE PUMPS ASSIST IN BULK TANK LOADING An international manufacturer of vehicle lubricants in the North of England has equipped a new storage tank facility with Blackmer sliding vane pumps from AxFlow UK Limited. The decision to equip the new facility with eight

Blackmer NP3F pumps was based on company’s long experience with this particular pump type for bulk loading applications at the facility. The production plant processes and blends lubricants and oils to customers’ specific requirements. Finished products manufactured at the plant include engine oil and hydraulic lubricants, and these are transferred to storage tanks ready to be moved directly to filling lines or straight on to bulk tankers. The new facility contains eight storage tanks in total and the pumps are fitted to these for transfer duties. Four pumps are located indoors and four outdoors, and all are operated as and when needed according to customer demand. Before the introduction of the new pumps, the four external storage tanks shared two pumps, so with the arrival of the new pumps each tank now has dedicated pumps and lines. The internal pumps are running on inverters and later this year the external pumps will be retrofitted with inverters. The pumps work very well on inverters and enable the manufacturer to balance production as some of the pumps are supplying the bottling lines where there is a requirement to reduce pressure. AxFlow Sales Engineer Brendan Orange says that the transfer application is not a particularly challenging application in terms of product corrosiveness, temperature and lubricity, but efficiency and leak-free operation are major considerations. “The Blackmer NP3F pumps were selected because there are

other Blackmer pumps of the same type on site and all have given good service over the years,” comments Orange. The cast iron Blackmer NP3F pumps specified for Ferrybridge are fitted with single cartridge mechanical seals and deliver flow rates of up to 610lt/min at 5 bar and offer a maximum viscosity of 560Cst .The company’s long term plan is to standardise on Blackmer for all bulk transfer duties on site for ease of spares and maintenance. By virtue of their inherent energy and mechanically efficient designs, positive displacement sliding vane pumps are perfectly suited to offering operators immediate high value advantages and solutions in fulfilling both their fluid handling and energy efficiency objectives. Constant flow that is relatively independent of changes in system pressure. Positive displacement sliding vane pumps offer users a constant flow that is relatively independent of changes in pumpage viscosity, the ability to handle high viscosity products, self-priming, dry running for short periods and high efficiency. Sliding vane pumps operate through the use of a number of vanes that slide into and out of slots in the pump rotator when the pump is rotating. The vanes move outward from the rotor and ride against the inner bore of the pump casing, in the process forming pumping chambers. As the rotor revolves, liquid enters the pumping chambers from the suction port. The liquid is transported around the pump casing until it reaches the discharge port where it is forced out into the discharge pipe. This type of design almost eliminates slippage, meaning that the pump’s high volumetric efficiency is maintained. Because the self-adjusting sliding vanes continuously allow for wear, sliding vane pumps are able to maintain near-original

PROCESS INDUSTRY INFORMER March - April 2016

efficiency and capacity throughout their working life. The pump speed also does not need to be increased over time, making sliding vane pumps inherent energy savers. In the event of the sliding vanes wearing out or becoming damaged, replacing them is a simple and quick operation that does not require any special tools. Blackmer pumps have been used on bulk loading duties and over a period of five years and AxFlow’s customer says the pumps have handled many millions of litres without any problems. The pumps are used on the final products and depending on the particular application, they can be piggy-backed on to two more Blackmer pumps when undertaking bulk loading. Although the pumps do not work for long periods they do need to be available when called upon in order to satisfy customer orders. For more information contact AxFlow Ltd, Ealing, London. Tel: Tel: 020 8579 2111 E-mail: info@axflow.co.uk Web: www.axflow.co.uk

Launched 16 years ago, the Pump Industry Awards are now widely regarded as the industry event. Whether it’s recognising companies and individuals who go the extra mile or acting as a motivator to encourage more companies to 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 at the Crowne Plaza Hotel, Heythrop Park on the fringe of the Cotswolds on Thursday 10th March. The awards ceremony was the highlight of the evening, hosted by the enchanting BBC News Presenter Mary Rhodes and held in association with the BPMA and sponsored by Process Industry Informer, KSB, SPP Pumps, AESSEAL, WEG, Tomlinson Hall & Co and World Pumps. The 2016 finalists were awarded certificates on stage and the eight worthy winners announced and presented with certificates & trophies to the usual ‘unruly’ celebrations. After dinner entertainment followed with the hilarious Dominic Holland whose performance was greatly received by the guests.Finally and to round off the evening we held a charity raffle to raise money for WaterAid, we managed to raise a staggering £1800.00!

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

MEET THE WINNERS

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

Dramatically faster evacuation down to deep vacuum levels with less power, smaller footprint, quieter, safer, and cleaner by harvesting the Kinetic Energy of heavier rotors which run five-times faster than usual machines. Mass inertia is stored during idle periods and released immediately on demand. Game-changing hydraulic optimisation allows pump pressure gradients of one-million-to-one while in the rough pressure area. This is unique and would normally need a high number of pressure stages. Mechatronically synchronised, contact-free, moving parts removes the need for oil-centric lubrication. TECHNICAL INNOVATION – PROJECTS SPONSORED BY: KSB WINNER: NEPTUNO PUMPS : ENERGY EFFICIENT PUMPS HELP FIGHT CLIMATE CHANGE

Los Pelambres Mining Co., located at 3600 m.a.s.l. in Chile, wanted to increase its pumping capacity, improve its energy efficiency and reuse components from its old equipment. Neptuno Pumps designed and manufactured new pumps under a circular economy approach with recycled materials and 30% less components, which increased the pumping capacity by 5%, using 33% less pumps, while improving energy efficiency by 15.4%, saving US$ 579,033 and reducing 3798 tons of CO2 emissions annually. ENVIRONMENTAL CONTRIBUTION OF THE YEAR SPONSORED BY: SPP PUMPS WINNER: BEDFORD PUMPS SAVE STAKEHOLDERS £3M ON FISH FRIENDLY SCHEME

Bedford Pumps’ Fish Friendly pumps successfully pass eels and fish in compliance with the EU Eel Regulations. They worked with Peter Brett Associates to evolve the civil engineering and pipeline design at Webb’s Hole Pumping Station to mitigate damage to eels and fish whilst also delivering stakeholders £3M in capital savings against their national framework estimate. It is the first of its kind to fully embrace the regulations from concept to commissioning. MANUFACTURER OF THE YEAR SPONSORED BY: AESSEAL WINNER: KSB

KSB is one of the largest manufacturers of pumps, valves and automation products in the world. Founded in Germany in 1871, and now with 16,000 employees, KSB is truly a global company. Present in the UK since 1896, KSB is able to offer customers a large variety of products and services. Investing in people, manufacturing and innovation has helped maintain KSB’s place as a market leader in the supply of pumps to many industries.

DISTRIBUTOR OF THE YEAR SPONSORED BY: WEG WINNER: TOMLINSON HALL & CO. Tomlinson Hall’s engineering heritage – built up over 97 years and reinforced by our team’s technical expertise – enables us to create bespoke solutions for customers. We ensure clients can meet the challenges they face, whatever the scenario. As both a pump manufacturer and a pump distributor, we understand industrial challenges from multiple perspectives. Remaining committed to service excellence, in 2015 we significantly enhanced our customer service provision and also invested heavily in training. SUPPLIER OF THE YEAR SPONSORED BY: TOMLINSON HALL & CO WINNER: JOHN CRANE John Crane is a global leader in engineered technology, supplying engineered products and services to energy services customers and other major process industries. The company designs and manufactures a variety of products including mechanical seals, couplings, bearings, filtration systems and artificial lift equipment. John Crane employs about 6,900 people and has more than 230 sales and service facilities in 50 countries. ENGINEER OF THE YEAR SPONSORED BY: WORLD PUMPS WINNER: RYAN PEARSON, GRUNDFOS PUMPS Ryan has worked in the water industry for 12 years and is passionate about what he does. He has a helpful ‘can do’ attitude, which he combines with practical ‘hands on’ knowledge and excellent communication skills, making him a highly thought of, well-respected member of the Grundfos team. Ryan understands the importance of sharing knowledge, he always goes the extra mile. LIFETIME ACHIEVEMENT AWARD SPONSORED BY: BPMA WINNER: KEN HALL, MANAGING DIRECTOR OF CALPEDA PUMPS Ken joined with Calpeda Pumps in 1986 and in 1995 became MD. He has been a member of the BPMA council for over 20 years, and been BPMA President on two occasions. Still a Director of the BPMA, and BPMA representative on the council of the European Pump Manufacturers Federation (Europump) Ken has been their President in 2007 and 2008. The architect and driving force behind Europump`s acclaimed energy policy ECOPUMP, he has promoted the pump industry European and UK energy policy across the world and continues to serve on the Europump council.

PROCESS INDUSTRY INFORMER March - April 2016

WELDING NEW DOUBLE PULSE MIG WELDER FROM JASIC New from Global Welding Manufacturer Jasic, the Pro MIG 350P Multi Process Separate is an IGBT inverter designed for industrial use in MIG/MAG, pulse, double pulse and DC MMA processes. DSP digital technology provides optimum welding performance as well as featuring easy parameter settings for the operator.

This model offers an abundance of features; synergic control with pre-programming of common materials and wire diameters for time saving as well as self-diagnostic protection systems for extreme reliability. This 3 phase inverter offers 350 Amps at 60% duty cycle. The package includes power source, wire feed unit, 2m interconnecting cable, trolley, water cooler, MIG torch, earth return & gas regulator. Free product demonstrations are available through authorised Jasic Distributors Readily available through Jasic UK equipment distributors, this machine is supported by a 5 year warranty when registered at jasic.co.uk. Wilkinson Star Limited is the Sole UK Importer of Jasic Welding and Industrial equipment. Tel: 0161 793 8127 E-mail: wilkinsonstar.sales@wilkinsonstar.com Web: www.wilkinstar.com

ENCLOSURES RUGGED SET POINT STATION CAN BE INSTALLED IN AN Ex e, Ex n, Ex p or Ex t PANEL ENCLOSURE

A new BEKA ATEX & IECEx certified intrinsically safe rugged panel mounting Set Point Station [set point generator], enables the current flowing in a 4/20mA loop to be manually adjusted from within a hazardous area. Housed in a 316 stainless steel enclosure, this new instrument may be safely installed in an Ex e, Ex p, Ex n or Ex t panel enclosure without invalidating the enclosureâ&#x20AC;&#x2122;s certification allowing easy integration with plant control equipment.

The instrument is loop powered and displays the process variable represented by the 4/20mA signal in engineering units on an 11mm high display. Frequently used values may be entered as pre-sets. A display backlight, which may be loop or separately powered is available as a factory fitted option. For general purpose applications, the complementary BA647E-SS is a noncertified version, the stainless steel enclosure and impact-resistant armoured glass window make it ideal for installation in severe environments. For further information including datasheets and certificates please visit BEKA associates, Hitchin, Herts. Tel: 01462 438301 or http://www.beka.co.uk/rugged_setpoint_stations.html

PROCESS INDUSTRY INFORMER March - April 2016

FOOD SPECIAL FOCUS STEPPING UP THE FIGHT AGAINST FOOD CONTAMINATION: METAL DETECTORS ‘V’ X-RAY Sarah Ketchin, Managing Director at Fortress Technology tackles the equipment options in the most widespread food and packaging application scenarios, cuts through the confusion on the pros and pitfalls of metal detectors versus x-ray, and highlights the importance of arming yourself with all of the facts to make an informed decision based upon the most prevalent contaminant risks.

n some applications, it’s obvious which type of inspection technology to opt for, since only one of them can reliably detect the contaminants that pose the risk you’re trying to mitigate. However, it’s not always that straightforward. The two technologies will often succeed or fail depending on two different sets of criteria. Success with metal detectors tends to depend on the materials involved (the product, the packaging and the contamination), while x-ray detectors are more likely to be affected by other parameters such as the shape of product and the mode of transport through the unit, in addition to density differentials. Putting this into context, x-ray systems cannot generally be used on free-falling products because of the in consistent density within the falling product stream. This rules them out of many bagging operations, such as VFFS lines. Meanwhile, if stone, glass, high-density plastics or bone poses the biggest risk, a metal detector will obviously be unable to spot them. It is, however, it’s worth noting that even an x-ray system will only be able to deliver reliable protection against these non-metallic contaminants under certain conditions. This still leaves many applications in food and packaging open to interpretation. Faced with making a choice about which technology to invest in, Fortress provides several impartial pointers to help make the decision-making process less of a minefield.

ROUND 1: COST COMPARISONS The upfront financial outlay of installing new equipment is naturally a major consideration, yet so too are ongoing maintenance costs, which contribute to the total cost of ownership over your equipment’s lifespan. Metal detectors are typically less expensive up front. What’s more, the price differential between metal detectors and x-ray systems increases incrementally according to the size of the aperture. So, for smaller units the difference in upfront cost may not be a deal breaker if investing in x-rays, but it may become insurmountable if a physically bigger system is required – for instance if you’re checking whole chickens rather than chicken nuggets. Energy consumption contributes to ongoing costs. The difference here depends mainly on whether or not the x-ray system requires cooling systems, such as fans or air conditioners, which drive up energy consumption. In contrast, metal detectors are designed to be more robust in extreme environments, e.g. freezers, wet processing plants such as fish packing, and when dry ingredients are prevalent, such as flour in bakeries and food manufacturers that use or pack spices and seasonings. Another factor is the cost of spares and ongoing maintenance. Although much more reliable than predecessors, generators and sensors still feature on new x-rays and remain consumable items. Spare part prices are typically quite high compared to a

metal detector. In addition, support costs, such as paying for an independent Radiation Protection Advisor to conduct the HSErequired yearly safety inspections on x-rays, also need to be considered. With travel expenses, prices for this inspection can range from £600 to£1,000 per annum. Added up, the cost differences can be substantial. In the worstcase scenario, the total cost of ownership for an x-ray inspection system can be more than 100 times greater than that of a metal detector. In addition, potential safety and liability concerns mean that x-ray systems offer almost no resale value. Of course, other factors may outweigh cost considerations. Before investing, users need to feel confident that an x-ray system will add considerable value in terms of risk reduction as well as versatility for their specific application.

by product effect. Solutions, such as simultaneous multifrequency,are now available on the market to address this longstanding issue. In the case of an x-ray system, the product density and how uniform it is will both affect its sensitivity.

ROUND 2: APPRAISING SENSITIVITY

ROUND 3: PRACTICAL The sensitivity of both metal detectors and x-ray systems MATTERS deteriorates as the size of the aperture increases. However, a number of other factors can impact on the sensitivity of the two technologies quite differently. Metal detectors can identify all types of metal based on magnetic and conductive properties, while an x-ray system depends on density differentials. This means that an x-ray system may struggle to detect aluminium, including foil or metallised film. On the other hand, foil packaging can present a challenge for metal detectors, which can only detect magnetic or ferrous metal contamination inside the package, while an x-ray system can detect all metals to some extent. Then there is the ‘orientation effect’ and the ‘product effect’ to consider. The orientation effect occurs if a contaminant is non-spherical, such as a piece of wire, in which case the ability to spot it may depend on the orientation it presents to the detector. In the case of x-rays, the presenting face must be equal to or greater in size than the base resolution of the detector diodes, which is analogous to the pixel resolution in a camera. Metal detectors are certainly not immune to the orientation effect, but they do not have this absolute cut-off. A so-called product effect may be produced by the product itself or by its packaging. Until recently, anything wet or conductive impacted the performance of metal detectors, especially in the case of stainless steel contaminants. This is because metal detectors work by spotting materials that create a magnetic or electrical disturbance as they pass through an electromagnetic field. Unlike ferrous and non-ferrous metals, stainless steel is usually non-magnetic and a poor electrical conductor. Consequently, a stainless steel swarf, metal shard or narrow wire hidden in a dry product typically needs to be 50% larger than a ferrous sphere to generate a similar signal size. This disparity can rise to 300% in wet products, such as ready meals, meat, fish, sauces, preserves and bread, because moisture acts as a conductive and the metal detection signal can be swamped

A number of practical factors also determine the type of system that may better suit a particular application. Among them is the footprint of your facility. Limited space usually favours metal detection, as do applications where the speed of the product through the machine is very fast or very slow. Maintaining a reliable performance over time demands periodic calibration and validation checks on both types of technology. In some cases, the process can halt production several times each shift. Users may therefore want to reduce the frequency, but they need to bear in mind that the longer the interval, the more product may have to be discarded or recalled if a problem with the inspection system is discovered. While a well-maintained x-ray system presents a minimal hazard, some systems require protective lead curtains to contain the x-rays. These in turn need condition monitoring and must not come into contact with unpackaged product. Care must also be taken that they don’t impede the passage of lightweight products through the system. Summing up, Sarah comments: “Some users naturally gravitate towards x-ray systems because they are perceived to be more versatile. It’s true that they have the ability to carry out further product inspection functions that are beyond the scope of metal detectors, such as spotting missing or broken products or checking the fill level. However, users need to be sure that any technical advantage will actually add value, since the pros and cons of metal detection and x-rays often make it difficult to see which technology is the most effective and cost-optimised solution in practice.” Fortress recently created a succinct and candid whitepaper providing five key questions to keep investors focused on achieving a successful contaminant protection programme. To request a free copy, email Info-UK@fortresstechnology.com.

PROCESS INDUSTRY INFORMER March - April 2016

PROCESS CONTROL INDUSTRIAL NETWORK MARKET SHARES 2016 ACCORDING TO HMS Industrial Ethernet is growing faster than before and now accounts for 38% of the market. EtherNet/IP is in first place within industrial Ethernet globally, followed by PROFINET. However, classic fieldbuses are still dominating the fragmented world of industrial networks with 58% and PROFIBUS is still the most widely used industrial network. Furthermore, the Internet of Things is driving wireless technologies which are now on the chart for the first time. Fieldbus vs. industrial Ethernet and wireless HMS’s estimation for 2016 based on number of new installed nodes in 2015 within Factory Automation. The estimation is based on several market studies and HMS’s own sales statistics HMS Industrial Networks now presents their annual analysis of the industrial network market. As an independent supplier of products and services for industrial communication and the Internet of Things, HMS has a substantial insight into the industrial network market. Here are some of the trends they see within industrial communication in 2016. Fieldbus is still growing Looking at new installed nodes within factory automation globally, fieldbuses are still the most widely used type of networks with 58% of the market. Fieldbuses are still growing by approximately 7% per year as users ask for simplicity, tradition and reliability. The dominant fieldbus is PROFIBUS (17% of the total world market including industrial Ethernet) followed by Modbus (7%), and CC-Link (6%). Industrial Ethernet is growing faster than before According to HMS, industrial Ethernet is growing faster than previous years and taking more market shares. At a growth rate of 20%, Ethernet now makes up for 38% of the global market compared to 34% last year. EtherNet/IP is the number one Ethernet network with 9% followed by PROFINET (8%). Runners-up are EtherCAT, Modbus-TCP and Ethernet POWERLINK. “We see evidence of an accelerated transition towards industrial Ethernet when it comes to new installed nodes,” says Anders Hansson, Marketing Director at HMS. “However, industrial automation is a conservative market and it will take time before industrial Ethernet outgrows fieldbuses.” Wireless is coming For the first time, wireless technologies are on the chart with 4% of the worldwide industrial network market. WLAN is most popular, followed by Bluetooth. “We see the Internet of Things as a big driver for wireless technologies,” says Anders Hansson. “Wireless opens up for new automation architectures and is increasingly being considered for machine connectivity and control, including Bring Your Own Device(BYOD) solutions via tablets or smartphones.” Regional facts In Europe and the Middle East, PROFIBUS is the leading network while PROFINET has the fastest growth rate. Runners up are EtherCAT, Modbus-TCP and POWERLINK. The US market is dominated by the CIPnetworks where EtherNet/IP is overtaking DeviceNet in terms of market shares. In Asia, no network stands out as truly market-leading – PROFIBUS, PROFINET, Ethernet/IP, Modbus and CC-Link are widely used. EtherCAT continues to establish itself as a significant network, and there are early signs of CC-Link IE Fieldbeing adopted. More and more devices are getting connected “The presented figures represent our consolidated view, taking into account insights from colleagues in the industry, our own sales statistics and overall perception of the market,” says Anders Hansson. “It is interesting to see that industrial Ethernet is now growing faster and that wireless technologies are gaining foothold. What is completely clear, however, is that the network market remains fragmented as customers continue to ask for connectivity to fieldbus, industrial Ethernet as well as wireless networks. All in all, industrial devices are getting increasingly connected, boosted by trends such as Industrial Internet of Things and Industry 4.0. With our long-term motto ‘Connecting Devices,’ HMS is well-suited to grow with these trends.”

For more information contact HMS Industrial Networks, Sweden. Tel: +46 35172993 / E-mail: min@hms.se / Web: www.anybus.com

PROCESS INDUSTRY INFORMER March - April 2016

PROCESS CONTROL EMERSON & MYNAH TECHNOLOGIES REDUCE TIME REQUIRED TO CONNECT INDUSTRIAL APPLICATIONS TO THE DELTAV DISTRIBUTED CONTROL SYSTEM WITH ADDITION OF PROFINET The DeltaV™ system now connects directly to motor centre and variable speed drive applications

Emerson Process Management, working with MYNAH Technologies, has expanded customers’ network possibilities and application options by adding PROFINET protocol abilities to the DeltaV distributed control system (DCS) - further opening plant floor integration to DeltaV users. The addition of PROFINET saves DeltaV users time and effort by enabling direct connection between the DeltaV DCS and plant floor devices such as motor control centres, variable speed drives, and PLCs in process automation businesses. Taking advantage of PROFINET, users do not need to use a protocol converter to connect to the system. PROFINET joins a wide range of DeltaV Ethernet-based protocols, such as Modbus/TCP and Ethernet/IP. The new capability is easily added to the system via both M-series and S-series Virtual I/O Module 2 (VIM2) interfaces. The PROFINET driver supports simplex VIM2 modules deployed with standard commercial off-the-shelf (COTS) network equipment. For enhanced reliability and availability, simplex VIM2 modules can be deployed with an external switch that handles media redundancy network topology via Media Redundancy Protocol (MRP) and also behaves as the ring master. Saving time and increasing safety, the VIM2 interface and firewall function allow a high level of access without sacrificing control system security and integrity. The VIM2-based PROFINET architecture enables users to optimise expansion activities or perform maintenance operations on applications in remote locations using a laptop with vendor-specific diagnostic tools all while constantly monitoring applications from a centralised network. “PROFINET is a growing bus protocol choice in process industries,” said Emerson Process Management’s chief strategic officer Peter Zornio. “The DeltaV system has a strong history of interconnection to busses of all types with seamless information integration for end users. MYNAH has been a great partner in attaining this achievement, and the addition of PROFINET will help our customers reduce their integration costs.” “We are excited to work with Emerson to bring this technology to DeltaV users worldwide,” said Nobin William, vice president of technology at MYNAH. “The VIM2 Industrial Ethernet driver product family provides cost-effective, high-performance integration between DeltaV and an incredible number of plant floor devices. The PROFINET driver extends this integration capability to new markets and new users.” For more information contact E-mail: InfoCentral@EmersonProcess.com Web: www.EmersonProcess.com

RADIO INTERFERENCE MITIGATION SERVICE HELPS PROCESSING INDUSTRY DECREASE WIRELESS OPERATING COSTS Roke Manor Research (Roke) today launches its Radio Interference Mitigation service, which will help industrial processing plants that wirelessly monitor assets and operations to overcome interference, increase reliability and decrease operating costs of radio-based equipment.

The processing industry increasingly relies on wireless radio systems to acquire data remotely. However, they regularly experience downtime due to interference from other technologies which operate in the overcrowded VHF and UHF Radio Frequency (RF) bands. Businesses are therefore fighting escalating operating and installation costs as a decrease in system reliability necessitates the deployment of more expensive technologies, significantly reducing the benefits of using wireless monitoring. Bryan Rickett, Electromagnetic Business Area Lead at Roke, said: “The V/UHF bands are very popular with the processing industry due to their wide coverage, good propagation and low infrastructure costs. However, their increased usage means that they have become a victim of their own success as interference between different technologies is creating unreliable services that result in costing money rather than saving it. Roke has more than 30 years’ experience of solving RF problems and our new service will provide expertise to help businesses once again benefit from the use of RF technologies.” Roke’s RF interference mitigation service comprises

1. Planning and design advice 2. Analysis and modelling (propagation models through to detailed modelling) 3. Monitoring and diagnostics (direction finding of co-channel signals using superresolution technology) 4. Mitigation design, manufacture, fitting and testing (antenna layout, antenna selection, filtering, screening and various forms of cancellation technology) For further information please contact: Roke Manor Research Limited, Fareham, Hampshire. Tel: +44(0)1794 833488 E-mail: james.horne@roke.co.uk Web: www.roke.co.uk

FOOD SPECIAL FOCUS METTLER TOLEDO RELEASES GUIDE ON OXYGEN MEASUREMENT THEORY AND PRACTICE METTLER TOLEDO has produced a guide for the process industries that explains the measurement theory, sensor technology and practice of measuring dissolved and gaseous oxygen with in-line sensors.

Oxygen measurement and control plays an important role in many chemical, pharmaceutical, biotechnology, power, and food & beverage processes. In biofermentation, oxygen control leads to increased yield and decreased production of unwanted byproducts. Oxygen management in the chemical industry helps to avoid the formation of explosive gas mixtures, and oxidation control in the brewing industry results in increased quality and shelf life of products. The in-line measurement of oxygen in liquid and gaseous mixtures is vital in these and many other processes for providing continuous, real-time data on oxygen levels. METTLER TOLEDO’s new guide provides an overview of oxygen measurement theories, an explanation of amperometric and optical sensor technologies, and explains how sensors should be calibrated and maintained in order to provide reliable measurements. The guide is available to download from www.mt.com/pro-oxygen-guide

FORTRESS LAUNCHES STAINLESS STEEL INTERLOCK SWITCHES FOR HIGH PURITY APPLICATIONS F o r t r e s s Interlocks has launched a new range of rugged stainless steel interlock switches for high purity applications such as food, b e v e r a g e , pharmaceutical and chemical processing. It is also suitable for outdoor use.

Manufactured from 316 stainless steel and modular in design, the amGardS40 range can be configured to suit many industrial applications. Configurations for the amGardS40 include: • Solenoid locking safety switches • Non-solenoid tongue switches • Mechanical trapped key interlocks • Machine control stations The switches are supplied in enclosures sealed to IP69K, allowing them to be pressure washed at high temperatures; they also have a retention force of 10,000N – the highest currently available on the market – so are ideal for ensuring guard doors are held closed until machines and/or processes are in a safe condition. Each module is just 40mm in width, so can easily be fitted to 40mm guarding sections or other areas where space is limited. For more information contact Fortress Interlocks Ltd, Tel: +44 (0)1902 349000 sales@fortressinterlocks.com www.fortressinterlocks.com

PROCESS INDUSTRY INFORMER March - April 2016

FOOD SPECIAL FOCUS

HOW CHANGES IN THE RETAIL WATER SUPPLY MARKET MIGHT CUT COSTS With less than 12 months to go before further water market deregulation comes into effect in England, process companies should be ready to seize the opportunity to drive down costs, explains Nick Simpson, Marketing and Communications Director at SUEZ Treatment Solutions UK.

s of April 2017 the water market for England will follow the model already in operation in Scotland, and will enable companies (non-domestic water users) of all sizes to choose their water supplier. This is in much the same way as companies have in recent years been able to shop around for the best energy deals from different suppliers. In principle, this offers considerable opportunity for companies across the process sectors to cut their water costs, eliminate inefficiencies, reduce the complexity of sourcing across multiple sites and explore ways of reducing consumption. Process applications, from oil and gas to food production, use considerable volumes of water, so any potential cost savings will be welcome, as will the opportunity to explore further ways of reducing overall consumption to comply with sustainability targets. Two examples highlight this point: Scotland’s largest petrochemical site in Grangemouth consumes around 50 million litres of water per day – more than the entire city of Edinburgh, while the UK’s 1,400 or so breweries typically use between 60 and 300 litres of water to brew one single pint of beer.

THE RISE OF COMPETITION Competition for water services was first introduced in England in 2003, when high volume commercial (i.e. non-domestic) customers using more than 50,000 m3 (50 megalitres) of water per year were able to choose their suppliers. This Water Supply Licensing programme was, however, limited in scope and did not introduce realistic financial incentives or a suitable market structure to create true competition. Although the threshold in England was subsequently reduced to 5,000 m3 (5 Megalitres) per year the same basic restraints continued to apply to the market. In particular, with 22 different regulated water suppliers across the country, issues such as non-standardised billing, complex tariffs, low levels of customer satisfaction and high costs for companies in dealing with transactions across multiple sites, have become common. In Scotland, the situation is different. Water market deregulation has been in force since 2008. As a result, it is estimated that there has been efficiency savings worth over £43 million, with customers saving around 20 billion litres of water and around 50% of businesses taking the opportunity to renegotiate the arrangements for their water and sewerage services. The Scottish market structure is relatively straightforward, with the country’s 130,000 non-household customers being able to choose between 16 different suppliers or Licensed Providers. Each of these purchases water and sewerage services at wholesale prices from Scottish Water, which is responsible for maintaining the publically owned water infrastructure (pipes, mains and treatment facilities). The licensing authority is the Water Industry

Commission for Scotland, with a separate body, the Central Marketing Agency, being responsible for transferring customer information between retailers and for calculating the wholesale transactions between retailers and Scottish Water. The general consensus is that deregulation of the water market in Scotland has been successful. As a result, and based on this experience, the Government in England now proposes to remove the consumption threshold for all non-household premises in England in 2017. The first step towards this goal was the introduction of the Water Act, which passed into law in 2014. This Act is intended to allow all business customers, plus public sector, charitable and not-for-profit organisations in England, to choose their supplier of water and sewage services, regardless of where they are located in the country. The objective is to make it possible for businesses to negotiate the package of services that meets their requirements, in terms of price, efficiency, customer service and support. The Act also makes it easier for water companies to sell and supply water to each other and enables incumbent water or sewerage companies, with the consent of the Secretary of State, to withdraw from the market – the so called ‘retail exit’. Additionally, the Act enables owners of small-scale water storage facilities to sell surplus water to the public supply network. The organisational market model will be similar to that pioneered in Scotland, with wholesalers selling water to licensed retailers, who in turn supply non-domestic customers with retail services, billing, meter reading and operational information. Wholesalers can also supply operational services direct to their business customers, while a centralised market operator manages the flow of customer and transactional data between the wholesalers and licensed retailers. With around one million eligible companies, the English market is around eight times larger than that in Scotland. In Wales, however, the existing threshold of 50 megalitres will remain in place as the Welsh Government has no plans to adopt a similar programme of water market deregulation. In 2014, a programme of consultation and planning was put in place to develop and test the appropriate price control frameworks, IT systems and protocols to ensure a successful go-live date in the second quarter of 2017. A key part of the process has been finding ways to centralise and amalgamate multiple data sets, containing customer and supply records from all the current water companies, many of which use dissimilar legacy systems. This work is being managed under the Open Water Programme, which was set up by the Government, drawing together expertise from a variety of key market participants, including Defra, Ofwat, Market Operator Services Ltd (MOSL) and other interested stakeholders.

COST SAVING OR COMPLEXITY? In principle, deregulation could help process companies reduce their water costs. In reality, the situation is likely to become more

PROCESS INDUSTRY INFORMER March - April 2016

complex before its intended benefits are realised, with the risk that many companies will temporarily be diverted from their core activities as the 2017 deadline approaches. In simple terms, deregulation should allow businesses to reduce the cost of water and sewage services, either through renegotiation with an existing supplier or by transferring to a new one. In practice, there are likely to be some teething problems. For example, companies that operate from multiple sites around England, and which source water from different local water suppliers, might experience problems. There is a risk that pricing structures actually become more complex, rather than more transparent, which may make it difficult for all customers to negotiate worthwhile discounts. Another concern, however, for process companies is that some water retailers may not understand the demands and challenges of the water requirements for large industrial sites, and therefore may not be able to provide the most appropriate advice or support. It’s also true that, for some companies, the management of water and wastewater has not historically been a priority, so the expertise required to achieve the greatest efficiencies, in terms of the cost for source water, process water utilisation and savings, and wastewater treatment, recycling and disposal, may not exist within each organisation. As a result, preparing for the 2017 deadline, negotiating the best deal and managing this on an on-going basis could add to the overall operating costs. Nonetheless, to take advantage of the changes in the water market, process companies in England need to develop effective strategies for managing water and wastewater. For many companies, price may only be part of their requirement. They may, for example, place equal or greater value on factors such as single billing for multiple sites, flow monitoring, security of supply, greater water efficiency, enhanced customer or water hygiene services or carbon reduction. One option is to consider outsourcing the responsibility for water and wastewater treatment, including cost and contract negotiations, to specialised providers, such as SUEZ Treatment Solutions UK. In many respects, this type of outsourcing is no different to that of many other non-core business services such as warehousing, IT or payroll and brings similar advantages – allowing the company to focus on its core process business while delivering cost savings, risk reduction, efficiency gains and, ultimately, a return on the bottom line. Whichever approach is taken, the further deregulating of the water market in England offers real potential for those companies in the process sectors. However, the introduction date of April 2017 is looming fast, making the next few months the perfect time for both a strategic review of your water needs and the subsequent development of a long term water and wastewater optimisation and efficiency plan.

FOOD SPECIAL FOCUS

INNOVATIVE LOAD CELLS OFFER A FRESH START TO FOOD PRODUCTION PROCESS Developments in food production in recent years have resulted in more stringent hygiene requirements during the production process. Bernd Knoll, International Product Manager, explains these guidelines and looks at how the design of systems and the components involved play an important role in excluding micro-organisms from the production process.

istorically, preventive measures were not employed for microbial contamination of food during the processing cycle. Instead, the focus lay on the removal of micro-organisms after processing, for example by the application of heat, or the control of oxygen and carbon dioxide concentrations and the removal of the nutrients needed for microbial growth. However, in line with the recent trend for consumers to demand food that is fresh, untreated and without preservatives or other additives, it must now be virtually impossible for micro-organisms to enter any stage of the production process, making hygiene a crucial factor. In line with these industry demands and the publication of the EHEDG (European Hygienic Engineering and Design Group) guidelines, a visible shift towards preventative measures rather than reactive hygiene measures has become common practice. Made up of a consortium of manufacturers, food producers and research institutes, the EHEDG has laid out a series of guidelines which reflect the need for components of food processing equipment to comply with hygiene standards – the most important guideline being that systems and components must be easy to clean. However, how can we be sure that these guidelines do not leave too much room for interpretation?

environments which demand a high level of hygiene, such as the pharmaceutical and food industry, developers face a challenge. In order to meet this challenge adequately, designers must first understand the basic microbiological influences in the production area. Although the most common contamination may originate in raw materials, the product may also be contaminated with micro-organisms during the actual production process itself, as a result of poorly designed equipment for instance, equipment may be difficult to clean meaning that residues may be retained in crevices or dead areas, allowing micro-organisms to survive and multiply; which can then cross contaminate subsequent batches of product.

EXCLUDING MICRO-ORGANISMS FROM THE PROCESS

WEIGHING UP THE PROS AND CONS

Setting aside the actual surfaces that are used in the food production process, these measures are relevant to all systems and components, such as weighing systems used in filling and packaging systems, which are used in the production process. As systems and components are often used in areas where contamination or cross contamination is highly probable due to the direct or indirect contact with other products, the requirements for a hygienic weighing system design are particularly strict according to the guidelines set out by the EHEDG, so how does this apply to load cells? Up until recently, the development of load cells has been clearly focused on meeting the technical specifications such as quality and precision. However, as load cells continue to be used in

In order to comply with EHEDG guidelines and to avoid potential contamination, the housing of a load cell should be made completely of stainless steel alloy 1.4404 in accordance with AIS131L, which meets the requirements for corrosion resistance, mechanical stability and non-toxicity of components in contact with this product. In addition to this, the material used must also demonstrate particularly high corrosion resistance, even in the case of exposure to solutions containing chloride, dependent on concentration and temperature. Lastly, the complete housing should have smooth, stainless steel surfaces that are non-absorbent and free from imperfection such as grooves and gaps, to avoid gathering, and an even surface structure with low surface roughness of less that 1µm, which is necessary to provide optimum cleaning.

BASIC REQUIREMENTS FOR HYGIENIC DESIGN Although load cells do not come into actual contact with products in automatic mixing and batching equipment, it is essential to counter creeping contamination and the resultant spreading of germs. With this in mind, components are now being developed that are both hygienic and also provide the necessary technical solutions; meaning that the principles for hygienic design are now being employed on all equipment in the direct vicinity of food processing equipment.

Other features which also need to be considered when developing a hygienic load cell include:

- Welded joints – the micro-plasma welding process used should produce clean, smooth, welded joints with no roughness on which dirt may collect or become engrained. This would ensure the welded joints do not impair cleaning. - Rounded corners – all corners should be rounded and not

feature sharp edges. The adjustment chamber, for example, should be welded at the corners to ensure that sharp edges are avoided. - Self draining – there should be no horizontal surfaces on any part of the housing. The upper section of the housing should have an inclined surface to enable water to flow freely away. The adjustment chamber should also be rounded to prevent water from remaining on the surface.

GLOBALLY UNIQUE WITH EHEDG CERTIFICATION The PW25 and PW27 aseptic load cells from HBM have been specifically designedfor use in weighing systems in the food and beverage industry. To meet the fundamental requirements with regards to cleaning, they are hermetically encapsulated and are manufactured in stainless steel which guarantees that the load cells are compatible with all the cleaning and disinfectant agents currently used by the food industry. The design of the load cells also makes it particularly easy to clean for example, the top surfaces are inclined to prevent the collection of dust, product residue or water droplets, while laser etching replaces the usual specification stickers. With daily cleaning likely to include disinfectant agents and/or high-pressure steam cleaning, the PW25 and the PW27 is also ingress protected to IP68, with IP69K as an option for added protection. Furthermore, the PW27 hygienic load cell from HBM is EHEDG certified making it suitable for the humid and aggressive conditions which are typical for applications within the food sector.

CONCLUSION Although a primary objective of design is the need for the equipment to fulfil its engineering function, in the food sector there is the added imperative that food safety is never compromised. This means hygiene has to be taken into account in every part of the food manufacturing process, including the load cells. Upgrading equipment to meet the EHEDG guidelines may require initial capital outlay, but the long term benefits of doing so could not only enhance product safety but also increase life expectancy of equipment, reduce maintenance costs and consequently lower overall operating costs. Founded in Germany in 1950, HBM is today the technology and market leader in the field of test and measurement. HBM’s product range comprises solutions for the entire measurement chain, from virtual to physical testing. The company has production facilities in Germany, USA and China and is represented in over 80 countries worldwide.

PROCESS INDUSTRY INFORMER March - April 2016

FOOD SPECIAL FOCUS OPTIMISING SAFETY MEASURES IN HIGH PRESSURE SYSTEMS Albion Valves (UK) Ltd, an increasingly popular UK valves supplier is advising distributors to ensure they check for type test approvals and certification of the EU’s Pressure Equipment Directive (PED) conformity, when specifying safety valves, as opposed to relief valves in a pressurized system.

Both safety valves and pressure relief valves are used as the last safety device in a pressure system, however engineers and specifiers need to be mindful that requirements can vary significantly from system to system. In applications where PED is applicable, it is mandatory to use safety valves with the appropriate approvals. If a valve without type test approval is installed there is no guarantee that required blowoff at 10% would be reached, which poses a big safety risk. In a system that doesn’t fall into this directive, it is at the discretion of the engineer whether or not to use a type test approved safety valve. In this instance, generally a relief valve designed with proportional opening characteristics and therefore a lower blow-off capacity can be safely specified. However, it is important to realize that the liability for using a non-conforming product rests with the installer, which is why Albion recommends using a certified safety valve wherever possible. In order to help take the headache of complex EU legislation compliance away from their distributors, Albion has introduced an extensive range of PED compliant safety products. Safety valves are all either set, sealed and certified by the factory, or onsite at Albion on a test rig prior to dispatch. Each valve is laser etched with its own unique serial number to allow certification to be traced. Albion currently stocks over 5000 lines of commercial valves, suitable for applications predominantly within the process, water, building services and HVAC industries, all available from its distributor network.

For further information contact: Albion Valves (UK) Ltd, Barnsley, S.Yorks. Tel: 01226 729900 / E-mail: sales@albionvalvesuk.com / Web: www.albionvalvesuk.com

PROCESS INDUSTRY INFORMER March - April 2016

BEKO TECHNOLOGIES CAN NOW MEASURE COMPRESSED AIR TO ISO 8573-1 class 1 BEKO TECHNOLOGIES can now measure compressed air to ISO 8573-1 class 1 of the ISO standards. This is extremely important for industries such as food & beverage, pharmaceutical, medical, automotive and many more.

BEKO TECHNOLOGIES have a portable test rig which comprises of the following four components:• METPOINT OCV system for the measurement of hydrocarbon levels downs to 0.003 mg/m3, which allows for accurate measurement well below the class 1 standard of less than 0.01 mg/m3. • The METPOINT dewpoint sensor capable of reading down to -100c pdp which is also well below the class 1 for Moisture of -70c. • METPOINT BDL an innovative graphic display for the recording of the parameters for compressed air and gas applications. • Lastly we have a laser particle counter. This measures at 0.1, 0.5, and 1 micron particle sizes as per the ISO 8573 requirement, which allows the compressed air particulate contamination to be measured and classified as low as class 1 particulate. How it works: The Portable Tester is connected into the customers compressed air supply. The level of filtration and drying is then checked and confirmed that it has been sized to achieve a minimum of class 3 for particulate, class 4 for moisture and class 2 for hydrocarbons. This is done to ensure the unit is not contaminated. We then run the portable tester for a minimum of 1 hour, at a flow rate of a minimum of 1 m3/min, this allows the METPOINT OCV to get up to temperature, the dewpoint sensor to dry down, and the particle counter to purge itself and the pipework. Once the readings are stabilised, they are fed into the METPOINT BDL data logger then are recorded on a comprehensive test data sheet with classification findings. The results are then given to the customer with recommendations. We will be showing our portable air tester at the Foodex exhibition 18th-20th April. Please come and see us.

Alternatively for more information, please contact our service team on 01527 575778 or E-mail us at info@beko-technologies.co.uk or visit our Website: www.beko-technologies.co.uk

FOOD SPECIAL FOCUS

CLEARFLEAU COMMISSIONS FIRST ANAEROBIC DIGESTION PLANT TO ECLIPSE MAGNETICS REVEAL THEIR SUPPLY THE UK GAS GRID WITH BIOGAS GENERATED ONLY FROM CHEESE NEW COMPACT AUTOMATED FILTER PRODUCTION RESIDUES AT MACH 2016

Eclipse Magnetics is pleased to announce an exciting new addition to its leading range of advanced magnetic filtration systems, which was revealed at MACH Exhibition 2016. The Autofiltrex is an automated filtration device which

ensures ultra-polished fluids on a 24/7 basis. This revolutionary sub-micron filtration system is fully automated, features on-board PLC, automatic reclaim and cleaning. Effective in the vast majority of general machine tool and steel finishing operations, such as grinding, milling and turning machines, the Autofiltrex is the perfect solution for those requiring a sub-micron performance filter to improve product quality. As a fully intelligent filter, the Autofiltrex works offline with no interruption to the manufacturing process, and can be left on to polish fluid even when the machine itself is not in use. This ‘plug and play’ device effectively prevents the build-up of contamination in the tank, facilitates the simple reclamation of contamination, and extends fluid life by considerable margins. With virtually zero running costs and no consumables required, the filter features a large collection/contamination tray, and collapsible legs. The Autofiltrex also has the ability to interface with controls on CNC machine tools.

Eclipse Magnetics Sales and Marketing Director Steve McAllorum said: “We have designed and developed the

Autofiltrex as part of our development programme to provide worldwide markets with an automated filter for smaller applications. We are confident that the product satisfies a gap in the market for a high performance, reasonably priced, automated filter. The Autofiltrex is price positioned to be cost effective for single and multi-machine operations, providing effective contamination reduction.” The Autofiltrex filter will be unveiled at the Eclipse Magnetics stand at MACH 2016, where visitors will have the opportunity to learn more about how its unique sub-micron filter can improve the manufacturing process in a variety of sectors. With 100 years’ experience in magnetic technology, Eclipse Magnetics produces some of the most efficient and advanced filtration systems for industrial fluids in precision machining applications. They supply some of the leading names in the automotive, bearing manufacture, steel processing, tool cutting and grinding sectors with a range of manual and automated high performance filtration systems. For more information contact Eclipse Magnetics via Tel: 0114 225 0600 E-mail: info@eclipsemagnetics.com Web: www.eclipsemagnetics.com

Award-winning British company Clearfleau, leading British provider of on-site treatment solutions for the food and beverage sector, is commissioning its most complex plant to date, which will feed bio-methane into the gas grid in rural Cumbria. By feeding the bio-methane into the gas grid, the facility will produce over £3m per annum in cost savings and

revenue, while supplying up to 25% of the creamery’s energy requirements. The plant has been designed and built for Lake District Biogas, which will operate the site for twenty years taking feedstock from First Milk’s Aspatria creamery site. This comprises low-strength wash waters such as process rinses, supplemented by whey permeate (cheese production residue after protein extraction for use in energy supplements). This is pumped to the AD plant from the creamery. This is the first on-site Anaerobic Digestion (AD) plant in the dairy industry in Europe to feed bio-methane to the gas grid, generated exclusively by digesting its cheese making residues. When the plant is operating at full capacity later this Spring, it will treat 1,650m3 per day of process effluent and whey and generate around 5MW of thermal energy. It will produce 1000m3 of biogas per hour, of which over 80% will be upgraded for injection into the national grid. At least 60% of the bio-methane will be used in the creamery for steam generation, with the balance being used by local businesses and households in Aspatria. Revenue benefits include 20-year index-linked, government-backed incentive payments, with about £2 million per annum in support through the government’s RHI scheme and a further £1 million through the sale of gas to the wholesale market and from the Feed in Tariff scheme for the power generated in the CHP engine. The new plant, with its state of the art British technology, will take over from the outdated aerobic plant. This will have saved First Milk from having to upgrade the old inefficient plant, reducing their effluent treatment costs and carbon footprint, while cutting operational costs, which are borne by Lake District Biogas. Additional benefits from the deployment of on-site digestion in the dairy processing sector include reduced energy and off-site disposal costs. Clearfleau’s unique process takes the feedstock from the Aspatria creamery site, comprising low-strength wash waters such as process rinses, supplemented by whey permeate (cheese production residue after extracting protein used in energy supplements). The liquid is then pumped into the AD plant from the creamery where the bugs convert the fats and sugars in the feedstock into biogas. This is stored in the gas dome before being upgraded to bio-methane - 80% of the biogas is fed to a membrane based upgrade unit that removes carbon di-oxide from the gas to produce bio-methane with a comparable thermal value to North Sea gas (some biogas is also fed to a CHP unit to provide power to run the treatment plant). The food industry is now realising the contribution production residues can make to the circular economy. After the recent Paris Climate Change Summit, CEO’s of global food companies including Unilever and Nestle stated: “We want the facilities where we make our products to be powered by renewable energy with nothing going to waste.” Gordon Archer, Chairman of Lake District Biogas says: “Completion of this £10 million project on time, given the weather conditions in Cumbria this winter, has been a major achievement for the project team and Clearfleau. This is the largest AD plant on a dairy processing site in Europe dedicated to handling the residual materials from the cheese making process and we look forward to working with Clearfleau on future projects.’’ Craig Chapman CEO of Clearfleau Limited says: “Dairy processors can generate value from their residues with a better return on investment than for other more conventional treatment and disposal options. This project, generating biogas solely from creamery residues is based on British engineering and is transforming the way in which the dairy industry manages its residues. This shows how sustainability can be an integral part of our food supply chain. We are looking at other dairy projects as more companies realise the energy potential of their residues.” As an initial step, Clearfleau refurbished the existing aerobic plant to enable First Milk to significantly reduce levels of phosphate in their effluent, which is discharged to the River Ellen. Supported by the Environment Agency, this will ensure an early delivery of new tighter discharge standards, which are required by the Water Framework Directive. Clearfleau’s on-site AD technology is proven to reduce the chemical oxygen demand (COD) of the production residues by at least 95%. Aerobic polishing will then remove residual COD and nutrients (nitrates and phosphates) to allow safe river discharge. For more information contact Clearfleau Ltd, Bracknell, Berkshire. Tel: 0844 477 6292 / E-mail: info@clearfleau.com / Web; www.clearfleau.com

PROCESS INDUSTRY INFORMER March - April 2016

LAPPING & POLISHING SYSTEMS ENGIS LAPPING BOOSTS SEAL QUALITY & RELIABILITY Seals manufactured in advanced materials play a vital role in industry sectors including petrochemical, energy, industrial and defence and require extreme precision in flatness, parallelism and finish.

These components, produced in high volume, in carbon-based materials as well as silicon carbide, include mechanical seal faces and sliding axial and radial bearings in sizes ranging from less than 0.9mm to greater than 500mm diameter. Engis lapping and polishing systems, including machines, accessories and consumables, are capable of consistently generating extreme flatness with 0.5 nm RA surface finishing or better and are suitable for processing virtually all solid materials, including metals, ceramics, glass, semiconductor substrates and advanced materials. Engis UK offers customers an extensive range of grinding, honing, lapping and polishing products from consumables up to fully-configured manufacturing system solutions.... our expertise can put you ahead of the competition. For more information contact Engis (UK) Ltd., Tel: 01491 411117 E-mail sales@engis.uk.com / Web: www.engis.com

PROCESS INDUSTRY INFORMER March - April 2016

INFRARED CAMERAS FLUKE Ti450 INFRARED CAMERA WITH MultiSharp FOCUS DELIVERS IN-FOCUS IMAGES OF EVERYTHING IN THE FIELD OF VIEW FOR GREATER IMAGE CLARITY Fluke has introduced the Ti450 Infrared Camera, a new high-end model in its Professional Series, which takes focusing to a higher plane with MultiSharp™ Focus. An out-of-focus thermal image can be off by 20

degrees or more with no way to correct it once it has been captured, short of retaking new images. The new Fluke® Ti450 Infrared Camera, compatible with Fluke Connect®, solves this problem by delivering in-focus images of everything in the field of view. MultiSharp Focus is a new technology that rapidly takes multiple images focused near to far and combines them to produce one image with all objects in focus. The advanced focusing system enables users to capture an automated, in-focus image of all potential targets, delivering the image clarity needed by professional thermographers and maintenance managers to provide better images and avoid costly rework. SuperResolution mode increases image resolution to 640 x 480, delivering images with four times more pixel data than normal resolution.

For further information contact Fluke (U.K.) Ltd., Norwich, Norfolk Tel: 0207 942 0700. E-mail: industrial@uk.fluke.nl / www.fluke.co.uk

FOOD SPECIAL FOCUS

COMBATTING COMPRESSORS:

TACKLING ENERGY WASTAGE IN THE FOOD PROCESSING SECTOR

The food and beverage industry is one of the UK’s largest manufacturing sectors, both in terms of production and exports. Advances in modern production technology have given manufacturers much greater control over their operations, and temperature control – both in terms of process and facility cooling – is central to achieving consistent output. However, it often comes at a cost.

ith the shadow of energy consumption legislation lingering over the food and beverage manufacturing sector, Brent Hall, Technical Manager at ICS Cool Energy, outlines how the efficiency of refrigeration systems could hold the key to achieving the savings mandated by the European Union. There is often a misconception surrounding refrigeration in food processing applications. Whilst some may view it as a necessary evil, due to the fact it consumes a large amount of energy, it is nonetheless an integral element of nearly all applications across the sector. Like so many other market sectors of the UK economy, the food processing industry’s level of energy consumption is subject to strict governance by the European Union’s Ecodesign Directive. Given the majority of legislative changes are aligned to specific product groups, be it pumps, fans or compressors, there is a constant stream of updates of which end-users must be aware of in order to ensure their processing plant is operating in line with EU legislation. Whilst the sheer volume may be intimidating to the end-users, understanding the implications and ensuring any upgrades or investment to processing equipment is undertaken in line with the Ecodesign Directive’s respective legislative mandates will go a long way to reducing a site’s overall energy consumption, and ultimately, their utility bills.

DELVING INTO THE DETAIL Within a refrigeration system – be it a chiller unit or a direct refrigeration system – the compressor is by far the biggest user

of energy; and for me, one of the biggest energy consumption challenges facing the food and beverage industry over the next 10 years is how to reduce compressor power consumption without affecting the overall performance of a refrigeration system. However, achieving this is not an easy process. A compressor’s basic function is to pump a gas from one pressure to another, and that will always expend a certain amount of energy – that’s physics. Therefore, whilst the principles of vapour compression will remain the same, it is the compressor technology which must change in order to achieve the greater target efficiencies outlined by the Ecodesign Directive (Lot 31). In order tackle the issue of compressor efficiency in refrigeration systems, I would say that, collectively, the food and beverage industry needs to look for inspiration from the operating processes of some of the larger compressors. For example, oil-free compressors with magnetic bearings offer improved efficiency levels by reducing moving parts, removing the need for traditional bearings and the associated friction.

CONSIDERING THE VARIABLES Whilst oil-free compressors represent one potential avenue for inspiration, in reality the technology is not yet widely available in the sizes needed for use in chiller systems. Ultimately one of the most accessible methods of improving energy efficiency in the refrigeration market is the development of compressors which utilise optimised variable speed drives. Variable speed drives have become a go-to retrofit solution for curbing inefficiency in a number of motorised industrial processes, such as pumping systems, and the principal is just as suitable for compressors. Many compressors currently in operation are running on one

fixed speed regardless of demand, and generally achieve a co-efficient of performance (or energy efficiency rating) of 3kw of cooling to 1kw of power. However, applying part-load optimisation through a variable speed drive to Scroll and Screw compressors could allow operators to achieve a ratio of 4.5-5kw of cooling to every 1kw of power: an improvement of circa 5060 per cent. Whilst, as with most modern advances in technology, I would expect to see material cost being driven up, this initial capital increase is a nettle the industry needs to grasp. Doing so will pay dividends given the increased spend on new equipment will be offset by a reduction in energy consumption and, consequently, both carbon emissions and energy bills. Given the integral role of refrigeration within the food processing sector, this saving could easily translate into thousands of pounds in savings for processing plants each year.

FINAL THOUGHTS On the whole it appears that the technology is not too far away, as it is currently available as optional extras on larger plant. However for the food and beverage industry to realistically achieve the savings mandated by the EU, such advances must become commonplace across all chiller equipment within the next 10 years, if not sooner. In short, we need to ensure that advances in larger compressor technology continue to find their way down into smaller compressors, such as those used by chiller systems in the food processing industry. Given the amount of energy it traditionally uses, refrigeration technology is rightly under pressure to contribute to making significant energy savings; after all the planet is not an infinite entity and we have to do our bit to look after it.

PROCESS INDUSTRY INFORMER March - April 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves

Bürkert Fluid Control Systems has recently launched the latest incarnation of its diaphragm valve body that has been manufactured using hydroforming technology to deliver a number of benefits. Designed for use in hygienic process

applications, the new tube valve body meets the latest standards for pharmaceutical, cosmetic as well as food and beverage industries. Fluid control systems within hygienic applications demand high standards in terms of clean ability which can be affected by a number of design characteristics. The base material is normally 316L stainless steel which requires an excellent surface finish in order to maximise the efficiency of the clean-in-place (CIP) process that is used to sterilise the process pipework. Coupled with excellent thermal properties, the design of process valves has become a complex process. Bürkert has delivered the next evolution of valve manufacture by patenting a new procedure to create process valves using hydroforming technology. This has significantly reduced the amount of material used as well as allowing uniformly high quality laser welds that do not add any further material to the component. The process starts with the flange, which is laser cut and milled, and the tube, both of which are from 316L stainless steel. The tube is placed in a mould, filled with a water-oil emulsion and subjected to around 3,000 bars of pressure to produce the required flow path to and from the weir. The flange and tube are then laser welded together before the new component is annealed in order to relieve residual stress within the material. This heat treatment process also increases the durability of the material by improving the corrosion resistance. This is enhanced by precision machining of the surfaces of the flange before the final polishing stages are completed. In the past, the polishing process may have been completed by hand using small electric polishing wheels, which can be rather labour intensive and time consuming. For more information contact Helen Christopher, Marketing Manager Email: helen.christopher@burkert.com Tel: +44 (0) 1285 648720 www.burkert.co.uk.

GRIP COUPLING FOR ALL METAL PIPES TM

MV Fluids Handling’s Straub Grip Coupling simplifies pipework, design and installation over traditional pipe-joining techniques. Metal pipe from 3/4in to 24in can be joined in minutes. The Straub Coupling joins plainend metal (black, cunifer, galv., or stainless) pipe with axial restraint and without the associated risks of ‘hot-work’, welding, or burden of

expensive grooving/threading machines. The slim-line coupling encases a patented sealing gasket that is progressively activated by the media pressure in the line, whether it be gas or liquid. Since Straub’s progressive seal encapsulates the line medium, ensuring no contact with the coupling’s metallic casing, it provides a cost-effective means of joining stainless or exotic alloy pipes in chemical applications. Straub’s unique patented design guarantees full re-usability performance in joining plain-end pipework in high maintenance applications, such as frequent blockages and eroding bends, without call for preparation (machining), pipe setting-up, or coded welders and other complicated procedures involving safety permits.Increased coupling range now available from Ø26 to 609mm. Temperatures -30°C to +125°C in the range Ø26 to 60mm, and -30°C to +100°C up to Ø219mm, and beyond to 80°C. For more information contact MV Fluids Handling, Tel: 0118 9503707 / E-mail: straub@mvfh.co.uk / Web: www.straub.co.uk

PROCESS INDUSTRY INFORMER March - April 2016

COMPACT PUMPS FOR GENTLE PUMPING OF SENSITIVE INGREDIENTS When you need to transfer products and ingredients with suspended solids and particles such as those occurring in the food, brewing, beverage and pharmaceutical industries, the CSF range of progressive cavity pumps is the ideal solution. Available in the UK through liquids handling specialists PUMP ENGINEERING, the CSF range includes the eccentric screw, positive displacement MAE series of pumps.

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

WASHDOWN CLEAN UP... The CSF Steam Water Mixer is perfect for cleaning and washing down process machinery or storage vessels. ● Delivers water to a maximum temp of 95˚C

and volumes up to 10,000 litres/hour.

● Simple to install, safe to operate. ● Running costs minimised, because all the

heat energy in the steam is transferred to the water.

Safe, simple cleaning with CSF water mixer

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

AB15-911

NEW HYGIENIC DIAPHRAGM VALVE MEETS PHARMACEUTICAL, COSMETIC AND FOOD & BEVERAGE STANDARDS

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves VERDERFLEX DURA 5 & DURA 7 HPLV: HIGH PRESSURE LOW VOLUME DOSING PUMPS The Verderflex Dura is the first real advance in hose pump technology since the high pressure hose. The Verderflex Dura 5 and Dura 7 combine a close coupled

pump’s compactness with traditional long coupled pump benefits in superior High Pressure Low Volume dosing pumps. Unlike traditional high shear pumps that reduce flocculent particle sizes and result in both increased chemical use and higher operating costs, the Verderflex Dura 5 and Dura 7’s bring gentle pumping to sub-litre per hour flow rates. Off-Gassing liquids, such as Hypo, often cause traditional pumps to vapour lock, however, the Verderflex Dura 5 and Dura 7 readily pumps these liquids with ease. With no valves or stators to wear, Verderflex Dura 5 and Dura 7 pump lime and similar highly abrasive chemicals at a pressure of 5 to 8 bar with minimal downtime. Other features of Verderflex Dura 5 and Dura 7 include: •Care free dry running capabilities •No clogging maintenance costs •Long life heavy-duty hoses •True dry priming eliminating pre-wetting and priming •Superior secondary containment and viscous performance. In addition to the above advantages, the simple to use Verderflex Dura 5 and Dura 7 provide scalable performance and low maintenance. They are an excellent chemical dosing solution for water-treatment, brewing and food industries with much lower operating costs! For more information contact Verderflex Ltd, Tel: +44 (0) 1924 221020 / E-mail: info@verderflex.com / Web: www.verderflex.com

NEW WATSON-MARLOW 530 PUMPS ENSURE SAFE, ACCURATE AND INTUITIVE OPERATION FOR INDUSTRIAL & ENVIRONMENTAL APPLICATIONS •New 530 peristalic process pump delivers optimised chemical metering coupled with accurate and repeatable flows of difficult fluids. •Abrasives and suspended solids can be handled with ease. •With no seals or valves to wear rapid, simple maintenance and maximum process uptime is assured. •530 range delivers a range of control methods, manual, remote, analogue, digital communication and PROFIBUS. Watson-Marlow Fluid Technology Group, the world leader in peristaltic pumps and associated fluid path technologies, has introduced its new 530 peristaltic cased pump for metering and transfer applications such as surface coating, printing and lime addition. The cost effective pump offers easier operation and greater versatility coupled with high levels of accuracy. NEW FEATURES The new 530 models meet the demands of rugged and often remote environments and are built to operate 24/7 without interruption. Furthermore, it is possible to quickly check control parameters and avoid expensive errors with visual status through a bright colour display, while an intuitive menu structure makes for confident and easy operator interaction. Users will also benefit from the 530 models’ integrated PROFIBUS networking capabilities. With two-way, real-time communications, the 530 range offers increased diagnostic capability and faster response. This helps to optimise process control and minimise plant downtime. DRIVE AND PUMPHEAD OPTIONS The versatile Watson-Marlow 530 range of process pumps offers four drive options and nine pumphead variants. This enables users to choose from manual operation to fully automated control, including the ability to link up to 16 pumps and provide real-time communication. The pumps deliver flow rates from 0.0001 ml/min to 3.5 litre/min. It is the pumphead which determines both the flow rate and the pressure that can be achieved to match the needs of the specific process. 530 pumps can be fitted with either continuous tubing pumpheads, or with LoadSure tube element pumpheads for pressures up to 7 bar. MAXIMUM PROCESS UPTIME Meeting the demands of rugged and often remote environments, the new 530 pumps deliver maximum process uptime and are built to operate 24/7 without interruption. In addition, the 530 pumps have no expensive seals, valves or diaphragms, and do not suffer gas locking, corrosion or clogging. Furthermore, they require just a single spare part inventory – the tube. PUMP AND TUBING HAVE EQUAL IMPORTANCE As the only company to manufacture both the cased pumps and the peristaltic tubing, Watson-Marlow customers can be sure than their new pump will work right first time – and every time. For the new 530 models, the company’s long life and chemical resistant Marprene is the ideal choice for industrial applications. Marprene industrial grade thermoplastic elastomer tubing offers wide chemical compatibility and long life, along with low gas permeability. ERROR-FREE TUBE LOADING Depending on a user’s process needs, the 530 models can feature LoadSure tube elements, which fit into position for simple, error-free tube loading. Using the patented LoadSure D-connectors and easy-grip clutched rotor, the tube element can be changed in less than one minute without the need for special skills. For more information contact Watson-Marlow Fluid Technology Group, Tel: 01326 370370 E-mail: info@wmfg.co.uk Web: www.wmftg.com

PROCESS INDUSTRY INFORMER March - April 2016

FLUIDS & LIQUIDS HANDLING

incl. Pumps & Valves

NEW RANGE OF POMPETRAVAINI – BORA BLOWERS NOW AVAILABLE Pompetravaini - Bora positive displacement lobe pumps are characterized by innovative design and solutions which enhance performance, reliability and low life-cycle costs.

The three- lobe rotor is an evolution of the classic bi-lobe design, shaped like a figure “eight”. This design ensures higher bending stiffness, and lower pulsation amplitude which consequently reduces vibration. The economic advantage in bearing life is appreciable. The synchro-gears are case hardened and tempered. Gears are accurately ground to ensure optimal timing. The “long addendum” involute design gives maximum efficiency with virtually silent mechanical operation. This design allows the vacuum boosters to be installed without a sound canopy. Mechanical noise is kept to a minimum as a result of accurate design and assembly. The gear lubricant is a long lasting, low viscosity PAO oil which enhances machine cooling. The lubricant can be supplied “food grade” for certain applications. These features all help to decrease the machine’s life cycle costs. Pump body, sump and covers are assembled with flat gasket (blowers/exhausters) or O ring seals (Booster HV) to ensure maximum tightness. This results in increased reliability which decreases maintenance costs. Sealing of the rotors is achieved with labyrinth seals, which do not contact, and, therefore, do not create friction. This is ideal for the rotor’s high rotational speed. This solution saves money due to the decrease in energy dissipation, and the absence of any other expensive cooling system. Shaft sealing with double Silicon Carbide/ Graphite mechanical seals ensures high reliability and durability. The diameter of the shaft is specifically designed in order to maximize strength, and reduce peripheral speed, and the associated friction. For more information contact Graham Ikin, Pompetravaini Pumps UK. Tel +44 (0)1625 443170 Email: sales@travainipumps.co.uk Web www.travainipumps.co.uk

PREMIUM GOES PRIME Introducing the new standard in self-priming pump technology: The Alfa Laval LKH Prime The Alfa Laval LKH Prime Pump sets a new standard in selfpriming pump technology. Based on the market-leading Alfa Laval LKH pump range, it is a versatile, efficient, self-priming pump that uses a combination of air-screw technology and advanced design to meet the most stringent requirements in a range of industries, from food to pharmaceuticals. The superior efficiency of the Alfa Laval LKH Prime results in reduced energy consumption. This, together with the fact that it is based on the market-leading LKH pump range, delivers low cost of ownership and increased uptime. Designed for Cleaning-in-Place (CIP) duties containing entrained air, it can also pump product, potentially reducing the capital investment when designing process systems. Quiet in operation, Alfa Laval LKH Prime is engineered to meet the most stringent standards and hygienic requirements of the food, dairy, beverage, and home & personal care industries. The pump is also available as an UltraPure model, meeting the needs of pharmaceutical customers. For more information contact Alfa Laval Tel: 01675 465191 Email: sales@industrialtradingsolutions.com www.industrialtradingsolutions.com

PROCESS INDUSTRY INFORMER March - April 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves ENERGY SAVINGS + CO2 SAVINGS = GRUNDFOS PUMPS Energy as well as CO2 savings have become increasingly important targets to realise reductions in for many businesses today. There are occasions

when it is possible to simultaneously achieve these ambitions and this is true in the instance of pumps, as they provide the potential to deliver major savings on both fronts. So how can you achieve this? Well at Grundfos Pumps, we offer a range of diagnostic tools including an Energy Check or Pump Audit that will help to establish the current pump system performance. In fact, this is what we found out when we recently worked with a range of clients to see how we could help them. This included a brewery where we delivered an energy saving of 75% simply by identifying and changing key pumps; a chassis manufacturer that benefitted from a pump upgrade and saved 51%, while a power plant saw a saving of 50% from taking Grundfos’ advice. This means that regardless of the priority is cost reduction, CO2 savings, ROI, a water usage reduction or just simply to get advice on your current installations, Grundfos have the tools, expertise and integrity to help you to achieve your ambitions.

To find out more visit www.grundfos.co.uk and see how you could benefit.

THE GRUNDFOS HUB THAT IS ENGINEERED FOR ENGINEERS Grundfos launched their knowledge-based hub last year specifically aimed at engineers who work across multi-disciplines.

This means that regardless of whether your focus relates to commercial building services, process industry applications or the water supply and treatment industries, this on-line destination is for you. Designed by engineers, for engineers, this hub was developed to be an evolving platform whose aim is to keep all engineering partners who are interested in pump technological advances informed about the latest happenings in the industry as well as on the wider subject of fully integrated pump systems. It is broken down into easily accessible sections, with topics such as applications, products and engineering tools, as well as more in-depth areas on energy optimisation, how to build on system intelligence and an opportunity to watch a range of clips such as “Meet the experts” who share their expertise on various applications and their challenges. It is also easy to navigate and to access the information you need. To find out more and see the many benefits for yourself, log on to www. grundfos.co.uk/engineers as with so many dynamic changes happening in engineering, we think you will find this site will quickly become a firm favourite as a source for all things pumps. For more information contact Grundfos Pumps Ltd, Tel: 01525 850000 E-mail: grundfosuk@grundfos.com Web: www.grundfos.co.uk

PROCESS INDUSTRY INFORMER March - April 2016

REPAIR OR REPLACE: THE KEY CRITERIA FOR PUMP DECISION-MAKERS Deciding whether to repair or replace a pump is rarely a black and white issue. Andy Cruse, an expert in both wastewater and clean water pumping at ERIKS, defines the key decision making criteria for pump users and offers his verdict on the repair or replace dilemma.

CRITERIA #1: COST

with potential payback periods, by upgrading their pumping technology, before making a repair or replace decision.

In the end most things come down to cost. If the unit price for a new pump is relatively low it can make economic sense to replace. Our view is that single stage pumps up to 15-22 kW, used in light industrial and HVAC, are replace rather than repair, because the cost of repairing failed bearings or seals, for example, is uneconomic for the pump user. Bigger pumps, such as submersibles, are a different case altogether. This type of pump will have more of a wear characteristic for arduous duty, which is reflected in the price. At this point repair makes much more sense.

THE VERDICT

Repair: if your pump is modern, high efficiency and ErP compliant. Replace: if you are using old, inefficient pumping technology.

CRITERIA #4: PLANT ROOM DISRUPTION Another big issue for pump users. It’s all very well saying it’s easier to replace a pump rather than repair, but much of the

THE VERDICT

PRODUCTION

Arguably the key criteria for pump users in industry. I know of one pump user who accepted the fact that his pump would only have an operational life of circa six weeks and always kept a spare on hand to quickly plug in and keep production going. It’s not an option I’d recommend, because pump operational life can be subject to multiple variables not just the pump itself, but if repair is too costly in terms of downtime, then it is one way of keeping going.

THE VERDICT

Repair: if the pump is in a non-critical production area or a stand-by pump can be quickly brought online. Replace: if the pump is critical to production operations and there is no alternative pump available.

CRITERIA #3: ENERGY EFFICIENCY The European Union has been the driving force behind some very significant improvements in pump efficiency in recent years, which has added another criteria to the pump decision making process. The ErP Directive, for example, enforced a Minimum Efficiency Index which identified minimum hydraulic efficiency that all manufacturers must meet, dramatically increasing pump efficiency. A modern end suction pump, for example, is circa 13% more efficient than its predecessors. Pump users need to be calculating how much energy it is possible to save, along

THE VERDICT

Repair: if the pump is specialist or bespoke and has a long lead time. Replace: if stock is readily available and can be accessed within a short timeframe.

CRITERIA #6: SPARES AVAILABILITY Ready access to spares is a key criteria in assessing whether to repair or replace. For water pumps in light industrial or HVAC, all-toooften the cost of the part, labour and downtime means that any repair or replace calculation comes out on the side of replacement. Process and wastewater pumps are a different case, with manufacturers often making ‘repair kits’ available which have a variety of components that are prone to wear. Obsolescence is another issue. There are plenty of pumps still in the field that are more than 30 years old and which are no longer supported by the original OEM or, alternatively, the cost of spare parts is increasing year-on-year. Pump users need to assess whether continuing with these pumps poses a risk to their operations.

Repair: if you’re using bigger pumps, such as submersibles, circa 30-70 kW Replace: if your pump is in the 15-22 kW range and the unit cost of a new pump is relatively low

CRITERIA #2: DISRUPTION

Bespoke pumps for process applications with special options, such as different impeller sizes or coatings, are a different matter entirely, because they are not as readily available and often are subject to long lead times.

THE VERDICT

existing pump equipment, already in use, has configurations and dimensions bespoke to the manufacturer and not to a BIM or ISO standard. This can mean that direct replacement is nigh on impossible in some cases. What’s more, old plant rooms often have asbestos lagging around pipework which pump users are reluctant to disturb.

THE VERDICT

Repair: if it’s old plant with outdated dimensions and standards and where there is potential for significant disruption. Replace: if it is a modern plant manufactured to international standards offering an easy like-for-like swap.

CRITERIA #5: NEW PUMP AVAILABILITY A criteria that is very much dependent on the pump and its application. For smaller 15-22 kW pumps, both manufacturers and distributors keep plenty of ex-stock available on the most popular sizes, which can usually be shipped in 48 hours.

PROCESS INDUSTRY INFORMER March - April 2016

Repair: if spares and repair kits are readily available. Replace: if the pump is designed for replacement rather than repair and the cost, including parts, labour and downtime, make repair uneconomic.

CONCLUSION Pump repair or replace is not an easy decision, but whilst cost and potential disruption to production are the key criteria, other factors, such as plant room disruption, can lead a pump user coming to the conclusion that, despite increasing spares costs and all the potential for energy saving, there really is no alternative to soldiering on with their current pumps. My advice is to get advice. Often what seems like a pump problem is actually a system issue which the pump is getting the blame for. The only real way to get the best out of your pumps is to step back a moment, assess what the pump is actually being used and whether it is fit-for-purpose, before making informed long-term and strategic decisions.

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves EMERSON EXTEND TEMPERATURE RANGE OF ASCO SOLENOID VALVE FOR USE IN EXTREME CONDITIONS

HYGIENIC ROTARY LOBE PUMPS FOR FOOD & PHARMA DUTIES

The existing ASCO 327 Series solenoid valve has now been made suitable for use in temperatures as low as -60°C, considerably increasing its application options for our customers in the process industry.

Formerly suitable for use down to -50°C, this extension to the temperature range results in a reliable solution for Arctic and Polar conditions, which are increasingly common environments in Oil & Gas exploration. This ATEX certified solenoid valve is already a popular solution in the process industry, thanks to its proven high performance and robust construction. It also offers CUTR and IECEx certifications. This additional feature has been achieved thanks to the inclusion of a Fluorosilicone (FVMQ) seal which provides exceptional temperature resistance. This, in combination with a higher spring force and a power consumption of 5.6/5.7 Watt AC/DC, provides excellent sealing properties and a long life expectancy. Customers will benefit from the same high performance, long life and safety certifications always promised by the 327 Series, even in Arctic/Polar conditions. The total temperature range of the 327 Series now covers -60˚C up to +90˚C. The new feature is available on a range of 327 Series valves with a wide selection available via Express Fast Ship delivery. For more information please visit www.asconumatic.eu/327

For

pumping

applications

which

involve

liquids

containing solid particles such as chocolates and fats or those that are highly viscous, including syrups, honeys and gels; the Inoxpa SLR Rotary Lobe Pump is an ideal solution. Available through MICHAEL SMITH

ENGINEERS the SLR pump is a positive displacement sanitary construction rotary lobe pump suitable for use in the dairy, food processing, beverage, cosmetic, pharmaceutical and fine chemical industries. Designed for maximum efficiency and reliability the SLR pump incorporates two lobe rotors which rotate synchronously inside a casing without contact. As the rotors turn, the spaces between the lobes and the casing are filled with the product, and a fixed volume is displaced with each rotation. The pump generates a continuous smooth flow thanks to the tolerances between the lobes and the pump casing. This enables efficient, low shear pumping, even for delicate or viscous liquids and those containing solids. SLR pumps feature an RA surface finish of < or = to 0.8µm, a bright polished external finish and gaskets / seals to FDA standards to ensure no contamination to food products or other sensitive ingredients. CIP (clean-in-place) or SIP (steam-in-place) at temperatures up to 140ºC can be used as quick, easy and safe methods of cleaning the pump without disassembly. The pump is also reversible (when operated without a relief valve) allowing for unload / offload duties to be performed with the same pump. Units are supplied as standard with hygienic DIN 11851 connections, although other options including RJT, SMS and tri-clamp are available to provide optimum flexibility for specific onsite requirements. Options to suit specific pumping applications are also available including heated jacket to ensure product temperature is maintained and an ATEX rated option allowing flammable liquids to be handled safely. For more information contact Michael Smith Engineers Ltd, Woking, Surrey Tel: 0800 316 7891 Email: Info@michael-smith-engineers.co.uk http://goo.gl/tb3iHJ

PROCESS INDUSTRY INFORMER March - April 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves NEW SEAL-LESS HIGH-FLOW PUMP FROM WANNER A new, seal-less, hydraulically balanced diaphragm pump from Wanner offers flow rates up to 366 lpm at pressures up to 103 bar. Hydra-Cell T100E pumps are ‘packing-free’ and designed to replace horizontal multi-stage centrifugal pumps and packed triplex plunger pumps.

With multiple-diaphragms in a single pump head, Hydra-CellT100E pumps eliminate hazardous emissions and clean-up and disposal costs of packedpump leakage. The design also eliminates the need for external lubrication as well as the plunger wear problems associated with packing. Leak-free Hydra-Cell T100 Series pumps can run dry without damage, will operate with a closed or blocked suction line, and can pump abrasive fluids effectively. These performance features are claimed to enable the T100E pumps to compete successfully with conventional plunger pumps by offering a lower cost of ownership and reduced maintenance needs, while providing longer service life. Initially intended for such applications as salt water disposal, injection and hydraulic lift in the oil and gas industry, Hydra-Cell T100E pumps are already finding favour in other bulk transfer applications and in steam generation. For more information contact Wanner International, Tel +44 (0)1252 816847 Email: NHerrington@wannerint.com Web: www.hydra-cell.eu

Premium goes Prime

Introducing the new standard in self-priming pump technology: the Alfa Laval LKH Prime The premium Alfa Laval LKH range of centrifugal pumps just gained a new family member, the Alfa Laval LKH Prime. This energy efficient, self-priming pump uses a combination of air-screw technology and advanced design to meet the most stringent requirements of a variety of industries, from food to pharmaceuticals. Designed specifically for Cleaning-in-Place duties, this versatile, reliable primeperforming pump delivers low cost of ownership and increased uptime.

Alfa Laval LKH Prime

Alfa Laval LKH

Alfa Laval LKH Prime UltraPure

Alfa Laval LKHPF

Alfa Laval LKH Evap

Alfa Laval LKH UltraPure

It’s time to go Prime. Learn how at alfalaval.com/lkhprime

Industrial Trading Solutions Ltd Tel- 01675 465 191 Email- sales@industrialtradingsolutions.com web- www.industrialtradingsolutions.com

PROCESS INDUSTRY INFORMER March - April 2016

THE ROAD TO

PRODUCTIVITY Managers of process plants strive for increased productivity. Maximising throughput, availability and product quality, while minimising operating, maintenance and energy costs, lie behind getting the most from a plant. Steve Leech, Business Manager – Process Control Systems, Siemens UK & Ireland, outlines how some key areas such as operation, scheduling, virtual commissioning, security and lifecycle services can have a big impact on releasing a process plant’s productivity potential.

ecent headlines have concerned the taxing issue of national productivity. The Government wants, in the words of the Chancellor George Osborne, to ‘crack the UK’s productivity puzzle’, as a key factor for future prosperity, and as a response to the recent challenging economic conditions. While a slowly improving fiscal outlook and higher levels of employment are welcome steps in the right direction, nonetheless figures show that UK plc productivity has languished since the dark days of the financial crisis. According to the Office for National Statistics (ONS), the UK lags behind every G7 advanced economy bar one. Indeed, estimates indicate that output per hour and output per worker is 20% lower in the UK than that achieved by the USA, Germany, France, Italy and Canada. The Government’s ‘Productivity Plan’, published last year, demonstrates a desire to focus on technology investment, skills development, infrastructure spending and driving innovation to support general productivity improvements and fuel economic growth. But what does this mean for those charged with optimising process plants so that increases in productivity can help ensure a brighter future? There are many areas that can support productivity objectives and true optimisation across a process plant. The following are indicative - though not exhaustive - of some of the key aspects to consider on the road to improved process plant productivity performance.

TRANSPARENT PROCESS OPERATION The distributed control system (DCS) is the ‘window to the process’ - the human-machine interface. Any action in the process plant can be operated and controlled via the DCS. Clearly structured user interfaces offer an excellent overview of the entire production process and provide safe and comfortable process operation. Considering the overall supply chain of a production plant from raw material supply via production to product delivery, the production itself is the central step, and the DCS is the central data source for information on production. The integration of the DCS into the IT processes of supply chain management is the foundation of cost transparency in production, such that the financial effect of specific operation sequences can be accounted or predicted.

ADVANCED PROCESS CONTROL (APC) APC methods can be an essential tool to help improve the productivity of a process plant with regards to product quality,

operability and availability, agility, safety and environmental issues. APC solutions can be realised much more cost effectively due to a DCS embedded implementation with standard function blocks and pre-defined wizards and templates for implementing basic APC principles.

The transformation of production orders to a detailed schedule of batches on certain plant units at given starting times contains optimisation potential in the sense of efficient plant operation. Several optimisation targets have to be pursued at the same time while considering limited production resources. These can include: compliance with delivery dates and specifications of product quality; maximising capacity throughput; minimising cleaning efforts when different products are run in the same tank reactor and avoiding peak loads in energy consumption. Again, process optimisation tools such as SIMATIC BATCH can help with batch planning and automatic execution of planned batches.

two major potential factors that impact on productivity. The use of Safety Instrumented Systems (SIS) that comply with the international standard IEC 61511 has been the process industry norm for many years. There are distinct economic benefits that can be achieved through taking a ‘safety integrated’ approach to SIS. The goal of safety engineering is to avoid accidents and consequential damages after occurrence of errors to achieve maximum safety for humans, process and the environment. Operation and construction of process plants with risk potential have to comply with the international standard IEC 615 11 for functional safety of safety instrumented systems. The connection between SIS and Industrial Security is a focus for the process industry. The threat of a cyber security attack in relation to SIS can have long-term damaging effects on a business in terms of impact to human life, ability to produce and brand image. Increasingly, the need to consider and develop an industrial security strategy is becoming day-to-day life for the process industry, a defence-in-depth based approach provides the best opportunity to overcome this issue and ensure that safe production can carry on.

VIRTUAL COMMISSIONING AND SIMULATION TOOLS

LIFECYCLE SERVICES

If the process sector is to match the automotive and aerospace examples with regards to productivity levels, then the use of agile, flexible and proven automation technology solutions such as virtual commissioning and simulation tools to aid engineering projects, automation system design and, even, new plant delivery, holds the key. The requirement for ever shorter commissioning and start-up timescales for new production lines, plant migrations or new plant facilities, is a reality for many. This is where the added value advantages of virtual commissioning through a simulation framework can offer tangible and proven time, resource and cost benefits. Virtual commissioning enables real-time simulation of extensive engineering projects to design, engineer and test automation projects without the risks of working within a ‘live’ environment. Consequently, automation system design testing and the delivery of higher quality code can, for example, shorten overall commissioning times, reduce project risk, eliminate human error, support operator training goals and, ultimately, allow automation projects to move from a test to live environment seamlessly and speedily.

The costs arising in the operational phase of a process plant constitute a significant share of the overall life cycle cost over the typical 15-20 year asset life of a plant control system. The baseline for profitable life cycle costs is high plant availability, achieved by a robust DCS with solid application software based on standards and by preventative plant maintenance. Service costs for engineering support, maintenance and upgrades play an important role as well. Consequently, plant management should be aware that the main requirements for a comprehensive service package include: investment protection through service products; system availability by ensuring serviceability; serviceability using suitable migration concepts and clear obsolescence management linked to the market withdrawal of technical components or software versions. Obsolescence has typically proved a cyclic problem which has culminated in the large amount of legacy control systems we see on UK plant infrastructure. The conclusions that plant owner/operators quite rightly draw is that a large part of the decision-making process to migrate to a modern process control system is its ability to be modernised and innovated without reproducing the same legacy issues that have gone before. A modern DCS platform such as Simatic PCS 7 comes with those lifecycle guarantees built in, and so process manufacturers no longer need to feel that this is a cross they have to bare.

BATCH SCHEDULING

SAFETY AND INDUSTRIAL SECURITY Increasingly safety and industrial security are being seen as

PROCESS INDUSTRY INFORMER March - April 2016

PROCESS MEASUREMENT & INSTRUMENTATION WORLDS FIRST 80 GHz RADAR LEVEL SENSOR FOR LIQUIDS VEGA introduces VEGAPULS 64, the first 80 GHz frequency contactless liquids radar level sensor. This higher

frequency enables improved focusing of the radar beam, making measurement easier and more reliable, even under difficult conditions, in vessels with heating coils, baffles or agitators. The VEGAPULS 64 has a beam angle starting from only 3° with an 80mm/3” antenna size. This allows the sensor to be used in vessels with many internal installations or heavy build up on the walls, the focused microwave beam simply avoids them. The smallest antenna is no larger than a £1 coin, yet still has a narrow 10° beam angle. These compact dimensions enable the sensor to offer an excellent level measurement solution for even the smallest of process vessels. It can also even measure very low dielectric products like hydrocarbons and liquid gases reliably, with an accuracy of +/-2 mm, over a range of up to 30 m. Designed for use in the chemical, oil and gas, pharmaceutical and food industries, the VEGAPULS 64 has a wide range of resistant materials, connections and hygienic designs. In addition to mainstream manufacturing and processing industries, this sensor opens up application possibilities in pilot plants and even laboratories which, for space reasons, could not use radar level technology before. Bluetooth programming options using free downloadable app or PC offer added convenience and user safety. More information available at: www.vega.com/radar or contact VEGA Controls Ltd by Tel: 01444 870056 or E-mail: info.uk@vega.com

PULSAR’S MICROFLOW NON-CONTACTING LIQUID VELOCITY SENSOR UK measurement specialist Pulsar Process Measurement’s latest launch is MicroFlow, a microwave based non-contacting velocity sensor that mounts simply above a channel to provide maintenance-free, reliable, repeatable and accurate velocity measurement.

For flow volume measurement, velocity x area provides a cost-effective alternative to a channel restriction such as a flume, and a viable solution in situations where system hydraulics do not permit the installation of any primary measurement device. MicroFlow can be used as a stand-alone device, outputting velocity data via RS485 Modbus with a measurement accuracy of ±0.033m/s or 0.5%, whichever is greater. The industry-standard data can be used for datalogging or alarm purposes, or processed further in a PLC. MicroFlow can also integrate with Pulsar’s FlowCERT ultrasonic flow measurement controller and a transducer such as Pulsar’s flowPulsar’s MicroFlow offers costdedicated dBMACH3 to create a complete open channel effective, low maintenance flow measurement system. velocity and flow measurement. MicroFlow consists of a compact, lightweight low-cost sensor, and is simply installed on a bracket above the flow at a 45º angle. Loop power and straightforward RS485 PC set up means that connection is simple and quick. Signal processing is via Pulsar’s wellproven digital algorithm and is a development from the system first seen in their award-winning FlowPulse device for measurement in closed pipes. For more information contact Pulsar Process Measurement Ltd, Tel: 01684 891371 E-mail: info@pulsar-pm.com/Web: www.pulsar-pm.com

ACCURATE DOSING OF CONFECTIONERY ADDITIVES Manufacturers in the confectionery market have discovered that they can realise substantial savings on production costs by taking control of additions and dosing through utilisation of the Bronkhorst Coriolis instruments. These

mini CORI-FLOW™ Series Mass Flow Meters and Controllers distinguish themselves by their capability to measure and control (ultra) low quantities of both liquids and gases, fast and accurately. Automating process control allows manufacturers to switch quickly and efficiently between production processes reducing down time and operator involvement. Bronkhorst Coriolis instruments using our own proprietary software, FlowPlot™, or by being added as part of an overall PLC controlled system will add the functionality to include data acquisition capability. Both of these features allow manufacturers to make strides towards better final product quality and consistency while at the same time generating data to allow traceability and quality control. Standard weigh scale/volumetric methods have many limiting factors that can be both inaccurate and costly. These traditional ways of managing the addition of flavours and colours can require heavy involvement of operator knowledge and experience. This can lead to slow change over times and inconsistent/inaccurate addition of flavours and colours. Making the change to Bronkhorst Coriolis Mass Flow Meters and Controllers, utilizing CoriFill™ Technology can bring immediate bottom line rewards to the business. Bronkhorst Coriolis Mass Flow Meters have the added functionality of directly controlling a secondary instrument required to achieve the end result, either a pump or valve, using our on-board PID control provides quick and accurate response times at flow rates between 0.05 g/hr and 600 kg/hr. Finally, by taking advantage of the control functionality provided by the Bronkhorst on-board PID control the integration of the solution into a current application or manufacturing process is simple and straightforward. For more information contact Bronkhorst UK Ltd, Tel: 01223 833222 E-mail: sales@bronkhorst. co.uk Web: www.bronkhorst.co.uk

PROCESS INDUSTRY INFORMER March - April 2016

PROCESS MEASUREMENT & INSTRUMENTATION ALL FOR ONE, ONE FOR ALL

FIRST 79 GHz HIGH-ACCURACY RADAR INSTRUMENT FOR LEVEL MEASUREMENT IN LIQUIDS Endress+Hauser presents the world’s first radar with a transmission frequency of 79 GHz for level measurement in liquids. The new Micropilot NMR81 for high-accuracy custody

The N21 digital meter can cover most common applications with a single unit. Universal measuring inputs include: -

voltage ±60mV, ±10V, current ±20mA and temperature, PT100, J, K –type thermocouples which make the N21 very flexible. Configuration is easily done through a standard mini USB cable and free eCon software and includes the option of defining your own unit of measure. The addition of a single relay output and auxiliary transducer supply output make it ideal for simple control systems. This compact 96x48x64 panel meter uses the latest OLED technology giving a clear bright display with a wide viewing angle. •Universal input •Universal supply 24V-230V ac/dc •Relay alarm output •OLED Display with Bargraph •IP65 For more information contact OEM Automatic Ltd, Tel: 0116 284 9900 / Web: www.oem.co.uk

transfer applications is certified by independent test authorities to an accuracy of ±0.5mm. The sharply focused microwave beam angle ensures safe and reliable measurements without any interfering signals even in narrow tanks with baffles. Being the technology leader in process instrumentation, Endress+Hauser regularly sets standards in level measurement instrumentation. The new 79 GHz radar is the newest innovation, providing a solution for even the most sophisticated level measurement applications in liquids. Micropilot NMR81 utilizes 79 GHz technology to generate a narrow beam angle of 3° or 4°. Measurements are substantially more reliable even in narrow tanks because the radar beam avoids obstacles such as baffles on the tank walls, and is thus unhindered by interfering signals. For more information contact Endress+Hauser Ltd, Tel: +44 161 286 5152 E-mail: helen.white@ uk.endress.com Web: www.uk.endress.com

PROCESS INDUSTRY INFORMER March - April 2016

FAST TRACK, QUALITY INSTRUMENTS Endress+Hauser has put together a package of instruments for basic applications to suit smaller budgets.

Endress+Hauser is known for its h i g h - q u a l i t y, technologically advanced products that are suitable for the most complex applications. But the company also manufactures a range of low-cost instruments for light duty applications. This range of pressure switches, pressure transmitters, thermometers, level switches and flowmeters offers basic functionality without compromising on quality. Almost every item featured in the fast track brochure is kept in stock, guaranteeing availability and quick delivery. Each device also comes with a 15% discount when purchased with one or more of its featured accessories. Download a copy of the brochure today at www.uk.endress. com/fast-track

INSTRUMENTATION IS THE KEY TO CHPQA BENEFITS CHP plants that meet the requirements of the CHPQA scheme qualify for a number of valuable benefits. Alan Hunt, Product Specialist for ABB Measurement & Analytics in the UK, explains how measuring CHP plant performance through good instrumentation is the key to gaining them.

n today’s energy climate, it’s easy to see why Combined Heat and Power (CHP) plants are so attractive. Essentially, CHP plants generate electricity while capturing the heat produced during the process for other uses, such as industrial production or district heating schemes. Compare this with conventional electricity production where vast amounts of heat are simply released to the atmosphere via cooling towers, wasting up to two thirds of the energy consumed. By making use of this otherwise wasted heat, CHP plants can be 80 percent efficient, compared to the figure of around 50 percent for most UK gas fired power stations. This huge gain in efficiency means it’s no surprise that the government is trying to encourage the installation and operation of good quality CHP projects by offering various benefits. It does this through the Combined Heat and Power Quality Assurance (CHPQA) scheme, a voluntary programme that assesses the energy and environmental performance of CHP projects. Those operators that can show that their plant is eligible can currently benefit from the Climate Change Levy Exemption, Enhanced Capital Allowances and exemption from business rating for CHP plant and machinery.

PROVING ELIGIBILITY To make their plants eligible for Climate Change Levy exemption on the gas used to fuel CHP schemes, operators must achieve certain metering criteria. These can be divided into two scheme types – those below 2MWe and those above 2MWe.

ABOVE 2 MWE For these schemes, operators need to be able to measure the gas used, the heat supplied and the electricity generated. The gas meters must be pressure and temperature compensated and

the heat meters must use a water meter to measure actual flow.

BELOW 2 MWE Schemes below 2 MWe can be further subdivided into those that have heat dumps and those that do not: • CHP Schemes less than 2MWe WITH Heat Dumps These schemes require various combinations of gas, electricity and heat metering. If the unit is less than 500kWe and is on the approved CHP list as issued by the CHPQA, then the gas consumption may currently be calculated by using the CHP units’ electrical efficiency as stated on the list. However, if the unit is greater than 500 kWe or below 500kWe but not on the approved CHP list, then gas metering is required and the meter must be pressure and temperature compensated. The gas meter installed must be of a quality specified by S.I. 1983/684 (Statutory Instruments 1983 No. 684, Gas (Meters) Regulations 1983). For metering electricity, clearly labelled commercial/industrial three-phase electricity meters of billing quality should be used. CHP units will normally supply heat as either hot water or steam. For measurement of steam mass flow and energy content, meters with an overall uncertainty of ±2.0% of span (full-scale) are required. For measurement of hot water, where stand-alone commercially available heat meters are used these must be manufactured to metrological Class 2 or Class 3 as defined in BS EN 1414–1997 (~ ±1.5%). For fluid temperature measurements, matched pairs of platinum resistance thermometers to BS 10413:1989 and BS EN 60751:1996/IEC 60751:1983 are preferred. • CHP Schemes less than 2MWe WITHOUT Heat Dumps For these schemes, the measurement of gas and electricity is the same as for units that have heat dumps installed. The difference comes in the measurement of heat.

Existing schemes below 2MWe with no heat rejection facility are not required to meter heat outputs, as the heat output may be calculated using the design Heat/Power ratio for the unit. For new schemes or those which supply heat in the form of steam, heat must be metered in the same way as units greater than 2MWe. Oil burned as either a main or a standby fuel will need to be monitored and recorded. Oil products are usually sold by the litre and this will require a volume flow meter with an uncertainty no greater than ±1%. CHPQA is an annual certification process. At the end of each calendar year, a designated Responsible Person must compile the CHP scheme energy data monitored over the previous year; assess the scheme’s performance and submit this data to CHPQA on the appropriate forms for validation.

GOOD BOILER OPERATION IS KEY Operating the boiler in the optimum way is key to an efficient CHP plant and measurement is the way to ensure this. The key is to make sure you are only generating what you need. Measure the demand and compare it with what the boiler is generating to identify whether steam is being lost before it reaches the point of use. This will ensure that the full supply of steam is reaching the place where it’s needed most rather than inadvertently heating up your factory. It’s also important to optimise the combustion process by monitoring the flue gases. Careful monitoring will allow you to strike a balance between supplying too much air, which carries heat away up the flue, and insufficient air, resulting in incomplete combustion. It is also important to ensure that boiler duty is at optimum efficiency. For example, don’t use two boilers at 30 percent output if you can run one at 60 – 70 percent output. Checking that your instrumentation is up to scratch should also

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be a priority. Modern instruments are typically more robust and more accurate. They are also easier to maintain, and are less prone to problems such as drift.

THE CHALLENGE OF HEAT The measurement of electricity and gas flow is relatively straight forward. However, because it depends on the flow of water and in particular steam, the major challenge in CHP schemes is the accurate measurement of heat. In any boiler based system, the critical measure of the amount of energy flowing round the system is the mass of the steam. It takes ten times the energy to create 1 m3 of steam at 10 bar than at 1 bar, yet the volume is the same. This has traditionally been the domain of differential pressure meters such as orifice plates. The disadvantage with these is that they require a lot of ancillary equipment such as line pressure transmitters, temperature sensors and a flow computer to produce mass readings for steam. This introduces an extra maintenance burden and thus increases operational costs. A better alternative is vortex and swirl meters. These have virtually no maintenance requirements and offer a greater level of accuracy, particularly in situations or applications were flow can vary over a large range. Orifice plates offer an accuracy of only two percent of the upper flow range, whereas vortex and swirl meters can produce an accuracy of 0.5 percent over the entire flow range. Their turndown, or the effective range in which they can accurately measure, is also up to ten times greater than that offered by an orifice plate. Vortex meters rely on the phenomenon of eddies or vortices which form as an obstruction resists the flow of fluid around it. The meters measure the frequency of the eddies as the fluid passes an obstruction known as a shedder. By contrast, swirl meters use static veins at the meter’s entrance to induce the fluid to rotate. This automatically sets up a secondary helical rotation, the frequency of which is measured by the flow meter. The frequencies of the vortex street in a vortex meter and of the secondary rotation in a swirl meter are each directly proportional to the volumetric flow rate of the fluid. There is no need to compensate for changes in pressure, temperature or density – the only parameter the meters need to know to calculate the mass flow is the temperature of the steam. A major benefit of swirl meters is their ability to be fitted

almost anywhere, which makes them ideal for retrofitting to existing steam systems. To achieve the greatest accuracy, the vast majority of flow meters need to receive an undisturbed flow of fluid. This entails positioning them downstream from any sources of flow turbulence, such as bends in the pipe, valves or other obstructions that could disturb the flow. For example, vortex meters require straight inlet and outlet runs of up to 50 pipe diameters and 10 pipe diameters respectively following a modulating valve. Swirl meters need just two or three diameters in most applications, greatly reducing the installation space required. This is possible because the rotating flow pattern inside a swirl meter is specially set up by a series of blades at the inlet to the meter and ‘deswirled’ again at the outlet. This effectively isolates the flow pattern inside the meter from many of the disturbing influences that can cause inaccurate readings in other designs.

DON’T FORGET SERVICE Of course, even the most accurate and sophisticated meter will not continue to perform well if it does not receive the correct servicing at the appropriate time. Reputable manufacturers should be able to help with this by offering a service programme tailor made to the instrument and its application. Other services may be designed to maximise the performance of the instrument. These could include services such as fullytraceable verification of flow transmitters, certifiable inspection of primary flow devices, assessment of the device’s installation, design of optimum calibration schedules for the unit and upgrade services for measurement devices and installation and commissioning of new devices As well as instrument maintenance, servicing and performance optimisation, some of the more advanced and customer-focused instrumentation vendors may also be able to offer a number of other services. Some of these will be directly applicable to achieving the benefits available through the CHPQA scheme. Examples could include verification of the F4 self-assessment form; verification services; life cycle services to maintain CHP performance and support for the annual self-assessment process. The CHPQA scheme is a major encouragement to CHP plant operators – monitoring the performance of such plants by efficient, accurate meters, backed up with the support of innovative vendors such as ABB, will ensure its valuable benefits help make a difference to their business and to the environment.

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OPTIMISING CUSTOMER SERVICE

Six key links in the supply chain

Outstanding customer service sets the standard for specialty chemical companies to differentiate their value proposition around the world. As oil prices remain low, a chain reaction has opened up opportunities to improve margins and strengthen market position. Chemical companies are optimising assets through cost reduction logistics, segmenting demand versus supply strategies and tackling complexity. Managing the unknown more effectively and being more flexible across the organisation will reap greater rewards. By Laura Rokohl, Supply Chain Manager, AspenTech

ith increasing pressure to respond to demand and provide quality products on time, smart businesses are optimising six key supply chain areas and embracing cutting-edge software to achieve competitive advantage.

SIX KEY LINKS IN THE CHAIN Despite volatility and uncertainty, the chemicals market is projected to grow significantly in the near future. As competition increases, best practices and innovative technology adoption remains key to competitive advantage. Chemical companies in the U.S. are increasingly focused on emerging regions to capitalise on business potential. China, on the other hand, is expected to increase in population over the next ten years resulting in more internal consumer demand for differentiated products that are specialty chemicals related. Specialty chemicals are mainly manufactured in chemical plants using batch processing techniques. Products are typically high value with many specification variations and differentiators. The major product segments in this sector include paints and coatings, adhesive sealants, dyes and pigments, industrial gases, resins and plastic additives - all manufactured at predetermined and scheduled intervals. By being more demand-driven, business can maximise market potential while mitigating risk. To do this effectively, organisations must address six key links in the supply chain to achieve best practices: 1. Improve customer service Customer service is paramount for specialty chemicals producers and it is a standard measure of business performance. There is constant pressure to reduce order lead times to retain customers, as well as pressure to maintain appropriate stock to meet demand. Customer service levels are typically measured by ontime shipments of the right quality product in the appropriate quantity. 2. Decrease inventory Inventory is expensive to store and ties up working capital. Companies require the ability to closely monitor inventory levels and track common metrics, such as inventory turns and number of days of demand that the current inventory can cover. Demanddriven chemical companies are able to optimise their inventory and reduce inventory buffers, which are typically kept at higher levels than necessary in order to maintain good customer service levels. 3. Optimise production Production lines need to perform smoothly to ensure batch product quality is maintained within specifications. Having an effective supply chain management system that can optimise batch

sequencing means production is more likely to run efficiently, less time is spent in setups and clean-outs, and delays or disruptions can be addressed proactively, before they can impact customer orders or incur unnecessary expedited transportation costs. 4. Be agile The ability to respond quickly to planned and unplanned supply chain shocks (i.e. equipment failures, raw material availability, labour shortage, stock-outs, unexpected demands, new orders, etc.) is essential to remaining profitable. By being equipped to analyse different responses to the unexpected, companies can choose the most appropriate response to issues and take corrective action that secures plant profits and meets customer contracts. 5. Reduce costs Procurement, working capital, inventory storage, distribution and labour are key areas to potentially reduce supply chain costs. Costs related to purchase of raw materials, carrying inventory, distribution and other costs are spread across the supply chain and, therefore, make the supply chain a logical place to track cost savings. Each company has its own individual metrics, such as best delivered cost or cost of raw material per tonne of product produced. At the plant level, asset utilisation and product yields contribute to operating costs and must be tracked with their own metrics. 6. Manage materials Managing fluctuating raw material costs is especially important to specialty chemical manufacturers in order to set the right price expectations to customers. Robust planning and effective communications will protect customer relationships, which can have a significant impact on margins. Also, specialty chemicals companies in particular often have shelf life constraints where Schedulers need to have forward visibility into materials that must be used before they expire in order to minimise product loss.

COMPLETING THE CHAIN Cutting-edge, end-to-end supply chain software improves forecasting, enables greater collaboration and assists with customer prioritisation. Empowering operations with easy to use planning and scheduling tools facilitates better decision-making to respond quickly to disruptions in plant operations. For example many companies have adopted AspenTech’s supply chain software solutions as the link to optimise end-to-end supply chain capabilities. Additionally their Supply Chain Planner can navigate supply chain complexity and identify problems in the plan that needs urgent attention. The intuitive interface enables planning to be performed easily so that Planners can determine the optimal production plan and maximise the potential of assets across the network. Using powerful analysis capabilities, Planners can develop and evaluate an unlimited number of ‘what-if’

scenarios to quickly optimise inventory management, minimise transportation costs and balance supply with demand. This can be done knowing that the software tools accurately model production activities with sufficient fidelity to allow the Planner to accurately and realistically evaluate alternatives. In the instance of the Aspen Plant Scheduler , this dynamic tool enables Schedulers to react to operational changes within minutes. Crucially, Schedulers can personalise their workspace, simultaneously view inventory levels and immediately see the impact of changes for a common group of production activities or facilities. This greater visibility means they have access to information they need to gain detailed insights into production scheduling, such as raw material availability, equipment constraints, batch dependencies and, ultimately, make better decisions to manage the plant schedule more effectively. In addition, the Campaign Manager feature in the Plant Scheduler can be used to easily define preferred sequences for each production facility, enabling the entire sequence to be scheduled all at once when appropriate for a particular asset.

PROFITABLE VALUE CHAIN Specialty chemicals companies survive based upon their ability to react quickly to market forces and offer added value, such as impeccable service, quality products and on-time deliveries. Therefore, chemical companies require knowledge of best practices and on-going innovation to help differentiate their business and stand out from the competition. Companies that deploy supply chain optimisation software have the potential to realise significant margin improvement of 10% by: • Increasing capacity 3 - 5% • Improving customer service 5 - 10% • Improving first-quality production 5% • Reducing costs 4 - 6%

The latest supply chain software enables companies to optimise trade-offs between customer service, inventory levels and manufacturing costs and accelerate process innovation. A supply chain best practice is to integrate supply planning with scheduling at the operating level to ensure that the supply plan translates to a detailed schedule for execution. Therefore, having a holistic view of the supply chain network means it is possible to build an optimal procurement, production, distribution and inventory plan, which will profitably meet customer demands. With integrated planning and scheduling software, plant complexity is mitigated and key decision-makers can easily analyse all costs and constraints to ensure a globally optimal plan. To meet financial targets, integrated supply chain software helps companies cut costs and produce products faster and more efficiently to meet demand. By focusing on asset optimisation and tackling the six key areas of best practice, chemical producers can gain the upper hand and significantly improve customer service across the entire value chain.

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HEALTH & SAFETY CROWCON EXTENDS ITS RANGE OF NEXT-GENERATION “INTELLIGENT” FIXED-POINT GAS DETECTORS TO NEW SECTORS KEY FACTS: • Adds detection of ammonia and sulphur dioxide to 10 other flammable or toxic gases • Hot-swappable sensors eliminate the need for hot work permits • Fast installation and commissioning minimises time spent in hazardous areas • Allows the head to be installed with dummy sensors prior to commissioning • Enhances site safety with Crowcon’s unique Positive Safety features

Crowcon Detection Instruments Ltd – a leading manufacturer of specialist gas detection equipment – announces that the nextgeneration XgardIQ gas detector can now be fitted with sensors for the detection of ammonia or sulphur dioxide, in addition to the existing range of sensors which covers 10 different toxic or hazardous gases. “The ability to detect ammonia or sulphur dioxide will allow industries such as fertilizer and petrochemical production, to use the intelligent XgardIQ to increase on-site safety for employees as well as reducing operating costs for employers,” explains Andy Avenell, Senior Business Development Manager at Crowcon.

In addition to the flexibility to detect a wide range of gases, the XgardIQ also offers special features to reduce installation and operating costs. For projects in which gas detectors are installed months ahead of commissioning, the XgardIQ transmitter can be fitted with a dummy sensor which is replaced with a fresh pre-calibrated sensor immediately prior to the commissioning date. This allows the user to benefit from the full operational lifetime of sensors. The XgardIQ transmitter further minimises commissioning and maintenance time by automatically configuring to the correct type of gas, scale and alarm levels. Sensors can also be removed temporarily for calibration in a safe area, rather than requiring the engineer to carry compressed gas cylinders for on-site testing. These features all help to eliminate the need for hot-work permits and minimise the time that employees need to spend in hazardous areas. XgardIQ also integrates Crowcon’s unique Positive Safety feature which confirms that the detector is operating safely and enables the unit to automatically alert operators to any irregular events. To minimise the amount of time and gas required for interim safety checks, the ‘Speedy Bump’ and ‘Smart Bump’ options enable users to perform a quick and simple bump test, rather than a full calibration, to verify that the sensors are fully operational. With a comprehensive set of output interfaces the XgardIQ transmitter can integrate seamlessly with virtually any control system such as PLCs, DCSs and SCADA, whilst HART communication enables XgardIQ to be logged and monitored automatically on asset management systems. According to Avenell, “The positive feedback we received on the XgardIQ system from customers in the oil and gas industry was critical in our decision to extend the range of gas sensors to enable other industries to benefit from XgardIQ’s innovative safety features.” The range of gases which the XgardIQ system can now detect is: ammonia, carbon monoxide, ethanol, hydrogen, hydrogen fluoride, hydrogen sulphide, LPG, methane, oxygen, pentane, propane and sulphur dioxide. More sensors will be introduced during 2016. For more information contact Fiona Macrae, Crowcon Detection Instruments Tel: +44 1235 557700 / Email: fiona.macrae@crowcon.com

SLIMLINE HOLDER DESIGN, ENSURING CORRECT RUPTURE DISC PERFORMANCE WITHIN CONFINED INSTALLATIONS Slimline holder enhances Elfab’s product offering, making upgrading hassle-free.

Elfab Ltd, a market leader within the pressure management field, are now offering an improved slimline holder design. With over 80 years’ experience in the pressure field, Elfab are pleased to announce it has expanded its range to allow for prospective customers to easily upgrade to Elfab supply without having to go to the expense and complexity of having to change pipework. Elfab understand that within certain plant operations, limited installation space can be an underlying issue, hence the offering of Slimline Holder configurations (minimum face to face 22mm) preconfigured to work with its industry-leading non-invasive detection system, Flo-Tel+™. These new holders will now allow customers to benefit from technical-superior bursting disc performance with industry best lead times. For more information or product information contact: Elfab Limited Tel: +44 (0)191 293 1234, E-mail: deborah.bevan@elfab.com Web: www.elfab.com

SEISMIC SAFETY SWITCH PROVIDES HIGH-INTEGRITY PROTECTION High integrity seismic protection of critical assets such as oil, gas, nuclear and hydro-electric installations, pharmaceutical and medical facilities, where accurate detection of structural vibration in conjunction with safe shutdown procedures is an essential requirement. SENSONICS, the leading supplier of seismic monitoring protection systems to

the UK’s nuclear industry, offer a range of solutions which are ideally suited to most applications. The SA safety seismic switch is a good example of Sensonics expertise in developing innovative seismic monitoring and protection systems which are trusted by the UK nuclear industry. The SA-3 seismic safety switch provides triaxial vibration detection and is ideal for protecting vulnerable structures from ground borne vibration events and incorporates a range of safe shutdown options, depending on the application. The SA-3 model features three high-integrity low-noise piezoelectric seismometers positioned at 90º to each other along with the associated alarm circuitry housed within a robust weatherproof painted steel enclosure. It is seismically qualified to IEEE-344 (Standard for Seismic Qualification of Equipment for Nuclear Power Generating Stations) and utilises technology operationally proven in harsh environments. The switch operates on seismic events and when the signal from any axis exceeds the pre-set alarm level, the alarm relay is activated. The sensors consist of a unique system of matched piezoelectric elements arranged in a ‘reciprocal’ configuration providing a functional test capability. Application of a 1Hz signal to the calibration crystal element mechanically excites the measuring elements resulting in a defined signal output which can be used to perform a full loop check of the seismic switch. Such a facility is essential for applications where the switch is located in a hazardous area and requires full-proof testing on a regular basis. As well as the usual seismic and EMC approvals the SA-3 switch is available for functional safety applications up to SIL-2 and can also be provided in an explosive-proof housing for intrinsically safe applications. For more information contact: Sensonics Ltd, Tel: +44 (0) 1442 876833. Email: sales@sensonics.co.uk Web: www.sensonics.co.uk

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HEALTH & SAFETY FORTRESS UNVEILING STAINLESS STEEL INTERLOCK SWITCHES FOR HIGH PURITY APPLICATIONS AT AUTOMATICA Industrial safety specialist Fortress Interlocks is unveiling its amGardS40 stainless steel interlock switches for high purity applications at this year’s Automatica trade fair in Munich.

The company will be in Hall B5, Booth 105. Automatica is the leading trade fair for industrial automation and mechatronics. The amGardS40 is designed specifically for the food, beverage, pharmaceutical and chemical processing industries; it is also suitable for outdoor use. Manufactured from 316 stainless steel and modular in design, the amGardS40 range can be configured to suit many other industrial applications. Configurations for the amGardS40 include: · Solenoid locking safety switches · Non-solenoid tongue switches · Mechanical trapped key interlocks · Machine control stations The switches are supplied in enclosures sealed to IP69K, allowing them to be pressure washed at high temperatures; they also have a retention force of 10,000N – the highest currently available on the market – so are ideal for ensuring guard doors are held closed until machines and/or processes are in a safe condition. Each module is just 40mm in width, so can easily be fitted to 40mm guarding sections or other areas where space is limited. For more information contact Fortress Interlocks Ltd, Tel: +44 (0)1902 349000, E-mail: sales@fortressinterlocks.com / www.fortressinterlocks.com

NEXT GENERATION LASER BASED SOLUTION FOR NOX EMISSION MONITORING The new LaserGasTM III DeNOx analyzer uses next generation laser technology to measure NOx-emissions from refineries, power plants, and industries such as chemical, petrochemical and steel. The instrument increases safety and helps reduce costs in plant operations.

NEO Monitors introduces a new generation of the safest and most precise instrument to measure NH3 for any type of DeNOx system. NEO Monitors LaserGasTM III ammonia analyzer is designed to operate in hazardous areas to increase efficiency of the DeNOx-processes and minimize emissions. “Meeting strict HSE-regulations is becoming even more business critical. New environmental regulations and the need to decrease emissions of toxic gases is a business critical process that has become an area of concern for corporate management. Our new solution ensures better answers faster, gives more accurate information on critical operational processes and reduce costs,” says Ketil Gorm Paulsen, CEO at NEO Monitors. The instrument helps the industries achieve better processes control, increase the efficiency of emission reduction and decrease the use of costly consumables such as urea (ammonia). Customers in industries such as oil and gas, power, chemical, petrochemical and steel will benefit from lower operational cost as well as less NOx-emissions. The instrument has been tested in Asia, and 20 units have already been sold, following great feedback and impressive results from pilot installations. The Single path (SP) configuration is a transmitter/receiver solution for cross-duct/stack installation. The measuring principal is based on Tunable Diode Laser Absorption Spectroscopy (TDLAS). “Installation is quick and easy because of the compact and improved design, maintenance costs are low, and the system is factory calibrated, meaning no need for field calibration.” says Paulsen. For more information contact Ketil Gorm Paulsen, CEO in NEO Monitors E- mail: ketil@n o.no Tel: +47 917 77 170 www.neomonitors.com

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BIO-THERMIC DIGESTERS -

A NEW APPROACH TO SOLID & LIQUID ORGANIC WASTE? Cleaner wastewater for food processing industries

Solid organic waste and waste water is an increasing issue for food processing, water treatment and some pharmaceutical sectors. Craig Shaw, CEO of Advetec, a leading UK specialist in advanced environmental technologies for the treatment of effluent and solid waste, explains why extremophile bacteria and bio-thermic digester technology could be the solution.

SOLID & LIQUID BIOLOGICAL WASTE Food processing industries including brewing and beverages, dairy, ready meals, meat processing and abattoirs, as well as the pharmaceutical and waste water treatment sectors all need to deal with solid and liquid biological production residues that are rich in nutrients and organic content. Until recently such production residues have been regarded as a costly overhead which requires treatment before safe discharge to sewers or disposal off site.

ISSUES FACED BY FOOD PROCESSING INDUSTRIES Food processing organisations must address various issues in order to meet environmental targets. Disposal of waste by-products is a heavily-regulated area which is becoming increasingly stringent. Food manufacturers must meet Trade Effluent Consents and require pollution prevention and control (PPC) permits or Waste Management Licences. Reducing Biological Oxygen Demand (BOD) to meet trade discharge consents is also a major issue. There is growing pressure from the UK government to reduce the biological load in wastewater discharged from production processes and for zero organic waste to be sent to landfill. We see similar environmental pressures in the USA and Europe. Legislation and taxation are pushing hard to limit dumping, but in many instances there are few alternatives. And all the while volumes are increasing… A high water content makes solid and liquid waste very expensive to transport, as well as costly and inefficient to incinerate. As a result, most production facilities require an on-site effluent treatment plant.

CURRENT TREATMENTS Conventional processes to treat biological waste include settlement tanks, sand filters, membrane filters and bioreactors, activated sludge processes and dissolved air flotation (DAF) systems, plus expensive chemical interventions - all designed to filter out and remove suspended solids, BOD, plus oils and greases - to leave clean water. The focus here is on reducing the biological load so that waste water meets discharge consents. However, the problem still exists of dealing with the solid residues which need to be hauled away for disposal to incineration or landfill. In addition, they are not particularly suited to dealing with solid food waste or waste containing a mixture of different solids. Anaerobic Digestion (AD), which is becoming increasingly popular, can provide part of the solution, but even here a considerable residue is left as the AD process is unable to deal with some of harder-to-digest organics. Throughput is also slow and incorrect loading of waste material, combined with the inability to control the internal environment, or the digestive rate of the bacteria,

frequently leads to poor performance and breakdown of the process. This requires the machine to be manually emptied and then eventually restarted. This process does not guarantee a certifiable product either. To compound the problem AD infrastructures can take up significant space and the process tends to be slow.

LATEST BIO-THERMIC DIGESTER & BIOREACTOR TECHNOLOGY One approach is to use advanced thermal technologies and extremophile bacteria to literally consume all of the organic material – or certainly a much higher percentage than conventional solutions - leaving a small inert residue for use as RDF (refuse derived fuel) or as a soil improver, and clean water. In California for example, where environmental regulations for waste organics are increasingly stringent and both disposal and haulage costs are prohibitive, a recent trial for pre- and postconsumer food waste for example achieved a better than 91% reduction rate. Bio-Thermic Digester (BTD) technology is an in-vessel solution engineered to rapidly digest organic waste. As well as being optimised for fast throughput it also has a smaller footprint than other processes, an important factor where site space is limited. More importantly it is able to handle a wide spectrum of organic material including normally indigestible hard carbons, cellulose and lignin-based materials. In addition to food waste therefore, it can also handle organics from abattoirs, sewage sludge, as well as waste from fat traps, septic tanks, filter cakes, gully cleaning and trade effluent, and of course green waste. At the heart of the process is a blend of extremophile bacteria and specially-developed nutrients on which the bacteria thrive at high temperatures, enabling them to rapidly digest all of the organic material. This innovative thermal process has proved to be far more efficient than AD alone. The latest bio-thermic digesters have been designed to minimise the need for further processing whilst enabling food processing companies and the like to discharge clean water to sewers within Integrated Pollution Prevention and Control (IPPC) regulations. The advantages of such a high temperature aerobic digestion process, is that it is extremely rapid by comparison to conventional in-vessel composting. Some equipment has a heat and moisture recovery system which improves biological efficiency and reduces running costs. This takes heat generated by the exothermic process and re-uses it to sustain the high temperature environment (90125 Dec C) required for the bacteria. This can cut energy running costs by as much as 60%. Biothermic digesters are also impervious to contamination and some can digest all the organic matter present in mixed waste in just 72 hours. Consequently, operating costs drop after the initial start-up procedures. Water from steam is condensed out and filtered to deliver a similar quality to tap water if required and all moisture extraction and odour control are built into the system as standard. Bio-Thermic Digesters will safely convert 32+ tonnes of organic

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Advetec’s new biothermic digester The Raptor food waste into water and a dry powdery by-product. The on-site process can deal class 3 type animal by products wastes such as feather, blood and offal from every stage of dairy, slaughterhouse and food production process, which only takes around 72 hours. This new technology has been trialled in various applications over a period of four years in the UK, the US and the Middle East and now there are pilots starting in Italy and Spain. Key to the process is an in-depth understanding of aerobic bacteria, along with the nutrients and bio-stimulant technology used to invigorate and speed up the digestion process. Of course not all waste streams are the same and continuing research blending different strains of extremophile bacteria and the nutrients that encourages them to thrive, is helping to answer the problem of dealing with more complex organic waste streams. Operating environments are different too and careful monitoring and adjustments of the internal process including temperature, nutrients, oxygen and waste gases, is key to optimising throughput and maintaining the health and activity of the bacteria. Developments here in terms of remote telemetry and the control software enables the delivery of completely managed services for customers, operating a machine 24/7 anywhere in the world from UK facilities. A BTD needs to be part of a complete advanced engineering system consisting of hoppers, shredders, augers, storage tanks and piping, designed and tailored to match each customer’s differing needs to increase throughput and ensure an optimal and robust processing environment. With the growing requirement to limit or end the disposal of organic waste to landfill and ever stringent environmental consents for the discharge of wastewater to sewers, the ability to fully process waste water and solid waste from production processes on site, effectively plumbed in to the manufacturing process, is becoming increasingly important. Conventional systems only provide part of the solution. Extremophile bacteria and bio-thermic digesters can help complete the waste management cycle. For smaller sites with limited space they might offer the only solution.

CENTRIFUGAL SIFTERS HEAT TRANSFER & ENERGY GERICKE MK III CENTRIFUGAL SIFTERS Proven Reliable Solutions for Product Screening and Particle Size Control.

For more than 50 years Gericke has provided Centrifugal sifting solutions to the solids and powder handling industry. Building on our proven technology Gericke has introduced a complete NEW range of centrifugal sifters with updated design and operational features necessary to satisfy the demands of today’s processing industries. The Mk III centrifugal sifter provides three modules incorporating twelve standard configurations which can be optimised to suit almost any application requirements. The Baseline model provides a cost effective solution for general applications. The Multi-purpose unit includes additional features such as hinged doors for increased access for cleaning and maintenance. The Hypergienic model is designed to meet the most stringent of requirements for cleaning and hygiene and features a cantilevered shaft assembly, three hinged interlocked doors, quick release fully welded paddle assembly and integral discharge hoppers. For more information contact Gericke Limited, Ashton-under-Lyne, Lancs. Tel: +44 (0)161 344 1140 Web: www.Gericke.co.uk

FULTON TO LAUNCH THE MOST RADICAL CHANGE TO BOILER DESIGN IN NEARLY 70 YEARS In the year that sees the company celebrate 50 years of UK manufacturing in the UK, Fulton is also launching its latest heat transfer solution, claiming that the all-new, nextgeneration SRT Series is the most radical change to vertical steam boiler design for nearly 70 years. Commenting for Fulton, sales and marketing manager Doug Howarth says: “This will be quite a year

for Fulton. Not only are we celebrating 50 years of manufacturing in the UK, but we’re also launching a great new heat transfer solution that we believe to be the most radical change in steam boiler design since we pioneered the vertical tubeless boiler in 1949!” By adopting a systems engineering approach to design and using its own ‘PURE’ technology, Fulton’s SRT Series challenges the heat transfer and mechanical design principles of traditional vertical steam boilers. With over 30 worldwide patents pending, the new vertical boiler’s spiral-rib tubeless design is a world first that has enabled Fulton to create a compact boiler with the industry’s smallest footprint. In fact, compared to the equivalent 30hp model from the company’s renowned J Series, the SRT Series is an impressive 40% smaller. Using a combination of in-house modelling with computational fluid dynamics and finite element analysis, the ‘PURE Optimised’ design of the SRT Series makes the new boiler durable and reliable in operation; and with up to 6:1 turndown and featuring a fully-modulating burner, the SRT also boasts industryleading performance with an 84.5% Gross (93.5% Net) thermal efficiency and 99.5% steam quality from a fullywater-backed design with no refractory. The SRT Series features patented, self-compensating stress relief architecture that virtually removes longitudinal stress and deflection absorption. And, to comply with anticipated EU regulations, the boiler’s combustion technology has also been completely reconfigured, with the mesh burner and furnace designed as a single component, resulting in ultra-low NOx emissions of less than 40mg/ kWh. Fulton has further reason to celebrate, as 2016 sees the company celebrate 50 years of UK manufacturing, with the Bristol-based facility now an important design and manufacturing base in Fulton’s global network, which includes production facilities in the USA and China.

For further information contact Fulton on Tel: 0117 972 3322, E-mail sales@fulton.co.uk www.fulton.co.uk.

“FAR MORE THAN A THERMAL FLUID FIRM” TFS HITS 20 AND SHARES SECRETS OF SUCCESS Pioneering technology and a service predicated on riskmanagement lie at the heart of the success of the first company to bring thermal fluid reconditioning to process industries worldwide, according to UK system support and maintenance provider, Thermal Fluid Solutions Ltd, in its 20th anniversary year.

TFS was the first firm to offer thermal fluid reconditioning, facilitating the maintenance of vital fluid safety parameters such as minimum flashpoints. A quick, cost-effective, environmentally sustainable alternative to replacement, HTfluidfit extends fluid life by a factor of at least 10, saving customers up to 70% of their thermal fluid costs. Since its launch as Heat Transfer Systems in 1996, Derbyshirebased TFS has reconditioned over 10 million litres of thermal oil across 150 systems in 15 countries, saving customers in excess of £20 million in the cost of replacement oils, excluding the cost of disposal and downtime.

According to managing director, Richard Franklin, the market was quick to adopt its pioneering reconditioning service: “Until we introduced HTFluidfit, companies were

having to spend thousands on replacing degraded oil in order to ensure that they complied with UK DSEAR (Dangerous Substances and Explosive Atmospheres Regulations) and European ATEX (Atmosphère Explosible) legislation; we offered a cost-effective alternative.” The company also attributes its success to its comprehensive, continuous risk-management service, which ensures the safe and efficient operation of customers’ thermal fluid systems and legislative compliance, via the creation of bespoke improvement plans. Said Franklin: “We’re far more than a thermal fluid firm. We’re our customers’ risk-management partner, assisting them to meet their responsibilities for the safe, compliant operation of their thermal fluid systems, enabling them to focus on other aspects of their operation. One of the things we’ll be doing in our anniversary year is developing our risk-management offer further, and we look forward to sharing details of this with the industry later in 2016.” Since 1996, the company has established a strong international customer base, and in 2011 launched HTFluidfit in North America. It has clients across a range of process manufacturing sectors, including food, wood panel, petrochemicals and fine chemicals. Over the last 20 years, TFS has worked for numerous high profile firms, including Premier Foods, Dow Chemical Company, Pfizer and Airbus. In addition to HTFluidfit, TFS’ individual services include fluid testing, analysis and advice; water removal; drainage and refill. The company also supplies thermal fluids and a range of ancillary products. For further details, please visit Web: www.thermalfluidsolutions.com.

PROCESS INDUSTRY INFORMER March - April 2016

PROCESS SAFETY DATA:

IS YOUR DATA VALID? by Vahid Ebadat, Ph.D., Chief Technical Officer - Process Safety, DEKRA Insight & Hervé Vaudrey, Regional Director Process Safety, DEKRA Insight It is not uncommon to find companies that fail to properly assess and correctly interpret the hazardous potential of chemical reactions performed in their organizations. But unfortunately it is not alone. Newsfeeds are replete with industrial accidents, some of them catastrophic, that could have been prevented had the right process safety data been available.

ollowing a major incident, many organizations attempt to preclude a recurrence by implementing data acquisition procedures and programs, and sometimes even invest in their own process safety labs. Their efforts are understandable and well-meaning, but are often not enough. In our experience, many of these companies overlook to actualize, update, and review the data they collect. Process safety information should not be seen as a collection of static documents grouped in a binder but as a live ecosystem of knowledge that evolves during the lifecycle of the process. It is usually necessary to perform new experimental data acquisition following process or parameter modification to answer questions such as: Is the fluid more corrosive when temperature increases? Is the mixture less stable thermally if the recipe is changed even slightly? Is the safety valve still able to evacuate the flow rate of gases? When process safety data collection and testing is done properly, this shall maximize safety and direct resources where they are truly needed. To get there, it is essential that the entire organization develop competency around process safety data: which data to collect, when and how to get and produce data, and how to interpret them. Different strategies for the collection of process safety data are discussed in an available publication by DEKRA Insight entitled “Process Safety Data: A Critical Ingredient in Process Safety Excellence”.

STARTING THE PROCESS Management of flash fires, explosions, and runaway reactions resulting from the use, handling, and processing of flammable liquids, explosible powders, and reactive/unstable materials often involves taking the following steps: • Establishing a sound process safety management system and competency within the organization that is based on appropriate data, information, expertise, and experience in all related process safety areas, including: - Having appropriate data for the understanding of the flammability, electrostatic properties, reactivity, and explosion characteristics of the fuel(s) - Understanding of all operations and processes - Identification of locations where flammable atmospheres are, or could be, present during normal and foreseeable abnormal operating conditions - Identification of potential ignition sources - Defining the “Basis of Safety” including proper process and facility design to prevent and/or minimize the occurrence of flash fires, explosions, and uncontrolled reactions • Establishing a safety culture that starts at the top but pervades consistently through the whole organization

• Regular review and maintenance of data, information, behaviors, systems, facilities, and equipment

PROCESS SAFETY DATA - FLASH FIRES & EXPLOSIONS The First Step - Formation of a flammable/explosible Atmosphere. A flammable atmosphere is formed when a sufficient amount of a fuel (gas, vapor, or/and dust) is mixed (suspended) with an oxidant. As is highlighted above, in order to assess flash fire and explosion hazards in a facility and to select the most appropriate basis of safety, fire and explosion characteristics of the fuel(s) that could be present must be determined for handling and processing conditions. The first step in the assessment of flash fire and explosion hazards is to establish whether a gas, vapor, and/or dust cloud atmosphere, if formed, is flammable/explosible under the process/operating conditions. For a table of methods used for conducting the tests, download a Process Safety Testing Guide.

DETERMINING IGNITION SENSITIVITY Once the flammability/explosibility of a material or an atmosphere is confirmed, then testing normally falls into two groups, “Ignition Sensitivity” and “Explosion Severity”. Ignition Sensitivity - There are a number of tests that are designed to determine the sensitivity of a flammable atmosphere to ignition by the type of ignition source(s) that could be present during normal and also foreseeable abnormal operating conditions. So, the selection of appropriate “ignition sensitivity” test(s) requires a good understanding of the type of ignition source(s) that could be associated with specific unit operations and activities in a facility.

DETERMINING EXPLOSION SEVERITY The severity of an explosion that is caused by the ignition of a flammable gas, vapor, and/or dust cloud atmosphere in a confined space/enclosure is defined by the (maximum) rate of pressure rise resulting from the expanding fire ball and the maximum explosion pressure. The maximum explosion pressure and maximum rate of pressure rise are typically measured in a 20-liter or a 1m3 spherical vessel. These values are used to calculate the Deflagration Index for a gas/vapor atmosphere (Kg) or a dust cloud atmosphere (Kst) to classify the atmosphere’s explosion severity.

PROCESS SAFETY DATA – CHEMICAL REACTIVITY Chemical reactions are frequently associated with considerable heat exchange. Large amounts of energy can be released when decomposition reactions are initiated unintentionally through

PROCESS INDUSTRY INFORMER March - April 2016

inappropriate operations such as loss of power, loss of cooling, loss of agitation, and/or unintentional mixing (e.g. waste/ disposal) of incompatible chemicals. This can cause a destructive force resulting in the rapid release of the reaction products, including toxic gases and vapors. Hence, the identification, assessment, and characterization of both intended and, more importantly, unintended exothermic reactions are critical for ensuring the safe scale-up and operation of a chemical process (Ref 10, 11, 12, & 13). Chemical reactivity hazards can be grouped into a number of general categories including: • Self-reactive materials (e.g., polymerizing; decomposing; rearranging), • Self-heating materials (smoldering, burning) • Reactive with other materials (e.g., oxygen; water), and • Intentional mixing of two or more chemicals in a chemical process. Safety and environmental regulations require systematic risk analysis to be carried out on potentially-hazardous processes in production plants, pilot plants, and auxiliary installations. The risk-assessment strategy would generally include determining heats of reaction/decomposition, exotherm initiation (onset) temperature, pressure generation, water reactivity, sensitivity to light and air, and spontaneous combustion. “Design of Runaway Scenario” is a powerful method that can be employed for conducting thermal process safety analysis of a batch, semi-batch, or continuous process, taking into account the thermal characteristics of both the desired and unwanted reactions.

CONCLUDING REMARKS In our work, we see too often situations where large risk goes unnoticed, process hazard analysis efforts are invalid or flawed, or vital process safety data are entirely absent. These breakdowns create major risks and ruin the well-intended efforts of the organization. Process safety data should be managed in an active knowledge management system that is sustainable for the organization. Failing to do so means you aren’t getting valid information—leaving you at risk of severe consequences as processes could be in an intrinsically hazardous state without anyone being aware. Invalid data can also cost the organization when unnecessary safeguards are implemented or preventative measures are inadequately designed. Valid process safety data is critical if leaders are to make sound judgements. Without them no PSM can work. Testing Guide for Management of Flash Fires, Explosions, and Runaway Reactions provides a starting point for this basis of safety and helps leaders get ahead of the risks created by the use or presence of flammable gases and liquids, explosible powders and dusts, and unstable or reactive materials.

SPECTROMETERS OCEAN OPTICS ADDS MINIATURE NIR SPECTROMETER FOR PHARMACEUTICAL RESEARCH & PRODUCTION Versatile, powerful Flame-NIR offers the power of NIR analysis in a small-footprint instrument

Ocean Optics has expanded its Flame spectrometer family. FlameNIR delivers powerful near infrared spectroscopy in a compact, affordable instrument. Costing around 75 per cent less than a traditional NIR system, Flame-NIR pairs a high-performance uncooled InGaAs array detector with a small optical bench for spectral response from 950-1650 nm. Flame-NIR can be used as a lab-based instrument for ingredients identification, blending measurements and quality control testing; embedded to power handheld sensing devices; or integrated directly on processing lines. Flame-NIR is sensitive, fast and easy to use. Unlike other lowercost NIR spectrometers, Flame-NIR uses an InGaAs diode array detector for high sensitivity with concurrent measurement of all wavelengths. It also delivers high thermal stability and low unit to unit variation without compromising the flexibility and configurability that are the hallmark of modular, miniature spectrometers. Spectrometers come preconfigured or custom configured, with a replaceable slit design that enables users to adjust resolution and throughput on demand. Complete systems, including accessories such as fibers and light sources, can be configured for under $10,000 (USD). Until March 18, 2016 Ocean Optics is offering a 10% discount on Flame-NIR spectrometer pricing. Operation of Flame-NIR is plug and play. A choice of USB or RS-232 communications, supported by drivers and software, makes it easy to integrate into almost any system. Indicator LEDs show continuous power and data transfer status. Flame-NIR is compatible with Ocean Optics’ range of light sources, optical fibres, sampling accessories and software.

For more information contact Ocean Optics, Geograaf 24, 6921 EW Duiven, Netherlands Tel: +31 (0)26 319 05 00 Email: info@oceanoptics.com / Web: www.oceanoptics.com

COMPRESSORS NEW BOGE COMPRESSOR COMBINES HIGH FREE AIR DELIVERY AND ENERGY EFFICIENCY WITH EXTREMELY QUIET OPERATION BOGE launches a new oil-injection cooled screw compressor that sets new standards in the 11kW performance class

BOGE Compressors, a leading supplier of industrial compressed air systems, has launched a new oilinjection cooled screw compressor that combines high free air delivery and energy efficiency with extremely quiet operation. The C 16 F(D) is designed to meet widely fluctuating compressed air demands and enable users to make significant energy savings. Part of the popular C Series, the BOGE C 16 F(D) provides the highest free air delivery of any 11 kW compressor on the market. This is achieved through the use of a BOGE’s most efficient airend to date, the BOGE effilence, which allows for high performance while consuming very low levels of power due to its high-efficiency IE3 motor. The compressor features integrated frequency control, which is ideal for businesses with fluctuating compressed air demands. The frequency converter ensures the delivery of continuous free air in the 25 – 100% control range. If the demand for compressed air drops, the compressor’s energy use falls. This eliminates idling times and cuts energy use by up to 30 percent as a result. A silenced intake filter and sturdy grey cast iron housing make it one of the quietest compressors in its class and ensure extremely quiet operation even when working at full capacity. This allows businesses to operate the C 16 F(D) in close proximity to the workforce and workstation. The C 16 F(D) has also been intelligently designed for easy servicing and maintenance. All maintenance parts are arranged so that they are easily accessible. In addition, ease of use has also been prioritised. Information can easily be read off the highresolution colour display and touchscreen buttons make it exceptionally simple to operate. Businesses can also benefit from fitting the C 16 F(D) with BOGE’s modular focus control 2.0 control unit. This provides users with total and easy control of all compressor functionality and up to four compressors can be used in combination. The C 16 F(D) is available with a maximum pressure of 8, 10 and 13 bar and free air delivery from 0.46 to a maximum of 1.99 m3 per minute.” For further information contact: BOGE Compressors Ltd. Tel: +44 14 84-719921 E-mail: m.heeley@boge.com www.boge.co.uk

NETWORK & COMMUNICATIONS HARTING preLink® CONNECTION TECHNOLOGY NOW AVAILABLE IN HAN® 3A HOUSING HARTING’s preLink® end-to-end Ethernet connection technology is now also available in the form of an RJ45 connector face in a robust Han® 3A connector housing.

preLink® offers a fast and easy way to set up enterprise-wide networks that extend all the way from IT through to the manufacturing level. With the preLink® concept, HARTING has succeeded in separating the previously fixed connection of cables and connectors into two independent, reusable components: the preLink® termination block and the interchangeable sockets and connectors. The preLink® termination block incorporates a holder for 4- or 8-wire Ethernet cable, which can be assembled with 100% certainty in a single step using the dedicated preLink® assembly tool. This termination block fits into a variety of RJ45 or M12 sockets and connectors. The advantage of this system is that the termination block can be removed in seconds and placed on a different connector. As a result, cables and connectors can be swapped independently of one another. When the termination block is placed in the familiar Han® 3 A housing, the result is a fully industrialstrength interface between machinery and equipment and the Ethernet network.

For further information contact Harting Ltd, Northampton Tel: +44 (0) 1604 827500 Email: gb@harting.com or visit www.harting.co.uk/prelink/

FILTRATION INTERNATIONAL FILTRATION LEADER LAUNCHES NEW CATALOGUE SHOWCASING LATEST INNOVATIONS An international filtration specialist has launched its new catalogue, consolidating its range of leading materials and products. Porvair Filtration

Group will be marketing its extensive offering through the catalogue, highlighting an ongoing dedication to delivering heightened efficiency and lowered costs across numerous industries. Porvair has a policy of continuous improvement in all areas of its business – and the publication of its latest products and materials gathers the best possible filtration and separation solutions for its customers in a single, easily accessible resource. The specialist in world class filtration solutions offers products across such markets as Aerospace and Defence, Energy, Process, Food and Beverage, Water Treatment, and much more. Managing Director, Tom Liddell, said: “Our on-going success is based on a dedication to technical excellence and superior customer service. Highlighting that ethos, the second edition of our catalogue showcases innovative new Porvair products that exceed the expectations of our customers in solving the challenges that they face. Quality is at the heart of every stage of our operation and a fundamental part of our culture. We are ISO9001 approved and hold many other accreditations for the various industries we serve.” Porvair Filtration Group – which has supplied the aerospace, nuclear, energy, process and bioscience industries with performance-driven filtration equipment for nearly 50 years – has an extensive network of sales offices and distribution channels throughout the world. The new catalogue is available to view online here: www.porvairfiltration.com/Brochure/5PFG008_Filtration_Catalogue.pdf

PROCESS INDUSTRY INFORMER March - April 2016

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