Process Industry Informer July 2016 by Process Industry Informer

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JULY 2016 Volume 12 No.4

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

The cleanest pump you will ever need In print | Online | Mobile - The UK’s No.1 Media for the Manufacturing Process Industries

A perfect view â&#x20AC;&#x201C; even with condensation! The future is 80 GHz: a new generation of radar level sensors

For the latest generation of radars, condensate on the sensor is not an issue. Totally unaffected by condensation or buildup on the antenna, VEGAPULS 64 accurately detects the liquid level. With the smallest antenna of its kind and exceptional focusing, it delivers outstanding performance every time. Simply world-class! www.vega.com/radar

CONTENTS. 4-5 News & Events 5-7 Applications 10 Test Measurement 10 Cables & Network 10 Network & Communications 13 Health & Safety 15 Infrared Cameras 15 Calibration 16-17 Process Measurement & Instrumentation 19-23 Fluids & Liquids Handling 27 Water Systems 29 SCADA

80 GHz RADAR: A MATTER OF FREQUENCY

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 TO KEEP YOUR COOL WHEN TEMPERATURES SOAR

HOW THE RIGHT FLOWMETER CAN MAKE YOU MONEY

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‘COMPANIES DO NOT LOOK AFTER THEIR ASSETS’...

A GUIDE TO CHOOSING AND SINE® PUMPS

HYGIENIC STANDARDS & PUMPS

IMPROVING SAFETY & RELIABILITY BY UNDERSTANDING MACHINERY HEALTH

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NEWS & EVENTS STAINLESS STEEL SPECIALIST TREBLES THE SIZE OF ITS MANUFACTURING FACILITIES Stainless steel specialist, Axium Process, has trebled the size of its Swansea based manufacturing facility to 30,000 sq. ft., enabling increased production capacity and providing customer benefits such as improved delivery times.

All processes have been streamlined and integrated into the new facility creating a “one stop shop” that encompasses professional CAD drawing office facilities, a CNC equipped machine shop, MIG, TIG, Automatic Orbital welding and metal fabrication departments, a high specification metal polishing and surface finishing department as well as bead blasting and an electro-polishing operation. The company has also invested in comprehensive inspection facilities and testing procedures to meet the stringent validation requirements for the most demanding of applications. As well as being one of the UK’s leading hygienic stainless steel fabricators, Axium Process is also a major player in the field of membrane and filtration technologies with extensive experience in liquid separation and filtration applications ranging from effluent treatment to product purification. Axium’s new facility includes a dedicated Wet Test Area and Laboratory Services for customers wishing to conduct Pilot Plant Trials and evaluate Membrane Filtration for any liquid process separation requirements. Axium’s expertise has been built on years of diverse and practical experience with projects in major sectors ranging from nuclear, aerospace, pharmaceutical, food, beverage and dairy applications; supplying fully automatic filtration systems, stainless steel frameworks, heat exchangers, tanks and pressure vessels through to component customisation, pipework fabrication, tees, bends and manifolds. The company is also the manufacturer of the renowned Pure-Screen wedge wire and Fine-Screen sintered stainless steel filter range which is used extensively in liquid processing applications world-wide. For further information contact: Axium Process Ltd, Hendy, Swansea Tel: +44 (0) 1792 883 882 Email: info@axiumprocess.com Web: www.axiumprocess.com

AN APOLOGY In our May issue of our report of the winners of this year’s PUMP INDUSTRY AWARDS event we unfortunately included an incorrect photograph for the winners of the ‘DISTRIBUTOR OF THE YEAR’, for which we sincerely apologise to the winners of this category, Tomlinson Hall & Co. The correct image is now shown with the original text.

BUCK & HICKMAN GOES LIVE WITH NEW WEBSITE In order to enhance customers’ experience online, Buck & Hickman, a leading distributor of tools, maintenance and health & safety products, has launched a new website combining a sitewide upgrade with a number of exciting new features.

The website, which can be accessed through www. buckandhickman.com, has been designed with customer usability at the forefront, with a new layout and navigation bar and advanced functionality throughout. As well as showcasing 6,000 new items, the website includes detailed product information and technical specifications to help customers make more informed purchasing decisions. Combining a quick order system and the ability to track purchases from order through to delivery, the website ensures the buying process is as convenient and hasslefree as possible. In addition, fresh content has been developed to provide a complete overview of all Buck & Hickman’s added-value services which include InvendTM and InsiteTM, as well as online e-procurement, purchasing manager and export. Peter Smart, Channel Director of Buck & Hickman explained: “We’re extremely excited about the launch of our new website which has undergone a complete redesign in order to provide our customers with a more accessible, convenient and informative product purchasing experience. “With more of our customers browsing and purchasing online, and recognising the importance of offering a 24/7 multi-channel approach, we felt we needed to reflect this through our online presence, and the new website not only offers improved functionality but a number of value-added features too. Wider product selection and improved navigation ensure customers have access to the right product for their application right at their fingertips, as well as the opportunity to discover new solutions and services.” To view Buck & Hickman’s complete range of products and services, go to www.buckandhickman.com.

BOWMAN ANNOUNCES NEW UK MANUFACTURING FACILITY L e a d i n g manufacturer and supplier of bearings and sintered components, B o w m a n International, has unveiled its new UK manufacturing facility.

The facility has been specifically designed to offer a faster and more efficient end-to-end service on larger, non-standard sized wrapped bearings above 75mm in diameter. Housed at Bowman’s headquarters in Abingdon, Oxfordshire, the manufacturing centre contains an array of market-leading machines capable of working a variety of materials in line with the distributor’s vast product portfolio.

Paul Mitchell, managing director of Bowman International said: “The key driver behind our decision to

manufacture on home soil is speed. Producing non-standard components here, instead of through one of our trusted international manufacturing partners, means we can fulfil special or urgent orders in days rather than weeks. “We can create OEM prototypes too, supporting tight design and build schedules with a reliable service which will be unrivalled for accuracy, quality and speed.” In addition to producing larger non-standard sized wrapped bearings, the site will also be equipped to make alterations to standard components, which will once again deliver time and cost efficiencies to the customer. Paul concludes: “Consistent quality and fast service are a prerequisite when you order standard bearings and sintered components from Bowman. Now, with a manufacturing facility in the UK, we can offer the same speed of distribution on larger non-standard items and special orders too; something which is already proving to be of great benefit to many of our customers.” For more information on the new manufacturing facility, contact Bowman International, Abingdon, Oxon or to discuss a specific project, call 01235 462 500. Web: www.bowman.co.uk

AXFLOW GROWS WITH STRATEGIC ACQUISITION IN SWEDEN Leading specialist in positive displacement pumps, fluid handling systems and related services, AxFlow, extends its product portfolio and Swedish market coverage with the acquisition of Esspump AB.

With 570 employees and sales of 175 MEUR, AxFlow is the largest distributor of high quality industrial fluid handling equipment in Europe and South Africa. The addition of Swedish Esspump is strategically important. ”Both AxFlow and Esspump are known for their products technology and application knowledge. Our expertise and strong customer and supplier relations give us a strong market position in Sweden. The two companies complement each other well. Together we will be able to offer our customers a much wider range of products and more extensive services and technical solutions”, says Fred Lindecrantz, Managing Director of AxFlow AB in Sweden. “AxFlow represents a number of leading pump manufacturers including Mono, Nash, Waukesha, Hermetic, Blackmer and Maag. With the addition of Esspump, our product range is extended to also include equipment from Wilden, Almatec, OBL, Mouvex, System One and Quattroflow”, continues Fred Lindecrantz. Niklas Holmstedt, Managing Director of Esspump, is equally as enthusiastic about the acquisition commenting: ”The synergy of complimentary products, strong technical and application knowledge resulting from this acquisition and the international resources available from AxFlow will bring considerable benefits for our customers and new business prospects.” AxFlow AB, Sweden was established in 1991. Since then it has established itself as a major force in the chemical, mining, pulp and paper and water and wastewater, food and pharmaceuticals industries.The acquisition of Esspump AB makes AxFlow AB one of the largest distributors of positive displacement pumps in Sweden.

For more information, contact: Ole Weiner, CEO, AxFlow Holding AB, Tel: +46 (0)8 545 476 72, | ole.weiner@axflow.com Fred Lindecrantz, Managing Director, AxFlow AB, Tel: +46 (0)738 33 15 40,| fred.lindecrantz@axflow.com Niklas Holmstedt, Managing Director, Esspump AB, Tel: +46 (0)70 520 06 99, |niklas.holmstedt@esspump.se

PROCESS INDUSTRY INFORMER July 2016

NEWS & EVENTS ABB’S BRISTOL PARTNER QUADRUPLES WAREHOUSE SPACE FOR DRIVES AND MOTORS STOCKHOLDING ABB authorised value provider, APDS, has quadrupled its warehouse capacity, with the acquisition of a 250 square metre facility alongside its existing premises in Bristol.

The warehouse enables APDS to stock a broader selection of ABB low voltage variablespeed drives from 0.12 kW up to 500 kW and ABB electric motors from 0.25 kW up to 710 kW. Also stocked are the latest technologies including the synchronous reluctance motor (SynRM) and the WIMES-compliant motor which targets the UK water industry. Alan Jones, Sales and Marketing Director for APDS, says: “Our growth means that we have out-stripped our current capacity. With this new setup and a dedicated team focused on local needs, we can be even more agile as an organisation and offer greater flexibility in the type of partnering we undertake with customers.” The existing premises are also being used to create a larger repair shop and to install a dynamic test rig for motor and drive applications. For more information contact ABB Ltd, Warrington, Cheshire. Tel: 01925 741517 E-mail: layla.hewitt@gb.abb.com | Web: www.abb.co.uk/energy

MARTINDALE AND WORCESTER, BOSCH GROUP, WORK TOGETHER ON SAFE ISOLATION SOLUTIONS Martindale Electric has supplied Worcester, Bosch Group with VIPD138 safe isolation kits which contain the industry leading VI-13800 voltage indicator and the PD440 proving unit. The VI-13800 allows Worcester,

Bosch Group engineers to prove the installations they are working on in the field are dead and avoid potentially hazardous live voltages. Worcester, Bosch Group, a pioneer in manufacturing oil and gas boilers since 1962 also leads the way with initiatives and technologies that are energy efficient and has a strong presence in the UK and globally as part of the Bosch Group. With more than 300 service engineers across the UK and a ‘people first’ philosophy, Worcester, Bosch Group wanted to increase each engineer’s safety in the field with a reliable solution that was easy to use and complied with the latest health and safety regulations for safe working. After researching the market, Worcester, Bosch Group concluded that the most suitable product was the VIPD138 kit from Martindale Electric. Nothing is more dangerous than failing to identify a live circuit due to a defective voltage indicator. Safe electrical work requires the use of a voltage indicator that has been proved with a proving unit before and after use. The VIPD138 contains the VI-13800 voltage indicator and the PD440 proving unit together with a carry case for storing both units. This enables Worcester, Bosch Group engineers to comply with health and safety recommendations for safe working and minimise the risk of possible accidents during their work while at the same time being a convenient and easy to use tool. The VI13800 is exceptionally reliable and safe because it’s simple, with no batteries, ranges or switches to worry about. Martin Andrews, Field Service Support Engineer at Worcester, Bosch Group who conducted the research and completed the purchase, said, “Martindale has been very efficient and we are very pleased with our purchase; our engineers can do their jobs easier and feel safer”. The fulfilment for the purchase was done through their local supplier which allowed for a timely delivery of the VIPD138 kits. Founded in 1928, Martindale Electric is a British owned company and the market leader in safe isolation solutions. For more information, please contact Martindale Electric on 01923 441717 or visit www.martindale-electric.co.uk

PROCESS INDUSTRY INFORMER July 2016

EMERSON INTRODUCES WIRELESSLY-MONITORED STORAGE TANK EMERGENCY VENTS New Enardo 2000 model with Smart Wireless technology provides immediate information to help prevent safety emergencies

Emerson has introduced wirelessly-monitored Enardo 2000 emergency pressure relief vents (EPRVs) that provide safety control by managing abnormally high storage tank pressures in the oil and gas, chemical, petrochemical and pharmaceutical industries. Under normal operating conditions, an EPRV remains closed. The immediate knowledge of an open position can be vital and should warrant quick investigation. However, because these EPRVs are located on top of storage tanks, they are difficult to monitor. Site managers are increasingly looking for ways to increase safety and efficiencies. The new product design consists of a proximity indicator and wireless transmitter integrated with an EPRV. The proximity indicator senses movement of the emergency vent. ‘Open’ or ‘closed’ signals are received by the wireless transmitter and can be sent to a control room via a WirelessHART® gateway. “Though EPRVs represent the last line of defence against tank overpressure, they have largely remained unmonitored,” said Steve Attri, product manager for Emerson Process Management. “Along with the recent introduction of wirelessly-monitored pressure vacuum relief vents (PVRVs), more information is now available to quickly identify and resolve pressure issues that can impact safety and emissions.” For more information, visit www.EmersonProcess.com/smarteprv.

ABB DRIVES CUT ENERGY COSTS & IMPROVE RELIABILITY AT SUSWORTH PUMPING STATION A surface water pumping station expects to cut the energy use of two submersible pumps by between 10 and 15 percent following the installation of ABB variable-speed drives (VSDs). The

VSDs also avoid the cost of installing a new transformer and improve the reliability of the site’s pumping system. Susworth Pumping Station, located in Lincolnshire, is managed by the Shire Group of internal drainage boards. The station, which discharges into the River Trent, uses the submersible pumps to transfer surface water runoff from the low lying catchment, protecting people, property, agriculture and the aquatic environment. The pumps are rated at 65 kW and 75 kW, with a combined full load current of 202 A. Both pumps run at 950 rpm. The pumping station’s electrical supply is via a remote pole transformer rated at 100 kVA. Because of the transformer’s rating, only one pump could run at a time, even during periods of prolonged rainfall. The solution was to use VSDs to run pump one at 41 Hz, drawing 38 kW with pump two running at 37.5 Hz, drawing 28 kW. This means that both pumps run at 80 percent capacity, with 29 A spare, over the full load current for both pumps. Running at this capacity means that the transformer is not overloaded and together the two pumps achieve a higher pumping volume than a single pump working at full rate. Inverter Drive Systems (IDS), an ABB authorised value provider, installed two 75 kW ABB general purpose drives and conducted a four week trial to determine the motor’s best speed for optimum pumping. During the trial, the normal pumping rate during non-storm conditions was optimised to achieve the lowest energy use for each cubic meter of water pumped. This has been set to match natural flow in the dyke, avoiding surges and unnecessary starts. Following the trial the VSDs were fitted in a permanent installation. Because both pumps can be run at the same time, the pumping system is more reliable and can run in fully unmanned mode. Sharing the load between the pumps means that there is no need to invest in a costly transformer, achieving further savings. With lower speeds and soft starts, the VSDs place less stress on the motors, helping reduce wear. For more information, contact: ABB Ltd, Daresbury Park, Warrington Tel: 01925 741111 Email: energy@gb.abb.com Web: www.abb.co.uk/energy

APPLICATIONS CHILLER HIRE KEEPS DIGESTER ON STREAM A packaged chiller solution supplied by Andrews Chiller Hire enabled a waste processing plant to maintain full operational status of its anaerobic digesters by reducing elevated waste temperature by at least 10oC, creating an ideal for environment for bacteria to produce usable gas output.

The company needed to reduce the temperature of waste to no more than 40°C, with approximately 90,000 litres of waste processed on a typical day.

The Process Anaerobic digestion is the natural breakdown of organic materials into methane and carbon dioxide gas and fertiliser, the reaction is either naturally occurring or takes place within an anaerobic digester; an industrial process for handling large quantities of waste and a preferred environmentally friendly method. There are essentially three main options for dealing with organic wastes: 1. bury it – a landfill options which is unpopular 2. burn it - which means incineration, gasification or pyrolysis 3. bio-digest it - which means either anaerobic digestion or composting The process of anaerobic digestion provides a source of renewable energy, since food and other ‘green’ waste is broken down to produce biogas (a mixture of methane and carbon dioxide), which is suitable for energy production. The biogas can be used to generate electricity and heat to power on-site equipment and the excess electricity can be exported to the National Grid. Also, after removing the carbon dioxide (and other trace gases using a variety of methods in a process known as upgrading) the remaining methane is known as Renewable Natural Gas or Biomethane. The uses for biomethane are therefore as varied as are those for natural gas, for heating, cooling, as a source of chemicals, fertiliser or hydrogen. The Problem When this major waste processing organisation experienced a slow-down in output due to an unexpected rise in waste processing temperature to 50oC, caused by equipment malfunction, it became too hot for the bacteria to produce gas. A call went out to Andrews Chiller Hire. With more than 25 depots nationwide and access to experienced engineers 24hrs, seven days a week, Andrews Chiller Hire is able to respond promptly when an emergency situations occurs. The swift reaction and local presence meant that Andrews Chiller Hire was able to conduct a thorough site survey within 24 hours of receiving the initial call from the waste processing plant. It allowed a regional technician and the customer to liaise directly and make a swift decision about which size chiller would best suit their needs. A stand-alone solution was required until their equipment could be repaired or replaced and put back on stream. To return the plant to normal processing duties Andrews delivered a total integrated solution including a 375kW chiller along with a generator and fuel tank to help bring temperatures down to the desired level. Once installed, the chiller reduced the temperature of the waste processing by 10oC, allowing proper bacteria reactions to take place and biogas manufacture. Anaerobic digestion is the only system for dealing with organic waste which is sustainable, recovers the maximum energy, is a completely closed system with no emissions to air or land, which retains the fertiliser and water content, and facilitates the recovery of heavy metals The intervention of Andrews Chiller Hire meant that the environmental waste company was then able to begin reproducing gas, feeding a turbine to re-start electricity production from the digestion plant. For more information contact Andrews Sykes Hire Ltd, Tyburn Road, Birmingham Tel: 0800 211 611 E-mail: s.salescentre@andrews-sykes.com Web: www.andrews-sykes.com

AXION CONSULTING SUPPLIES ‘POWERFUL’ DATA ANALYSIS TOOL Axion Consulting has designed and implemented a complex data analysis tool for a Yorkshire-based power generation client to simplify and streamline their monitoring process.

The six-month project was carried out by the resource recovery specialist’s team for Ferrybridge Multifuel Energy Ltd (MFE). The facility has a 70MW output supplying around 160,000 homes with low-carbon electricity from refuse-derived fuel. Previously, analysis of the annual 600,000 tonnes of residual waste treated by MFE was a time-consuming task for Dr Claire Spencer, Plant Chemist, Environmental Officer and Fuels Liaison. Checking weekly test and compliance data from up to a dozen different suppliers was a complicated process. “Axion’s spreadsheet system for the fuels combines all the data testing in one model that accurately describes the infeed materials and identifies contract compliance. This is an essential part of the quality monitoring process for what goes into the plant to generate power,” explains Claire. “The data tool has certainly made my job easier, saving time on analytical reports and putting the information into a straightforward format for management review.” Axion’s Senior Engineer Sam Haig says their system provides reports that help support both their client’s technical operation and contractual agreements with their suppliers, so the material will not exceed certain limits. “As well as reducing the time taken for the plant chemist to enter the data and analyse it, it has also allowed her to see information and trends that perhaps may have been missed before,” says Sam. He adds: “By streamlining the process, it provides ‘headline’ figures for speedier analysis. An added advantage of our system is that it can be applied to a variety of other process applications that require accurate and rapid analysis of complex data.” Axion Consulting, part of the Axion Group, develops and evaluates novel resource recovery processes, tests and operates innovative recyclable collection systems as well as offering business planning and financial analysis. It can supply the expertise, knowledge and necessary skills to implement projects in the Circular Economy sector, with a specific focus on working with supply chains to deliver successful outcomes, which are both environmentally sound and economically viable. For more information contact, Axion Consulting, Bramhall Tel: 0161 426 7731 E-mail: info@ axionconsulting.co.uk or visit the website - www.axionconsulting.co.uk @axion consulting.

RAPID INSTALLATION OF ABB DRIVE KEEPS SEA LIONS ON VIEW Colchester Zoo avoids disappointing visitors to one of its most popular attractions following the rapid installation of an ABB variable-speed drive (VSD) to replace a failed unit.

Following a power cut, the nonABB installed drive on the ozone pump in the zoo’s sea lion enclosure reported an undervoltage fault when attempts were made to re-start it. ABB authorised value provider, Gibbons Engineering Group, received the call from the zoo at 08:00 and had an engineer on site within two hours. After determining that the installed drive was damaged, a replacement 22 kW ABB drive was collected from Gibbons’ stock. Mains and control connections were set up and the pump was operational again by 13:00. The VSD plays a vital role in keeping the sea lion tank clean and the mammals healthy. Craig Hamnett, electrician for Colchester Zoo, says: “It was important that we get the pump back in operation within 24 hours, otherwise algae would develop in the pool, seriously degrading its clarity. This would have meant disappointing visitors to this popular attraction.” For more information contact ABB Ltd, Daresbury, Warrington Tel: 01925 741111 E-mail: layla.hewitt@gb.abb.com Web: www.abb.co.uk/energy

PROCESS INDUSTRY INFORMER July 2016

APPLICATIONS BREWERY REBELS AS FULTON’S THERMAL FLUID INSTALLATION IS ONE OF ONLY A HANDFUL IN THE UK Steam is often seen as a traditional source of indirect heat for brewing and distilling processes but, with the recent explosion in micro-breweries and resurgence in craft brewing, the regulations and additional ongoing investment required for running a pressure-based system often adds too much cost when considering steam as a heat transfer solution. So when Rebellion Beer Company was looking to replace its ageing steam boiler

system, they turned to two of the UK’s major thermal fluid specialists for help. Established in 1993 by two school friends from Marlow, Rebellion Beer Company is a medium-sized micro-brewery that uses traditional brewing methods and natural ingredients to produce four million pints of beer from its Chiltern Hills-based brewery every year. Having secured a new 20-year lease on its premises, and as part of a three-stage development plan for the business, Rebellion’s Mark Gloyens decided that an upgrade to some of the company’s original brewing equipment was required and, with its steam boiler reaching the end of its operational life, he started looking at options for new heat transfer equipment. “This was the first time we had approached thermal fluid system specialists for a project of this sort and, having met with two of the UK’s main suppliers to discuss the project, we were impressed with Fulton’s enthusiasm and interest in getting involved with what turns out to be one of only a handful of brewery-based thermal fluid heat transfer projects in the UK.” says Mark. Explaining the potential energy savings, Mark says that Fulton’s new FT-C 240 vertical coil thermal system should save money on the company’s energy bills as it is possible to easily turn the heater on and off as required, and with minimal heat-up time. In contrast, the old steam-based system needed to be turned on at the beginning of the day and left running regardless of the demand for steam. The new system also provided value-for-money, as thermal fluid heaters are non-pressurised systems and therefore not subject to the costs of running a system under the pressure regulations. For example, thermal fluid heaters use specialist oils as heat carriers and operate, at atmospheric pressures, up to 300°C. For Rebellion, the system is also much simpler than a steam solution and was therefore less expensive to set-up and maintain. Additionally, Fulton’s FT-C thermal fluid system is more compact than the original steam-based system, which has freed up much needed space for other valuable process equipment. The whole life costs for thermal systems can also be cheaper because they require fewer insurance inspections, which minimises production downtime and shut down periods. There’s also no requirement for water treatment or chemical dosing, which leads to zero waste disposal and minimal maintenance costs. Summarising, Fulton’s Doug Howarth says that whilst the company is known as a reliable source of multi-fuel-fired steam boilers, Fulton is also synonymous with heat transfer solutions and produces an unrivalled range of thermal oil and hot water solutions. And because Fulton offers a complete range, they are well placed to offer customers an unbiased review of their heat transfer requirements. For further information on its thermal fluid systems, including the FT-C vertical coil, FT-N vertical electric and FT-HC horizontal coil heaters, call Fulton on 0117 972 3322, email sales@fulton.co.uk or visit Fulton’s new-look website at www.fulton.co.uk.

PROCESS INDUSTRY INFORMER July 2016

80 GHz RADAR: A MATTER OF FREQUENCY Understanding the benefits of 80 GHz radar & its importance for all liquid level measurement applications With the recent launch of radar instruments in the 80 GHz frequency range for liquid level measurement, now is a good time to examine what’s behind this new direction in radar technology. So where does it come into its own and what are the benefits of using these new sensors in automated processes for control and inventory? This development signals a brave new world in level measurement, one where radar level measurement can go where it has never gone before. With high-frequency radar level devices on the rise, this is truly an exciting era in automation.

TECHNOLOGY ADVANCES CREATE AVAILABILITY The readiness to use radar level sensors is a function of cost and innovation. Decreased expense has led to increased use of the technology across multiple industries. Microwave radar is a popular format for level measurement, being solid state with no mechanical parts to drift or wear and, more importantly, its immunity to pressure, vapours, temperature, viscosity and density change. Just as computer hardware prices dipped low enough to put a ‘PC in every home’ and a ‘smartphone in every hand’, it is now possible to put the latest 80 GHz radar in virtually any vessel and every plant. Latest innovations have resulted in a technology that can be both affordable and relevant to even more general process applications. This latest generation of modern radar instruments are engineered out of decades of experience, culminating in the best ever optimised antenna designs, with larger dynamic ranges and software algorithms to filter out interference to perform even better. Now that 80GHz Figure 1 radar is available and highly applicable to almost any liquid level measurement, users should get to know and accustomed to the advantages these new contactless sensors provide. The main benefits are produced through better focusing, versatile sizes, enhanced resolution, the consequently easier set up and most importantly - high performance reliability.

SO WHAT, IN DETAIL, ARE THE MAIN AREAS OF DEVELOPMENT FOR 80GHz RADAR LEVEL SENSORS? Focusing: This is the primary advantage of 80 GHz radar - the one that makes virtually all the other benefits possible. In every contactless liquid measurement, signal focus is crucial to accurate

level measurement, and these new instruments emit the most highly focused signals on the market. Plant operators have struggled with less focused radar - and ultrasonic - sensors for decades. The wider beam angle of 26 GHz sensors (and still wider 6 to 10 GHz sensors before them) made it difficult for the emitted signals to miss agitators, baffles, ladders, heating coils and other vessel internal structures. The reflections from these installations distort and confuse the echo picture to the sensor, forcing users to make(often many) adjustments to follow the true liquid level. These new high-transmission models have narrower beams that completely miss vessel installations, as if they aren’t even there. That is welcome news in pharma, chemical and food production, where obtrusive internals are often the norm and space is at a premium. Mounting nearer to vessel sides and taller nozzles, without accuracy loss, is another area of advantage - enabling use of more existing connections, especially in taller vessels. They can also be easily installed to look through process isolation valves; an application area highly desirable in the Oil and Gas processing and storage industries, for example. In summary, the superior focus makes for accurate measurement, minimal adjustment, simpler installation and maximum signal return from the product surface. FIGURE 1: Using the same antenna size, this illustrates the radar beam width of 26 GHz as a grey signal path, and the narrower 80 GHz the yellow path. The sharper focusing demonstrates how it stays on the true liquid level, ignoring distracting false signals from nozzles, valves, internal structures or build on the vessel walls

Size: Because their focus is so improved, 80 GHz sensors have smaller antennas. They

feature the world’s smallest level radar antenna – smaller than the size of a £1 or €1 coin – so it doesn’t require a large horn to focus its beam at the product surface. A compact instrument design and small size also makes a huge impact when it comes to retrofitting. Plants can now integrate the most advanced radar devices into their process without shelling out thousands for vessel modifications. Smaller size and range instruments aren’t just good for old vessels, they can also help manufacturers stay nimble and market-responsive. There are more trends in the food, pharmaceutical and chemical industries toward batch production. Batching allows operators to produce profitable, special or seasonal versions and low-volume products, with lower financial investment. Small batches are produced in small vessels ,but conventional wisdom says using contactless radar is not possible - due to the small process connections, busy vessel internals and their reduced accuracy over very short measuring ranges. However, contactless, volume measurement is still highly desirable, especially if unaffected by temperature, pressure, viscosity, density and conductivity changes that can be seen in different product formulations. Now, thanks to the compact design and performance of 80 GHz radar level sensors, operators no longer have to sacrifice accurate measurement in the name of space.

Figure 2: Small antenna (and housing) sizes of 80GHz radars add

PROCESS INDUSTRY INFORMER July 2016

Figure 2

to versatility of application in small batch vessels and adaptability to existing nozzles, yet still with a measuring range up to 30m or more. Resolution: When looking

at the picture on a standard definition television next to that of HD TV, the higher resolution delivers a higher quality image: clearer, sharper and more detailed. Users will see a similar difference switching from lower frequency to highfrequency radar sensors. For example, when the level of a hydrocarbon liquid in a vessel is just starting to fill or empties down very low, lower frequency process radars do not have the resolution to distinguish the different reflections from the product level and the tank bottom, they just see one ‘echo’. This tells the user the vessel is empty when it isn’t, presenting a natural handicap to process efficiency. The new 80 GHz devices can measure liquid down to the last millimetre, providing accurate data they can use to optimize their processes. This is not just about small range applications either, the greater resolution is also particularly important for shipbuilders for example, who count on precise level in large cargo and ballast tanks, tens of metres high. It results in better measurement accuracy of every drop of liquid in tanks of all sizes, this is especially important with hydrocarbons in large storage vessels.

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,

Figure 3: 80 GHz high resolution means better accuracy and process detail, including the ability to detect even a few mm of hydrocarbon based product in a vessel bottom from many metres away.

PROCESS CAPABLE Getting close to the product in smaller vessels also means increasing the possibility of sensor build up, through splashing, sublimation and condensation on the antenna face. This can result in reduced antenna/signal efficiency, causing reduced measurement reliability. The latest sensors with optimal antenna design, dynamic range, sensitivity and filtering algorithms can handle these challenges with ease. This capability is essential to deliver higher operational reliability, even when the product gets where it shouldn’t! There are also units available with certified hygienic fittings for food and pharma industries to ensure thorough cleaning of any sensor process connection.

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 Prime UltraPure

IN SUMMARY High-frequency contactless radar sensors look set to be the next big thing in level measurement across many industries, processes and vessel types. They are the proverbial ‘giant leap’, a marker in time after which the process industry will never be the same. Their excellent focusing makes them perfect for vessels crowded with internals and difficult mounting nozzles; their small size makes them ideal for retrofitting and batch production; and their unrivalled resolution also allows users to get ever last drop of capacity from the largest of tanks. The future of level measurement is here. One way to learn more about 80 GHz technology, its uses and features is to visit www.vega.com/radar

PROCESS INDUSTRY INFORMER July 2016

Alfa Laval LKH

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

TEST & MEASUREMENT HYGENIC LOAD CELLS FROM HBM PROVIDE WEIGHING SOLUTION To

meet the strict hygiene regulations required in production, HBM – market leader in the field of test and measurement – has recently introduced the PW25 and PW27 range of load cells, which have been designed for use in filling systems and packaging plants, in multi-head combination weighers and static scales.

Suitable for use in beverage, food, pharmaceutical and bio industries, the latest range of easy to clean load cells are hermetically encapsulated and housed in stainless steel, making them compatible with all cleaning agents and disinfectant agents, which are commonly used in the production process. Featuring a clean and smooth cylindrical design that is non-absorbent and free from imperfection, such as grooves and gaps, to avoid gathering, the top surfaces of the new load cells are also inclined to prevent the collection of dust, product residue or water droplets. Furthermore, by replacing the usual specification stickers with laser etching, the possibility of contamination is less likely to occur. The PW25 and PW27 from HBM are ingress protected to IP68, with IP69 as an option for added protection. Furthermore the hygienic PW27 load cell, which enables efficient and accurate weighing equipment to be used in fields where aseptic production is required, has been developed to meet the guidelines set out by the EHEDG (European Hygienic Engineering and Design Group). These guidelines, set out by the EHEDG, reflect the need for all systems and components, such as weighing systems used in filling and packaging systems, of food processing equipment to comply with stringent hygiene standards. The latest range of load cells from HBM can be easily connected to the PAD series of digital transducer electronics from HBM to accurately digitise signals of analogue load cells or force transducers, even under the harshest of conditions. Developed to meet the demands placed on weighing components involved in dynamic filling and metering applications, the PAD series offers integrated measurement signal conditioning, including a selectable or automatic filter and two integrated digital I/O interfaces. Depending on the need, the PAD series from HBM can also be configured via RS485 or CANOpen interfaces, which enable analysis and remote access in networks. Depending on individual requirements, variants are also available with a pre-wired sensor connection cable (optionally as an aseptic version), or a plug/plug variant, ensuring flexibility for load cells or force transducers. Housed in welded casing and hermetically encapsulated, the robust PAD series offers an IP rating of up to IP68/IP69K, making it suitable for a wide range of demanding applications. The latest range of innovative load cells and the PAD series of digital transducers from HBM provide a hygienic solution for weighing systems, without compromising on accuracy and quality, which is an important factor in terms of minimising costs associated with maintenance and downtime issues. For more information, please contact HBM on +44 (0) 208 515 6000 or visit www.hbm.com.

CABLES & NETWORK TURNING CABLES INSIDE OUT: NEW CABLE ENTRY SYSTEM KDSclick REDUCES INSTALLATION TIME CONTA-CLIP is introducing KDSclick, a new cable entry system that minimizes the time needed for deployment, including assembly of an individual configuration. KDSclick achieves IP65 ingress protection.

The system comprises only three basic components – frames, inlays and sealing sleeves – due to its simple modular design: unlike conventional systems that require the frame to be opened and then screwed Figure: KDSClick: the easy-to-install, modular cable entry closed again to insert the system from CONTA-CLIP sealing sleeves, CONTA-CLIP’s new solution is based on a robust, but lightweight single-unit plastic frame. Creating frame openings in the desired size is made easy with click-on inlays, which are available as simple partitions, as tees or as cross and double cross forms. 18 frame variants for different wiring requirements can be readily assembled this way. This limited number also makes stockkeeping easier. CONTA-CLIP provides 39 different sealing elements to allow for the sealing of various wire diameters as well as feeding several cables through one frame opening. The conical shape of the sealing elements is particularly user-friendly: after sheathing a cable, the elements are fed from the inside of the cabinet to the outside through the frame openings created by the inlays. Thanks to conical tapering, the sealing elements are easily and effortlessly pushed into the frame openings/inlays. As a result, they reliably seal cable gaps and serve as a strain relief with absolutely secure hold on the cabinet exterior. At the same time, the sealing elements can be easily removed again, e.g. when new or additional wiring is necessary. This ensures comfortable changes to the wiring, even for single cables, without having to disassemble the frame. For comfortable cabinet assembly, the frame comes with the same mounting hole layout that is used as a standard for heavy duty connectors – the cable entry system thus fits into the cabinet openings without any special machining of material. CONTA-CLIP launches the new range with 107 x 71 mm frame dimensions. Four additional frames for larger and smaller dimensions as well as a frame with a snap lock for even faster assembly/disassembly are due to follow. KdsCLICK is available from OEM Automatic, Whetstone, Leicester Tel: 0116 2849900 Web: www.oem.co.uk

NETWORK & COMMUNICATIONS HARTING MAKES THE CASE FOR VIRTUALISATION IN MANUFACTURING AND IIOT HARTING has published two new ‘whitepapers’ for businesses planning to implement ‘Industry 4.0’ methods and ‘Industrial Internet of Things’ networks. The first paper, by Dr Karsten Walther and Dr Jan Regtmeir, makes the case for virtualisation using Linux Containers. The second defines the practical uses of Linux Containers and describes how to implement the technique using HARTING’s MICA (Modular Industry Computing Architecture).

Gavin Stoppel, Product and Applications Manager at HARTING Ltd., said; “Companies deploying large scale automation solutions using ‘Industrial Internet of Things’ networks and distributed control systems need this type of device. Ruggedised computers are a key element in delivery of Industry 4.0. MICA provides both the logical architecture and an industrial standard, ready-to- use hardware platform. These whitepapers argue the case for virtualisation in manufacturing and outline HARTING’s approach to delivering this vision.” Unlike other devices designed to run Linux Containers, MICA hardware is a fullyconfigured device, with a range of input and output options, and an industrial standard ruggedised case. It also has built-in security and a range of power sources, such as Power over Ethernet (PoE), allowing great flexibility in its deployment and implementation. Benefits of virtualisation include: •Cost savings through virtualisation of servers and computers in production environments •Security of investment through modular upgradability of existing equipment •Time savings through easy integration •Reduced overhead through user-selectable programming language Sample Application Areas •RFID readers•Cloud gateways•Production control systems•SAP integration down to production equipment level•PLC Orchestration•AI, neural network or fuzzy logic controllers•Predictive analytics systems To download HARTING’s whitepapers on virtualisation in manufacturing, please Enter www.harting.co.uk/MICA/whitepaper For more information contact HARTING Limited, Northampton, Northamptonshire Tel: +44 (0) 1604 82750 Email: gb@harting.com Web: www.harting.co.uk

PROCESS INDUSTRY INFORMER July 2016

HOW TO KEEP YOUR COOL WHEN TEMPERATURES SOAR Four steps to help ensure optimal process cooling this summer Chris Smith, Head of Temperature Control for Aggreko Northern Europe offers advice to managers seeking to optimise cooling performance and avoid system breakdowns this summer.

ummer is here, putting pressure on the process sector as managers face the challenge of ensuring reliable cooling plant for their production facilities. Hotter weather can overburden cooling plant at manufacturing and processing sites. For every extra degree in ambient temperature over a designed specification, the cooling kW output of refrigeration equipment reduces. This can make it difficult to maintain required temperatures and kW cooling capacity during warmer weather. As a result, cooling plant, such as chillers, heat exchangers or cooling towers can be prone to breakdowns. This is a particular risk for sites with older equipment and where servicing and maintenance is not as robust as it should be. System failures can lead to a halt in production, damaged supplier relationships and consequential financial losses.

KEEP UP SERVICE AND MAINTENANCE REGIMES In Europe, new chillers are generally rated to handle ambient temperatures at 30/35°C, but their efficiency can swiftly decline if you fail to keep on top of service and maintenance regimes. These should be more than merely changing the oil - it’s important to pay particular attention to refrigerant, circuits and condensers too, or there could be problems ahead. Maintenance should include thorough cleaning and regular maintenance of condensers to ensure that they continue to operate efficiently. Higher ambient temperatures will put a strain on condensers as they work harder to reject excess heat. They will also need special attention if, over the year, attempts have been made to increase cooling by spraying them with water. Over time this destroys the fins, resulting in major capacity loss, even during the cooler winter months. Heat exchangers are also prone to fouling or corrosion problems. These are difficult to spot and can develop gradually, or appear without warning. This is more likely when production is pushed to its maximum, such as in summer peak seasons. During the hot summer months fouled heat exchangers can also limit a process unit’s operation and cut down on efficiency. This is because process units experience cooling limitations due to warmer cooling tower water, or because dry coolers using the warmer ambient air become less effective. If a plant isn’t maintained to work to its full capacity and fails, it can mean shutting down a production line, resulting in capital expenditure running into the tens of thousands. Complete replacement of a chiller system or heat exchanger can take months. Regular, general equipment maintenance schedules should also include preventing system leakage, e.g. the plant

refrigerants, control calibration, electrical checks and water treatment. Rental equipment can support production and cooling during maintenance and servicing, thereby minimising downtime and ensuring production quotas are met. This is the approach taken recently by a leading food manufacturer, which needed to refurbish its chiller system. Aggreko installed a complete cooling rental package, including 800 kW chiller, 750 kW heat exchanger, 3-way valve, process pumps and generators for power. Once up and running the customer took their existing cooling process offline, enabling them to carry out the repairs with peace of mind that their produce would remain in optimum condition at the required temperature.

CHECK PAST EFFICIENCY DATA It’s important to learn lessons from previous summers by reflecting on past experience. If there were any minor issues last summer, there’s a likelihood that these will reappear as major issues this year. Examine historical system efficiency data and trends to check how your refrigeration equipment coped with higher ambient temperatures. If you saw dips in performance then you may need to act soon to ensure the system hasn’t deteriorated over the past 12 months. Use this to analyse risk and build a robust risk management strategy.

MAKE SURE YOU HAVE SUFFICIENT CAPACITY You may have expanded your production lines, manufacturing facilities or cold storage areas without increasing your refrigeration capacity. Your current plant may also be starting to deteriorate in performance. During winter months the existing cooling infrastructure might suffice, but higher ambient temperatures over the summer may highlight the insufficiency of your cooling capacity. This indicates that it might be time to think about upgrading or increasing your cooling infrastructure. However, it might be difficult to justify this capital expenditure to cover annual peaks in demand that occur for only approximately 20% of any given year. A more cost effective alternative, therefore, may be to supplement your existing plant with hired-in cooling equipment to manage exceptional summer demands. This will avoid capital expense and has the flexibility to be scaled up or down depending on the site’s demand. An initial site survey to understand your potential requirements will ensure additional cooling plant can be onsite quickly when required.

If additional temperature-controlled storage is needed during times of peak demand over the summer period, this can also be achieved with rental equipment. For example, using very low temperature chillers that can achieve temperatures as low as -45ºC, (when combined with air-cooled chillers or cooling towers) allows temporary chilled storage facilities to be created from a standard warehouse. For example when Five Star Fish, part of the 2 Sisters Food Group, underwent a cold store refurbishment at its Grimsby production site, we installed a complete temporary cooling scheme that enabled a total shutdown of the permanent cooling plant for upgrade and maintenance. The 150kW @ -18°C scheme used Very Low Temperature Fluid Chillers, combined with air handling units and ancillary equipment to maintain a consistent temperature and ensure the preservation of stock.

HAVE A WELL-REHEARSED CONTINGENCY PLAN IN CASE DISASTER STRIKES If your refrigeration equipment breaks down and stops production, every minute counts before you might be faced with discarding valuable stock, letting customers down and sending employees home. It’s critical to have a robust, well-rehearsed emergency plan in place. This will include reactive maintenance and repair procedures to cover every eventuality and a 24/7 on-call process for engineers. It is also essential to have considered what back-up equipment you may need so you can continue production while your equipment is out of action. Discussing your needs with a rental temperature control equipment supplier will help build a contingency plan should the ‘worst case scenario’ occur. A reputable supplier will spend time with you on-site, understanding your needs, identifying the most suitable equipment to meet them and producing a detailed site plan. This should take into account specific technical, logistical, safety and training issues, so everything is considered and planned for in advance. In this way you can ensure fast and effective installation and commissioning to get the process back up and running as quickly as possible. You should also agree appropriate lead times and costs for installation and delivery, maintenance and refuelling requirements, as well as decommissioning. Disaster recovery planning enables sites to implement a transitionary fix quickly, while a long-term solution is found. This level of proactive planning can also reduce insurance premiums over time as it demonstrates your business is doing everything it can to avoid a production shutdown.

PROCESS INDUSTRY INFORMER July 2016

HEALTH & SAFETY WORKERS IN SAFE HANDS WITH NEW Q-SAFE GLOVES Q-Safe, a comprehensive range of personal protective equipment (PPE), which is exclusively available from Buck & Hickman, has launched a new innovative range of gloves which not only offer superior hand protection, but benefit from a variety of enhanced functionality and user benefits.

The new range, developed using Dyneema® technology, a high modulus polyethylene (HMPE) fibre which is cut resistant, includes gloves with a level 3, and level 5 cut protection - the highest level of protection according to EN 388. In addition to their protective qualities, Q-Safe Dyneema® hand protection also has multiple functional benefits, including an ultra-lightweight design and enhanced dexterity, and the ability to radiate heat away from users’ hands, ensuring allday comfort. What’s more, the gloves have been certified ‘vendready’ and are available through Buck & Hickman’s industrial vending service, InvendTM. Nadine Sherwood, PPE Product Manager of Buck & Hickman, explained: “We’re really excited about the launch

of the Q-Safe Dyneema® hand protection and pleased to be making the gloves available to our customers. With changes to EN388 coming into force this year, our customers can rest assured the gloves have undergone the most rigorous testing and retain either a level 3 or level 5 cut rating. As well as being extremely cut resistant, the gloves have been designed with the user in mind, providing optimum comfort and movability. For further information about Q-Safe, please go to www.q-safe.biz or for more details about Buck & Hickman’s InvendTM service, visit www.buckandhickman.com

FORTRESS tGard INTERLOCK SWITCHES & CONTROL DEVICES GET TÜV SÜD CERTIFICATION Industrial safety specialist Fortress Interlocks has achieved TÜV SÜD European, Canadian and U.S. approval for its tGard range of interlock switches and control devices. This means they meet all the necessary requirements of the European Machinery Directive and the Nationally Recognized Testing Laboratory Program (NRTL) in North America.

MARTINDALE PRODUCE NEW SERIES OF SHORT INFORMATION VIDEOS

Choosing the correct equipment can often be daunting, so with this in mind, Martindale Electric - one of the most trusted brands in electrical safety testing - has created a ten-part series of short videos detailing the benefits of choosing the correct equipment for the job.

Presented by industry personality Dave Austin, the new collection of videos from Martindale Electric looks at the five key areas; 17th Edition Testing, Voltage Indication and Safe Isolation, Fuse Finder and Cable Detectors, PAT Testers and Sockets testers; and has been designed to help electricians and maintenance personnel perform safer, faster and smarter testing on-site. Focusing on key products from the Martindale Electric range, the new collection of video includes valuable information on the ET Series of Multifunctional Electrical Installation Testers, which have been designed to simplify testing to the latest Amendment 3 changes to the 17th Edition Wiring Regulations. As nothing is more dangerous than failing to properly isolate a circuit before maintenance, the new series also offers viewers the chance to take a look at the VIPDLOK138 and VIPDLOK150 kits in action which offer a complete solution to safe isolation. The kits contain everything you need to stay safe and include industry leading voltage indicators, proving units and a comprehensive set of lock out devices. The kits are a one stop solution enabling users to comply with Electricity at Work Regulations for safe working. The first two videos are available to watch now on the Martindale Electric You Tube channel https://www.youtube.com/ user/MartindaleElectric The new collection of informative videos includes a wealth of factual information and provides viewers with clear and concise visual demonstrations of how Martindale products can be used, in an easy to understand format. For further information on Martindale Electric, contact Martindale Electric on 01923 441717 Email - sales@martindale-electric.co.uk & Web - www.martindale-electric.co.uk.

tGard is a compact, metal-bodied interlock system that allows the configuration of a wide range of safety products, including electrical safety gate switches (with or without guard locking), mechanical trapped key interlocks and electrical operator controls – either as separate devices or integrated into one device. Highly versatile, tGard includes selector switches, safety switches (solenoid and non-solenoid), personnel keys (safety keys), emergency release, push buttons, estops, indicator lamps as well a choice of operating handles for both hinged and sliding guard doors. These elements are simply selected and then assembled into a robust housing which is suitable for mounting onto machine guarding. All tGard components are quick and easy to install and can be mounted directly onto a flat surface, doors or extruded aluminium profiles without needing mounting plates or brackets. Why not watch the tGard video (www.youtube.com/watch?v=j3CoY4IiDik) For more information contact Fortress Interlocks Ltd, Tel: +44 (0)1902 349000, E-mail: sales@fortressinterlocks.com | Web: www.fortressinterlocks.com

PROCESS INDUSTRY INFORMER July 2016

SAFETY DURING CIP ENSURED WITH IP69K-RATED INTERLOCKS & SAFETY SWITCHES FROM FORTRESS

Strict health and safety standards in the food, beverage and pharmaceutical industries require all machinery used in the production process to be thoroughly sanitised at regular intervals to keep equipment clean and eliminate the risk of bacterial contamination. This automated cleaning process, known as

Cleaning in Place (CIP), uses a mix of chemicals, heat and water to clean machinery, vessels or pipework without having to dismantle plant. Because of the high pressures, harsh chemicals and high temperatures used in CIP, an adequate safety system is needed to protect personnel. This safety equipment must itself be able to withstand the CIP process which can seriously damage electronic circuits and instrumentation and cause substances such as dust and food waste to penetrate the equipment, causing it to fail. This usually requires an ingress protection (IP) rating of IP69K – the highest rating available. Any interlocks and safety switches installed on safety equipment must also be IP69K-rated. Unfortunately most interlocks currently available offer very limited flexibility, focussing solely on achieving IP69K but failing to take into account other safety hazards manufacturers need to safeguard against. If, for example, access to a machine subjected to CIP is required but there is a possibility that a worker could be hidden from view while inside the machine, there needs to be an effective safeguard in place to ensure the guard door cannot be locked closed and the machine restarted until the worker leaves the danger zone. The most effective and simple method to achieve this is with a safety key which a worker takes inside the machine to prevent inadvertent start-up. With this in mind Fortress developed the amGardS40, a range of highly robust, IP69K-rated, stainless steel electro-mechanical safety interlocks and switches specifically designed for the food, beverage and pharmaceutical industries. Modular in design, they allow for many different configurations to satisfy almost any safeguarding application, allowing customers to purchase modules and build up their ideal safety system over a period of time. Each module of the amGardS40 has a slim 40mm body allowing it to be easily fitted to a 50mm guarding section or other areas where space is limited. The range also enables users to incorporate basic machine control functionality into their interlocking devices. All control elements, including push buttons, lamps, selector switches and e-stops are IP69K-rated and can tolerate extreme CIP conditions. This minimises downtime while simplifying the access procedure as ‘gate release/ machine restart’ can be controlled at the point of entry. As the amGardS40 IP69K range maintains optimal performance even after being repeatedly hosed down by high-pressure washers and subjected to harsh CIP chemical cleaning agents, it helps manufacturers achieve a high Overall Equipment Efficiency (OEE) rating. It also allows electrical engineers to rest easy, knowing that machinery will not experience constant interruptions due to electrical failures as a result of dust and/or food waste penetrating the casing of the safety switches. For more information contact Fortress Interlocks Ltd, Tel: +44 (0)1902 349000,

E-mail: sales@fortressinterlocks.com Web: www.fortressinterlocks.com

HOW THE RIGHT FLOWMETER CAN MAKE YOU MONEY Choosing the best flowmeter for measuring the flow of a gas or liquid through an industrial process often presents a series of technical challenges, but it is often also a decision that can impact business. David Bowers, process flow product manager for ABB UK Measurement &amp; Analytics, provides some tips on how to simplify the selection process and explains how Coriolis flowmeters are increasingly ticking the boxes when it comes to helping users to achieve cost savings through accurate and versatile flow measurement.

ell over a dozen technologies are used as the basis of measuring flow, each with their own strengths and weaknesses. But there are also so many variables that selecting the best technology for a given application can be a difficult exercise in managing compromises. It doesn’t have to be this way though. One way to simplify things is by summarising these variables into a ‘selection triangle’, comprising of three key values, specifically: • Capacity: The most important value, capacity refers to how much flow a meter of a particular size can handle, and the extent of the resulting pressure drop. • Accuracy: Most applications demand a high degree of consistency in results, but not all require the same level of accuracy. In slimming down the choice of flowmeter, ask yourself which types of device most closely match your accuracy requirements. • Physical dimensions: the space occupied by a flowmeter is assuming increasing importance, especially when a system is being upgraded and a new meter needs to fit into the same space as the old one that it’s replacing. Satisfying each of the values within this ‘selection triangle’ can provide a useful path to selecting the appropriate type of flowmeter for a given task. In a growing number of cases, this three-sided approach to flowmeter selection is pointing to Coriolis-type meters as a viable technology for a given increasing range of applications, particularly given the advances that have occurred in the design of the latest generation of devices. Commercially introduced in the 1980s, the Coriolis mass flowmeters have become one of the most versatile and reliable means of measuring the flow of liquids or gases. Their main strength is in their ability to measure multiple attributes over sustained periods with high repeatability and very little maintenance. In their earliest days, Coriolis meters had a few widely recognized weaknesses. First, accuracy suffered in instances when flow was extremely low. Further, extreme changes in ambient temperatures could affect accuracy, so use was limited in locations where temperature extremes were present. Their sensitivity to noise and vibration also

required rigorous installation standards. With advances in technology, these problems have all now been overcome, making current-generation Coriolis flowmeters among the easiest to deploy of available technologies in a broad range of applications and industries. The impact of this is that many industries thapreviously bypassed Coriolis flowmeters in favour of other meter types are now taking second look and recognising their value for deployment in a growing range of applications.

FUNDAMENTAL VERSATILITY Coriolis meters work by measuring the mass flow rate and density of a fluid or gas as it flows through a vibrating tube. By also measuring temperature, the meters enable additional calculations about the substance’s concentration. By measuring mass flow, density, concentration and temperature, a single Coriolis metercan do the work of multiple instruments, eliminating the cost of purchasing separate devices and minimising the requirement for spare parts and overall maintenance. This combination of measurements can be highly useful in many applications. In oil extraction, for example, the combined measurements available using a Coriolis meter canhelp determine how much water is coming out of the ground with the oil, providing a useful indicator of overall production efficiency.” The working principles of Coriolis meters offer several distinct advantages. With no moving parts that come in direct contact with the measured substance, whether gas or fluid, they require little maintenance or upkeep. Once calibrated at the factory, they also tend to remain calibrated throughout their lifecycle. In addition, because Coriolis is the only principle capable of measuring mass flow of gas and liquids without any calculation, results are independent of changes in temperature

or pressure. The use of Coriolis flowmeters also allows for density measurement, making the ma true multi-variable metering solution for filling operations in chemical, food and other such process industries. Furthermore, the multi-variable nature of Coriolis meters enables them to deal with issues that cripple other technologies. One example is in applications with turbulent flow. Where flow is turbulent, other metering technologies may require a run of straight pipe to smooth the flow before it’s measured. With no need for such measures, Coriolis meters can be installed in a small footprint, with the added option of the meters being able to work equally well when mounted either horizontally or vertically. For operators, this not only minimises the space required for installation, but also opens up financial savings through reduced expenditure on pipework alterations and overall engineering. The use of Coriolis meters can also deliver benefits

where the density of the measure substance isn’t uniform – such as in upstream oil and gas operations. Traditionally side-linedin favour of mechanical meters, Coriolis meters are now starting to appear in greater numbers in upstream oil and gas applications, particularly as mechanical meters lose accuracy over time and entrained gases can destroy them. Coriolis meters are proving the ideal solution to these problems, especially in remote locations where their low maintenance and stable calibration benefits are a major advantage.

NEW-GENERATION CAPABILITIES Even where Coriolis meters have been in use for years, organisations are finding reasons toupgrade. Older generation Coriolis meters required a lot of care in installation and called forspecific compensation or countermeasures to offset external influences that affectedaccuracy. These issues have been solved over the years. ABB’s new CoriolisMaster range,for example, represents the latest evolution of a meter that is hardly influenced byenvironment or installation. Newer devices are more compact, easier to operate, andincreasingly accurate. Perhaps most important, designs of Coriolis meters have becomemore efficient over time. The newest models require up to 25 percent less pump energy tooperate and create a smaller pressure drop, often 20 percent less than older models. One of the great advantages of a Coriolis meter is the reproducibility of its measurement. It will yield consistent results almost indefinitely without requiring maintenance or calibration. On the flipside, a major historical disadvantage has been cost, especially when it comes to calibration; the accuracy of the device is locked in through calibration performed during manufacture. The higher the accuracy, the more sophisticated and timeconsuming the calibration process is. Consequently, older Coriolis meters may have imposed a higher level of accuracy than necessary at a correspondingly higher level of cost. ABB’s CoriolisMaster line is designed around two tiers of calibrated accuracy in what otherwise is essentially the same device. For users, this means paying for consistency and features and not for unnecessary accuracy. It also offers other advantages, not least that one ABB meter is interchangeable with another in terms of installation and operation. For users, this means that they only pay for the level of accuracy their application requires, with less time, cost and effort involved in replacing a unit. The meters are also designed to be easy to use. An example is their intuitive three-button interface, which makes most routine functions accessible without consulting a manual. Further, when maintenance is required, the electronic module can be quickly inserted and removed, with no need for recalibration or configuration. Of course, no technology covers every circumstance for measuring flow. In common with any other flowmeter, Coriolis meters have their limitations. With no lining, their tubes are susceptible to corrosive or highly abrasive materials. Further, while ABB does make CoriolisMass Flowmeters as small as a millimetre in diameter, they generally become cost prohibitive for processes requiring measurement across more than a six-inch diameter.

SAVING MONEY WITH CORIOLIS METERING The inherent technical and operational benefits of Coriolis flowmeters enable them to deliver real and significant savings in a wide variety of applications. One example is a chemical manufacturer that changed its process for fulfilling customer-specified concentrations of acid, which were sold by weight. Originally, its process involved pumping a calculated amount of acid into a tanker truck, and then adding another calculated amount of water to reduce the concentration. If all went well, a truck could be filled in 40 minutes to a final weight and concentration that were within contracted tolerance. Today, using a Coriolis Mass Flowmeter, the acid and additive are mixed inline and pumped into the tanker in single process; the proper concentration is assured by the Coriolis meter’s ability to measure density; the proper weight is assured by its ability to measure the flow of mass. As a result of the change, the time it took to fill a truck was reduced by half. With 5,000 loads fulfilled a year, the savings amounted to 1,650 hours – about 10 weeks equivalent. The new flowmeter improved margins on existing business, and created an effective capacity increase that allowed the company to add new contracts.

SUMMARY The ability of Coriolis flowmeters to deliver versatile, highly accurate measurement in acompact, easy to install and use design, make them the better alternative to other flowmetertechnologies in an expanding range of situations.

PROCESS INDUSTRY INFORMER July 2016

INFRARED CAMERAS SPECIAL PRICE OFFERS ON FOUR POPULAR FLUKE THERMAL IMAGERS Fluke is offering significant reductions on the manufacturer’s recommended price of four popular and rugged thermal imaging cameras, the Fluke Ti300, the TiS75, the TiS40 and the TiS20. All models come with Fluke

Connect® which provides greater data management and reporting capabilities via the Fluke Connect app. See www.fluke.co.uk/ promotions The Fluke Professional Series Ti300 Infrared (IR) Camera features LaserSharp® Auto Focus which uses a laser to pinpoint exactly where the camera should focus, producing precisely focused, high quality images quickly. The Fluke TiS Performance Series IR cameras feature large 3.5 inch screens to help pinpoint issues while still in the field and offer one touch image access, which eliminates the need to scroll through a menu to view images. All thermal imagers in the offer, except the entry-level TiS20, offer IR-Fusion® Technology with AutoBlend™ combining a visible light and infrared image into one, with the ability to adjust blending levels—giving the details needed to analyse the problem and clearly identify the location. For further information contact Fluke (U.K.) Ltd., Northampton, Northants Tel: 0207 942 0700. Fax: 01603 256 606 E-mail: industrial@uk.fluke.nl | Web: www.fluke.co.uk

CALIBRATION FLUKE 154 HART CALIBRATION ASSISTANT PUTS HART DEVICE CONFIGURATION AT THE USER’S FINGERTIPS Fluke has introduced the Fluke® 154 HART Calibration Assistant, a standalone tabletbased communication tool that makes HART configuration easy. The 154 provides HART communication functionality that, when combined with a Fluke 750 Series Documenting Process Calibrator or 720 Series Multifunction Process Calibrator, enables the user to calibrate the full range of HART devices used in the process industry.

The Android-based tablet comes configured with the FlukeHART mobile app that utilises a longrange wireless HART modem, which connects to the HART transmitter being tested or configured. This allows technicians to wirelessly communicate with the device up to 250 feet away, eliminating the need for technicians to stand next to the device so they can work from a safer, more convenient location. The Fluke 154 provides full HART Device Description (DD) support of all HART devices and can monitor PV, SV, TV, QV, and other measured HART variables. It includes the Android-based tablet, charger and USB micro-cable, installed FlukeHART mobile application, HART modem, USB minicable, hook test clips, alligator clips, magnetic hanging strap, and hard-side case. For further information contact Fluke UK Ltd, Northampton, Northants. Tel: 0207 942 0700. E-mail: industrial@uk.fluke.nl Web: www.fluke.co.uk

PROCESS MEASUREMENT & INSTRUMENTATION BATCH TO CONTINUOUS PROCESS MANUFACTURING CHANGES By James Walker, Sales Manager. Bronkhorst UK One of the largest topics of conversation over the last few years in the chemical industry has been about the change from continuous to batch process production. Looking at both process methods on paper I could only see the benefits of working towards and investing in the continuous production process, the end result would be so much more predictable than with a batch production process and that was the goal. If I could truly predict the end result of the process it took away the deviations created by working in large unwieldly batches that required constant monitoring and adjustment. Firstly, I had to look at the bulk manufacturing process and learn more so that I could properly apply my reasoning and arguments for the continuous production process. I investigated the background of large scale batch chemical production methods. As with a lot of industrial processes it appeared to have evolved into what it is due to technology available at the time, it continues to work and therefore people are reluctant to change. Speaking

with production operatives and operation managers it was clear that several issues existed. Due to the limited technology available at the time of method development ensuring consistency and repeatability is a real challenge. Weighing liquids and transferring them always results in a deviation due to a percentage of loss to residue in containers, the potential for spillage, evaporation and inaccurate weighing scales. When you add multiple components this multiplies the percentage of error each time. Due to inherent errors in the system manual monitoring and correction of the process is required to arrive at a satisfactory final product quality. After all this work, the final product can still fail QC testing and is sold at a lower price, re-worked or disposed of, each in their own right costly and expensive operations.

Quality was a great place to start. As discussed above anything that you can do to remove inconsistency in final product quality is money in the bank. You have confidence in the product you are selling; this has benefits for customer satisfaction, retention and price negotiation. On top of all that you can use your increased quality asa marketing tool, leveraging extra value that has already delivered results. Waste is a natural follow on from quality, the better the quality and the higher the frequency of achieving that quality standard the less the waste and re-work required. This has huge returns on baseline production costs, doing things right first time increases delivery on time metrics and again were turn to customer satisfactions and retention through consistency of excellence. Safety was not originally on my list of improvements that would arise from continuous production techniques. However a quick review of the changes to the line meant that it had to be a considered factor. Using smaller continuous volumes means you can seal the process more effectively, reducing human interaction with the product and potential for splash hazards. Space is a commodity and by manufacturing in bulk you have to store bulk products, both pre and post production, by moving to a lower volume continuous production method you can have smaller more frequent deliveries enabling you re-use the old storage facility for extra production lines. With advances in metering and control instrumentation it would be remiss to not investigate the potential benefit an investment in continuous production could bring. The potential is there to achieve higher, more predictable final product quality resulting in less re-works and waste product. A reduction in production space required, safer work environment for the team, greater control and flexibility on supply chain operations and the ability to deliver smaller volumes to order increasing your potential customer base. Check out our YouTube channel: www.youtube.com/ channel/UCslfWlSquYtISwpqU-BUcBg Read our analytical literature: www.bronkhorst.co.uk/ en/markets_and_applications/analytical/ For more information contact Bronkhorst UK Ltd, Newmarket, Suffolk. Tel: 01223 833222 E-mail: sales@bronkhorst.co.uk Web: www bronkhorst.co.uk

PROCESS INDUSTRY INFORMER July 2016

PROCESS MEASUREMENT & INSTRUMENTATION NEW SENSOR FROM ABB OFFERS THE SIMPLE ANSWER FOR ACCURATE TURBIDITY AND SUSPENDED SOLIDS MEASUREMENT ABB has launched the latest in its range of Aztec digital sensors. Suitable for use across a range of industries subject to regulatory effluent discharge consents, including municipal potable and wastewater treatment plants; pulp and paper; food and beverage; oil and gas and marine and mining, the ATS430 features ABB’s EZLink technology. This enables a quick connection to an AWT440 digital universal transmitter, simplifying the installation process. Pre-calibrated, the MCERTS-approved sensor is also ready to use as soon as it is taken out of the box. The turbidity and TSS sensor provides ultra-stable and accurate measurement of turbidity and total suspended solids up to 4,000NTU (Nephelometric Turbidity Units) or 100,000 mg/l. Unlike conventional turbidity and TSS sensors, the ATS430 requires no servicing throughout its operational life, enabling it to offer the lowest cost of ownership. For more information contact ABB Ltd, Eaton Socon, Cambridgeshire. Tel: +44 1480 488328 Fax: +44 1480 213339 Web: www.new.abb.com/products/ measurement-products

Low Flow Coriolis Precise and Compact Mass Flow Meters / Controllers

FLOWMETER FOR METERING VISCOUS FLUIDS

Built for metering viscous fluids, such as hydraulic oils used in heavy machinery, at pressures of up to 700 bar and temperatures up to 150°C, the Titan Enterprises OG2-700 bar flowmeter is designed to be fully IP67 / NEMA 4 compliant.

With a standard flow range from 0.03 to 4.0 litres / minute on 30Cstk oil the flowmeter is able to routinely achieve outstanding accuracy (0.5%) and repeatability (0.1%). Combining robust 316 stainless steel design, durable construction materials and proven technology ensures the OG2-700 bar flowmeter will provide reliable, accurate operation over an extended product lifetime. To download full technical specifications for this durable, high performance flowmeter please visit www.flowmeters.co.uk/oval_gear_ meters.htm or for further information contact Titan Enterprises Ltd. now on +441935-812790 sales@flowmeters.co.uk

Fluid independent flow measurement and control Gas or liquid flow rates: 50 mg/h to 600 kg/h World‘s smallest Coriolis meters/controllers in size & flow High accuracy, excellent repeatability Fast and stable control with integrated pump or regulation valve IP65 design, optional ATEX approval Cat.3, Zone 2 Temperature and density outputs Innovation – Experience – Responsibility

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

PROCESS INDUSTRY INFORMER July 2016

A GUIDE TO CHOOSING AND SINE® PUMPS IN THE BAKERIES SECTOR With demand for fresh bakery products rising globally, bakers are seeking improvements in processing everything from dough and batter, to confectionery fillings and frostings. Consumers demand first class appearance, an even spread of ingredients and product integrity. The pressure to deliver these requirements passes far down the manufacturing process to the pumps deployed for operations such as transfer and mixing. Here, increasing numbers of bakeries are turning to MasoSine SPS pumps from Watson-Marlow Fluid Technology Group.

WHAT ARE THE MOST CHALLENGING APPLICATIONS?

Viscosities can register in the thousands, or even millions of centipoises Verso very specific pump capabilities are needed in bakery applications. For instance, custard and cream must be transferred without shearing or any change in viscosity. Similarly, batter must be pumped without thinning or aeration, as any change here may cause it to rise. Chocolate fondants and creams must be pumped gently without crystallisation or caramelisation, while the integrity of fruit in a batter mix is also important to avoid discolouring the batter and destroying the fruit. Are there pumps that can handle such challenging media? Absolutely! But, first you need to ensure correct pump selection. This is a decision that must involve additional considerations such as flow rate, system pressures, temperature, suction conditions and the size of any inclusion. The pump will need to be able to handle inclusions without blocking or causing any damage. At WatsonMarlow, we have teams of sector specialists who can help you to make the right selection.

WHAT’S THE SOLUTION TO THESE CHALLENGING APPLICATIONS?

The superior suction – suction lift or flooded suction transfer – and viscous product handling capability of our MasoSine sinusoidal pumps enable bakeries to transfer batters, doughs, liquid sweeteners, fruit fillings, creams and frostings mixes and ingredients with ease and without degradation. MasoSine pumps are designed to meet a range of requirements in the bakery sector that include low cost of ownership, reliability, ease of maintenance and conformity to recognised industry standards.

WHAT ABOUT LOW SHEAR HANDLING?

One of the biggest issues faced by bakeries is how to deal with shear sensitive products such as batters, dough, creams and custards, which change their viscosity when moved. For bakery products, maintaining integrity is vital for quality, brand and reputation, and the use of a low shear pump is essential. Sinusoidal pumps are widely regarded as being the best low shear option. The smooth, undulating contour of the unique MasoSine pump rotor transports confectionery blends through the pump whilst maintaining the product’s integrity, viscosity profile, texture, colouration and value – even at high flows. This gentle pumping action means • Improved batch consistency and final product quality • Virtually eliminated wastage of raw ingredients • No aeration and foaming during product transfer

WHAT ABOUT TRANSFER OF FILLINGS?

Pies present a challenge all of their own – but, with the right pump, the transfer of fillings is ‘as easy as pie’! Regardless of whether the pie is sweet or savoury, the fillings usually entail large pieces of fruit, meat or vegetables, for example, which need to stay intact when passing through the pump.

The transfer of such fillings – often involving high suction lift of the product from the mixing bowl to the depositor feed hopper – can be a significant challenge for bakeries. However, thanks to large pumping chambers within MasoSine pumps, product integrity can be preserved and maintained even for very fragile product such as soft fruit or pre-cooked meat.

WHAT ABOUT VISCOSITY?

The MasoSine SPS series and the latest Certa pumps offer capacity up to 99m³/hr and with pressures up to 15 bar and thanks to their heavy-duty construction. They can safely pump high viscosity products, while their innovative yet simple design allows economical in-line maintenance powerful suction up to 0.85 bar. Products with viscosities from 1 cP to 8million cP can be transferred with ease.

ARE SINUSOIDAL PUMPS EASY TO CLEAN?

Ease and speed of changing from one product/recipe to another is vital to efficient operations. Unlike other pump types, MasoSine SPS models can be dismantled and cleaned, and ready to go again in minutes. No special skills or tools are required and the task can be completed by production line operatives rather than skilled maintenance engineers. Certa TM is latest innovation from MasoSine, the creators of Sine® pump technology and sets even higher pumping standards in food processing. Offering EHEDG (Type EL Class I) and 3A certification as standard, Certa is extremely easy to clean for minimal maintenance and downtime. New MasoSine Certa pumps are cleaner than a lobe or circumferential piston pump • Superior cleanability

• Pump CIP can be performed in less than 10 minutes – cutting production downtime for cleaning • All contact parts FDA and EG1935 compliant • Reduces chemical and water use and wastewater for disposal

CAN ENERGY BILLS BE REDUCED BY USING A MASOSINE PUMP?

Yes, in viscous handling duties, MasoSine pumps use up to 50% less energy for the same flow in comparison with other pump types. MasoSine sinusoidal pumps move the product gently through the pump from suction to discharge, therefore handling within the pump is minimal, irrespective of viscosity. To prove that our pumps are virtually unaffected by increasing viscosity, we have created a set of flow/viscosity versus energy requirement performance graphs known as Mee curves. The Mee curves demonstrate that in viscous fluid applications, smaller motor drives requiring less power are required, in turn saving energy, so reducing your carbon dioxide output. Furthermore, energy savings contribute to a reduction in the total manufacturing costs of your product. A white paper on how Sine™ pumps benefit food and beverage plants is free to download from the website. http://www.watson-marlow.com/gben/news/Whitepaper- proves-SineTM-pump- benefits-for- food-andbeverage-plants/

In summary, Sine pumps’ gentle pumping with virtually no pulsation, superior viscous handling, simplicity, reliability, energy efficiency, interchangeable parts and low cost of ownership all help food and beverage plants compete in a highly competitive marketplace.

SINE PUMPS AT WORK MasoSine pumps provide granola ingredient measurement at S. Moores A company famed for its manufacture of traditional biscuits, is using three MasoSine pumps from Watson-Marlow Fluid Technology Group to help it produce up to 80 tonnes of granola a week. Importantly, the introduction of ingredients into the blending and mixing process is controlled precisely by counting the revolutions of the pump shaft, a shrewd strategy that hasnegated investment in a dedicated weighing assembly.

MEASURED PRODUCTION “The MasoSine that was previously deployed on our batch mixer was transferred to the new continuous mixer with the addition of a speed control for accurate blending,” explains Company Partner David Winship.“This allowed us to dose the warm oil-syrup blend into the mixer at theright rate. In effect, every revolution of the pump produces an identical volume of material. Hence, by controlling the speed, we can inject the precise amount of blend required.”

PROCESS INDUSTRY INFORMER July 2016

FLUIDS & LIQUIDS HANDLING

incl. Pumps & Valves

REMOTE VALVE OPERATOR EASES WATER AND WASTEWATER PROCESSES FlexiDrive controls valves up to 30 metres away The FlexiDrive from Smith Flow Control helps workers in the water and wastewater industry remotely operate valves in hardto-reach or hazardous locations. The FlexiDrive’s linear drive cable transfers torque from a handwheel to any conventional wheel-operated valve up to 30 metres away, accommodating 540 degree bends in the cable run. FlexiDrive can be used in the most extreme climates, making it suitable for water and wastewater applications. Valves in underground pits that create a risk of falling, or in areas with odours from chemicals or waste, can be operated from a safe location. A submersible version of FlexiDrive is available that operates valves in up to 15 metres of water. FlexiDrive is completely maintenance-free and available in two sizes to accommodate large and small valves. For more information contact Smith Flow Control, Witham, Essex Tel: +44 (0)1376 517901 E-mail: sales@smithflowcontrol.com Web: www.smithflowcontrol.com

UPDATED LabVIEW DEVICE DRIVERS AVAILABLE FROM ALICAT SCIENTIFIC

Compatible with Alicat’s latest Gas Select™ 6.0 firmware update Alicat Scientific has released updated LabVIEW instrument drivers for its line of standard mass flow meters, flow controllers, and pressure controllers running the company’s new Gas Select 6.0 Firmware.

Available for free download at www. alicat.com/support/software-drivers/, the new device drivers enable users to easily develop control interfaces to Alicat instruments, without PLC programming skills. LabVIEW provides data collection from Alicat instruments, instrument control capabilities, and integration with other process instruments. Common functions include evaluating data in order to trigger events such as changes to set points or flow rates, gas selection, validation, and monitoring ongoing trend data. With the industry’s highest turndown ratio, Alicat instruments precisely and rapidly control mass flow rate, volumetric flow rate and absolute pressure of gases. The new firmware and drivers are compatible with standard Alicat instruments—flow meters, flow controllers and pressure controllers— serial number 80,000 and higher.

To learn more about Alicat’s line of pressure controllers, mass flow controllers, meters, and accessories, and to download the updated drivers, visit www.alicat.com, or call +1 520 290-6060.

PROCESS INDUSTRY INFORMER July 2016

For more information contact E-mail: market@lcpumps.cn Web: http://www.lcpumps.com/english/ 19

FLUIDS & LIQUIDS HANDLING

incl. Pumps & Valves

NEW HYDRA-CELL MULTI-FUNCTION METERING CONTROLLER The exclusive new “Control Freak” electronic controller from Wanner International provides motor speed control for Hydra-Cell Metering Solutions pumps (or Hydra-Cell bare shaft pumps in metering applications) and is able to control multiple pumps with Variable Frequency Drives (VFDs) from a single point.

Because motor speed is directly proportionate to flow rate in a Hydra-Cell pump, high accuracy can be achieved through the use of VFDs. With an easy to use, 7” colour graphic touch-screen user interface the state-of-the-art technology provides optimum speed control based on your desired flow and pressure ratings. You can enter the desired flow rate or volume along with system pressure and the controller automatically runs the pump at desired flow rate or volume total/time, or in pre-set batches. With four configurable on-off relays, ten separate batch set-up screens and two user-configurable analogue input displays, this versatile controller enables programming for flow rate or totalisation. Pre-set (with password protection) for Hydra-Cell pump performance algorithms, the “Control Freak” can also be field-calibrated for greater accuracy. The “Control Freak” also has analogue and digital I/O for interfacing with external devices and includes a real-time clock. Safety features include emergency stop, loss of power, fault monitoring, and optional pump oil temperature probe. For more information contact: Wanner International, Fleet, Hants. Tel +44 (0)1252 816847 Email: NHerrington@wannerint.com Web: www.hydra-cell.eu

EASY-CLEAN, QUICK-STRIP PUMPS FOR FOOD AND PHARMA DUTY Transferring liquids in food, brewing, pharmaceutical and other similar hygienic process applications requires reliable, easy-to-clean and easy-to-maintain pumps. Liquids handling specialists PUMP ENGINEERING offer a wide range of pumps which are ideal for these situations. For example their range of CSF CS, CSA and CSM centrifugal pumps are capable of handling capacities from 1 to 550 m3/hour at heads up to 155 metres.

CSF pumps are manufactured in investment cast AISI 316L stainless steel, with stainless steel for all wetted parts. They also feature a 6 vane impeller which ensures gentle and effective handling of the ingredients used in many food and pharmaceutical processing applications, for example syrups for soft drinks manufacturing and those containing particles or small solids. The pumps are designed for CIP (Clean-in-Place) to ensure the absence of dead areas and feature electro-polished finishing of all surfaces. CSF pumps are available with standard or ATEX certified motors, these are back pull-out design and fitted with a quick-release clamp to enable fast and simple dismantling. The CSA version has an electro polished finish to 0.5µm Ra and is approved to US FDA 3A standard or European EHEDG standards, with an aseptic version available for pharmaceutical applications. Depending on the duty CSF-CS and CSA pumps can be supplied with an internal or external single mechanical seal or flushed double mechanical seal for handling high temperature liquids, or those with a tendency to crystallise. Elastomers are available in a choice of Viton, EPDM, silicon or PTFE Typical applications for CSF-CS hygienic pumps include transferring syrups, sugar solutions, flavourings, salad washing, alcohols, beer, milk, oils, vinegar, fruit juices, high purity water, CIP solutions, suspensions, yeast and melted butter. For more information please contact Pump Engineering Ltd, Littlehampton, West Sussex. Tel: 01903 730900 E-mail: sales@pumpeng.co.uk Web: www.pumpeng.co.uk

TAKE YOUR PICK WITH THE GRUNDFOS PRODUCT CENTER

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

Pick the perfect pump – from Pump Engineering

AB13-613

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

The Grundfos Product Center is an online selection tool that will help you to size and specify pumps for any need. Launched 2 years ago it has continued the tradition of offering a range of people who need to specify pumps with a leading edge pump selection tool. Today the Grundfos Product Center is fast, intuitive and designed to help let you find the answers you need. You can start your pump search in a number of ways such as searching for a pump you already have, sizing a new pump, finding a replacement pump or a pump for moving particular liquids. Once you have found the pump you want, you will find pump-specific documentation, CAD and BIM drawings, spare parts and service kits, as well as instructional videos. Simply visit www.grundfos.co.uk and click on the entire projects. Product Center link. While you are there sign up as a registered Grundfos Product Center user, as this will give you access to recent searches, products and give you the ability to save items for future reference, including Choosing pumps with the Grundfos Product Center is easy as it is always ready to help and is open for business whenever and wherever you need it. For more information or a Literature request contact Grundfos Ltd, Bedfordshire. Tel: 01525 850000 E-mail: grundfosuk@grundfos.com Web: www.grundfos.co.uk

PROCESS INDUSTRY INFORMER July 2016

FLUIDS & LIQUIDS HANDLING

incl. Pumps & Valves

VALVE ISLAND CUSTOMERS GIVEN GREATER FLEXIBILITY AS ASCO LAUNCH NEW SIZE VALVE New base plate enables valve sizes to be mixed on one island, further increasing flexibility.ASCO have added a new valve size to their Valve Islands range which gives users greater flexibility across a variety of applications and industries. The ASCO Numatics valve islands boast a wide capacity range of 400 l/min to 3820 l/min. The new 502 Series valve means that the range can now handle new mid-range flow requirements of up to 650 l/min. New base plates also mean it is possible to combine two sizes of valve on one island, enabling users to easily manage both valve actuator control and pneumatics. At 18mm in size, the 502 Series valve is easy to integrate into existing systems and comes fully assembled in a valve island. When coupled with the innovative G3 or 580 series electronics the valve islands boast one of the smallest footprints vs flow rates on the market. The full valve island offering is adaptable to a wide range of applications, from those in the automotive industry to packaging process lines, thanks to a wide range of accessories that makes them ideal for complex configuration requirements. This sometimes complex configuration The Green is kept easy using ASCO’s on-line configurator, which makes it possible for the full system with accessories to be defined. This enables users to reduce any manual assembly or configuration on site and get their process up and running as quickly as possible, reducing both downtime and engineering time spent on configuration and maintenance. As with all ASCO products, the 502 Series has been built to last. It has an IP65 protection level, a modular build, and is robust and reliable in operation. On the occasion that maintenance is required, feedback and diagnosis is made quick and easy thanks to the integrated graphic display located on the electronics module. For more information on the full range of ASCO Numatics valve islands, please visit asconumatics.eu/valve-islands

PerisTalTic PumP

Verderflex

NEW

Vantage 5000

GRUNDFOS SYSTEM DELIVERS LEAKAGE REDUCTIONS With global demand for clean and safe drinking water continuing to grow, one of the obstacles to meeting this remains leakage. Ageing networks cannot be easily replaced, but a problem that for example leaves London losing 1,000 million litres of clean water every day, and produces worldwide losses equating to the needs of 200 million people, is one that demands a solution. Grundfos Pumps have stepped up to the challenge and can demonstrate a practical solution that works.

Called Grundfos Demand Driven Distribution (DDD), this solution uses pressure control to match pumping against demand. The unique MPC controller in the Grundfos DDD system is programmed to automatically adapt the degree of pumping to match the actual demand, maintaining a proportional pressure and typically reducing leakage by 10-20%, though savings of as much as 80% have been seen in one example. In addition to the immediate benefits of reduced leakage and energy use, the multi pump control and proportionate pressure functionality in the Grundfos DDD system also bring long-term savings by dramatically lowering the risk of “water hammer”, one of the primary causes of pipework weakness.

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

www.vantage5000.com

PROCESS INDUSTRY INFORMER July 2016

HYGIENIC STANDARDS & PUMPS There are numerous regulations which apply to pumps in food, beverage and pharmaceutical processing, namely; EHEDG, 3A, BfR, FDA, USP Class VI, and EC1935/2004. However, which ones apply to a particular process or food product and, as some can increase the cost of the pump quite considerably, consideration has to be as to which is the most appropriate. Peter Carfrae and Malcolm Walker of AxFlow take a look at the various hygiene standards and their implication for pump sand their users.

lthough there is still no legal obligation on food manufacturers to use hygienically certified fluid handling equipment, the ever increasing costs both financially and potential harm to a brand’s reputation resulting from hygienically defective products, has meant that never before has there been so much pressure on food manufacturers to utilise the correct hygienic process equipment in the sight of the law. There are two basic groups of approval, those that apply to material compatibility and those to the actual design of the pump. Taking those concerning material compatibility, there several globally recognised approval bodies the oldest being the US Food and Drug Administration (FDA) and which is still seen worldwide as the basic benchmark for material compatibility. However, the new kid on block in the guise of EC 1935/2004 has by and large superseded FDA. The reason for this being that EC 1935/2004 has wider and stricter criteria. For instance, it requires that compounds must be examined to more specific tests than FDA and requires traceability, whereas FDA does not necessarily do this. The implication of this is that not all FDA materials will meet EC1935/2004 requirements. A third lesser known approval that should be mentioned in connection with FDA and EC 1935/2004 is the German (BfR) system which is widely used for some rubber compounds in the EU because there are gaps in both FDA and EC 1935/2004 when it comes to such compounds. Lastly, there is USP Class VI which some cite in respect to food and beverage production. The US Pharmacopeia (USP) and the National Formulary (USP NF)USP Class IV approvals are concerned with toxicity from direct contact with a material and a material’s resistance to biological activity with respect to the pharmaceutical and medical industries. Although it could be argued that there is some relevance to food and beverage production, USP approval is not actually applicable as direct contact from a pump’s component should not occur, unless something quite catastrophic has happened. Furthermore, cleaning along with pump design is considered the methods by which bacterial growth is avoided in the food industry. This brings us neatly onto the fact that food compatible materials in themselves are not sufficient in the majority of

It may be less expensive to use a higher priced hygienically certified pump design when you factor in labour costs for maintenance.

food production applications to make a pump hygienically acceptable, as its design and cleaning regime must be taken into account.

HYGIENIC DESIGN Although you don’t need to use hygienically designed pumps, they need to be clean and the amount of time spent cleaning a pumps depends to a large extent on their design. Hygienic design aims to reduce the possibility for the build-up of bacteria by minimising crevices and dead areas and take into account the ease with which the pump can be disassembled for manual cleaning and the nature of material surfaces. This means that it may be less expensive to use a higher priced hygienically certified pump design when you factor in labour costs for maintenance. Hygienic requirements are typically addressed at the design and development stages of a pump’s components as this will remove the need to make modifications or upgrade later in the development cycle, or after equipment has entered service. For pump and manufacturers it is essential to have the design tested against given requirements. The hygienic design of equipment is subsequently assessed and the clean ability of the equipment

can be tested. There are three main design standards that apply to hygienic design: The CE mark i.e. The Machinery Directive 2006/42/EC, A-3 and EHEDG. The Machinery Directive sets out very clearly the design considerations that need to be taken into account for a hygienically clean pump, but ultimately the manufacturer self certifies the pump so even if the they meet the additional hygiene requirements formulated in the European Standard EN1672-2 there is no absolute guarantee that the pump is biologically safe. Therefore, manufacturers can supplement the CE mark with certification from A-3 and EHEDG. The significant difference is that both these certification bodies go into much more detail having different requirements for different applications, and actually test the product with respect to cleanability rather than just relying on a risk assessment. The American A-3 organisation has existed since the 1920’s and originally concentrated on the dairy and egg processing industries. Since then it has widen edits scope to cover other applications. EHEDG is essentially the European version ofA-3 in the same way that EC 1935/2004 is the European version of FDA. Likewise it’s generally considered more comprehensive than A-3. However, both organisations have made considerable efforts over the last few years to harmonise their standards. Selecting the most appropriate pump for an application has to be a two-way decision made by the end user and the pump supplier. The pump supplier has to recognise that the end user will know exactly what hygiene standards have to be met in respect of their products and defer to their greater knowledge. Similarly, the end user must recognise that the pump supplier will be expert in fluid handling technology and must be able to offer a pump that fully complies with relevant standard(s) and cleaning regimes. The breadth of pump types that are available for food and drink processing applications is considerable and many of these technologies compete with each other. Thus, it makes good sense to review the different technologies either by talking directly with appropriate manufacturers or with a distributer that has a range of appropriate technologies within its portfolio and can provide unbiased advice.

PROCESS INDUSTRY INFORMER July 2016

FLUIDS & LIQUIDS HANDLING

incl. Pumps & Valves

NEW EFFICIENT HIGH-PRESSURE PUMP FOR A POWERFUL PERFORMANCE In June 2016 KSB Aktiengesellschaft, Germany, launched its Movitec 125 pumps, complementing its current range of vertical high-pressure pumps. The multistage centrifugal pumps are designed for fluids such as water, coolants, condensate and mineral oils. They are ideal for industrial recirculation and fire-fighting systems, cooling water circuits and washing plants as well as for boosting pressure in general process applications, for example. The engineers behind the new pump sets put special emphasis on achieving outstanding hydraulic efficiencies. The efficiency of a pump with a full impeller diameter is greater than 80 percent. The type series handles flow rates of up to 192 cubic metres per hour (at 60 Hz) at heads of up to 125 metres. The permissible fluid temperature ranges from -20 °C to +120 ˚C. As standard, the new pump sets are driven by 2-pole IP3 motors of 15 to 45 kW. Fitted with product-lubricated plain bearings made of tungsten carbide, cast bases, and torsion-resistant pressure shrouds sealed by confined O-rings, the pumps are highly robust and reliable. Corrosion-resistant hydraulic components made of stainless steel further add to these qualities. Several material variants and flange connection options provide users with maximum flexibility when it comes to installing and operating the new pump sets. With easy-to-replace standardised cartridge mechanical seals to EN 12756, the new Movitec 125 pumps are easy to service and built to last. As an option, the pump can be operated on a frequency inverter and combined with high-efficiency motors to increase the system’s efficiency and match the flow rate to actual demand.

For more information contact KSB KSB Aktiengesellschaft,Germany. Tel.: +49 6233 86 - 3702 E-Mail: christoph.pauly@ksb.com

PROCESS INDUSTRY INFORMER July 2016

Fig. 1: For food manufacturing facilities, ensuring the safety and reliability of milling equipment is a top priority.

IMPROVING SAFETY & RELIABILITY BY UNDERSTANDING MACHINERY HEALTH By Cranford Johnstone, Reliability Solutions Manager, Emerson Process Management Holistic Approach Uses Standards-Compliant Solutions to Streamline Maintenance Safety can’t wait. Ensuring that a plant’s staff and equipment are not at risk of accidents is the single most important thing any organisation can do to ensure long-term viability. Whether the economy is good, and organisations have more resources to work with, or markets are down and demand has shrunk, allowing gaps and blind spots in safety systems means jeopardising safety and putting workers, the company’s most essential asset, at risk.

hat many organisations fail to recognise is that safety does not exist in a vacuum. Some peace of mind is possible for plant managers simply by knowing that rotating equipment will shut down automatically when sensors detect a fault. However, true plant safety can only be achieved when systems are well integrated and implemented in a way that makes them easy for staff to use. Instead of focusing on individual pieces of equipment, organisations must examine how safety system upgrades can be performed holistically for long term-viability. By planning for long-term implementation and use of safety system upgrades, plants can not only improve safety, but also improve reliability, all while saving money and streamlining future improvements.

TAKE AN EXAMPLE... For a large food manufacturing company in the US Midwest, Emerson, was able to offer the perfect solution to implementing a safety system with the organisation’s future needs in mind. The organisation was working with machinery health monitors that were no longer supported by the manufacturer. Moreover, knowing that the system was obsolete and needed to be replaced, maintenance crews had given up on maintaining a standardised maintenance strategy. Because there was no corporate standard maintenance strategy, different plants operated systems very differently. One plant might have equipment measuring points that were non-existent at a plant in another state. There was no guarantee that a variable that one set of technicians depended on would be measured at every plant in the organisation. Even instrumentation could vary from location to location. The differences between plants were of particular concern for management because the organisation has a policy of moving experienced technicians between plants during outages. It is not uncommon for half of the maintenance staff of a functioning plant to help out at another location during serious equipment failure. However, when these technicians travelled to other plants, their ability to help was hampered. Many of the measurements and devices they had come to rely on at their home plant were not in place or functioning differently at the new location. As a result, the maintenance crew spent hours learning new ways to identify the problems rather than resolving the issues.

In addition to the lack of standardisation, the legacy monitors and will have constant access to a wealth of information about the slowed integration with the plant’s modern DeltaV distributed health of critical equipment. control system. The traditional control system integration that the At the end of the machinery health programme roll-out, all plants organisation had been using for its previous machinery monitors will function under a standardised machinery health initiative. The was non-intuitive and expensive. Discovery and integration of monitoring equipment and collected variables will be the same monitors was complex, time consuming, and expensive. Data from device to device, and from plant to plant, helping maintenance mapping was difficult and required regular maintenance, using up staff avoid having to re-invent the wheel for problem detection and time that could have been spent more productively on other tasks. diagnosis. It will also allow the organisation to track problems fleetEven when properly connected, the legacy monitors were very wide, so the maintenance team can identify trends in machinery limited in the data they could report to the control system, leaving health issues and begin preventing rather than simply repairing maintenance blind on many essential machinery health variables. many equipment problems. When the safety functions connected to milling equipment and wet process centrifuges needed an update, the organisation decided SAFETY FAST... to adopt a best-practice approach to improving the company’s standard for safety (Figure 1). This approach meant updating Maintenance teams no longer need to worry about integrating and improving all the designs for each safety function plants relied machinery health monitors with the organisation’s control system. upon. By standardising control system and The organisation engaged vendors with a machinery health monitoring equipment proven track record in best-practice safety under the umbrella of one vendor, the systems. Because of its long history organisation gained access to Emerson’s using DeltaV, the organisation contacted easy three-step integration between Emerson to evaluate the benefits of machinery protection and the DeltaV, rolling out new safety equipment. control system. Safety system adds and Emerson provided best-in- class changes that used to take days can machinery health and safety monitoring now be completed in under an hour. equipment in the CSI 6500. The vendor Any communication issues between also helped develop an enterprise-wide the monitors and the control system machinery health and safety programme can be easily and quickly detected and that standardised safety system diagnosed, without the need to untangle equipment, processes, and features at all a complicated web of integration. plant facilities. In addition, the company At the sites where roll-out is complete, gained a single point of contact for all technicians are already seeing stunning of its machinery health devices and results. Using the software configurable software, making implementation and interface for the CSI 6500, maintenance support significantly easier. crews can make adjustments and Working together with Emerson subject tweaks as needed to critical equipment matter experts, the organisation in the plant. Now, when crews try new developed a plan to roll out a standardised configurations to improve and optimise machinery health and safety system to production, they can see immediate the entire fleet over the next 3 years. By results and reports on the changes they 2018, all legacy monitors will be gone, make. The software provides a clear replaced by new equipment that can picture of what is happening with report far more detailed vibration Fig. 2: A software interface to safety equipment at any given moment data to the plant’s control system. equipment allows operators to quickly and (Figure 2). Plants throughout the organisation easily make changes, and assures that Technicians have even found will no longer have to worry about maintenance is never unsure of critical unexpected benefits from upgrading spurious trips due to aging monitors, asset health. monitoring equipment. Two separate

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plants immediately started seeing nuisance trips from thrust issues on start-up after implementing their new machinery health monitors. Because previous devices didn’t register the trip, the maintenance teams knew that the problem had to be a result of the more sensitive monitoring available on the new devices. After investigating the problem, technicians discovered that the vibration sensor was not mounted properly and was slamming against the bearing, tripping the system. Not only were the sensors now sensitive enough to detect the issue, but standardisation across the fleet allowed multiple teams to work together to bring the problem under control. Working with a trusted partner has opened up new opportunities for the organisation. The existing connectivity between the machinery health monitors and the DeltaV DCS simplifies the process for future safety system expansions. The organisation is already evaluating implementation of a predictive maintenance package, so the current machinery health infrastructure upgrade has been designed with that future in mind. Using standardisation as a guiding principle, the design and layout have been developed to make upgrading easier, with some power and wiring already in place. When the organisation decides to upgrade, it will be less expensive and simpler to install predictive maintenance options. By increasing the capabilities of machinery health equipment and making standardisation across the organisation a priority, the members of the implementation team have set the company up for future successes. The organisation can be confident that any equipment failures will be immediately addressed. They can also rest assured that any future upgrades, questions, or concerns can all be addressed from a single point of contact, making the system simpler to support, maintain, and upgrade.

DON’T TAKE ANYTHING FOR GRANTED.... It is important to understand some of the key measurement types in an online shutdown protection system. Not all assets will have all measurement types, but many will be common to multiple devices. As such, it is good to be familiar with all of them. Shaft Vibration (relative) This measurement type is always done on a fluid film sleeve bearing and is supplied using eddy current sensor technology. Shaft Vibration (absolute) This measurement type is always done on a fluid film sleeve bearing. Relative shaft vibration is measured, and the absolute bearing housing vibration is measured using an accelerometer or velocity sensor along the same axis as the eddy current sensor. Bearing Vibration Bearing vibration readings are taken on both antifriction bearings and fluid film sleeve bearings. Accelerometers, piezoelectric based velocity sensors, and seismic, electrodynamic based velocity sensors are usually employed to measure the bearing or machine case overall absolute vibration. Position Measurement

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Position and expansion on shafts, bearing housings, and machine cases are measured using eddy current sensors on rotating machines. Eccentricity Shaft eccentricity is the dynamic movement of the outer shaft surface to the geometrical centre of the shaft (also called residual gap). This measurement requires a tachometer phase reference to initiate the time series collection and the measurement consists of one complete shaft revolution measured with an eddy current sensor. Differential Expansion Differential expansion (relative expansion) is a measure of the change in the clearances between machine parts caused by thermal expansion or contraction. (e.g., rotor discs to turbine housing). The most common method to measure this effect is by using eddy current sensors. Valve Position Valve travel amount is used to determine whether a valve is open, partially open or closed. LVDT sensors have the long displacement measurement capability to measure valve position. Speed Measurement (acceleration, direction, and more)

Speed measurements are usually collected by an eddy current sensor reading a pulse wheel or a gearwheel. The current speed in hertz is calculated by dividing the amount of pulses per second by the number of gear teeth on the wheel. By having many pulses per revolution it’s possible to quickly determine if the asset speed is consistent, accelerating or decelerating. Axial Position Protection A fluid film sleeve oil ‘thrust’ bearing is designed to be the fixed bearing of a fixed/floating bearing pair. This bearing is expected to keep the shaft from wandering in the axial direction which will result in a catastrophic event when the clearances in a rotating machine such as a steam turbine disappear and high speed metal to metal contact of the rotor with the housing and seals occurs. Process Variables Because of the growing application of sophisticated and networked modern analysis and diagnostic online prediction and protection systems, it becomes increasingly easy and essential to capture process parameters and trend them along with the online prediction and protection analysis parameters to allow the visualisation of potential relationships between them.

‘COMPANIES DO NOT LOOK AFTER THEIR ASSETS’...

FACT OR FICTION? By Peter Jackson. BSc (Hons)Mech Eng. MIAM, MCP Consulting Group

As with life in general there are always two sides to an argument. This one is too wide sweeping to be totally true but for many UK companies, it is too close to the truth!

y name is Peter Jackson and I work as a consultant with MCP Consulting Group. Previously my background was in engineering and operations management with major blue chip companies before becoming an asset management consultant 20 years ago. In this capacity I have visited hundreds of different sites and been often surprised at the way assets are managed. So, I will try to explain, with backup from MCP data, why I consider the statement to be valid, even today.

ESTABLISHED PROGRAMME AMIS Logo here please You may have heard of the Asset Management Information Service (AMIS). It was25 years ago that a survey commissioned by the then DTI into the UK’s maintenance management practices revealed that an astounding £1.8 billion of potential savings could be made through increased understanding of maintenance management by industry. This led to the introduction of AMIS, the DTI supported benchmarking service provided by MCP. By 1997, it was estimated that the AMIS approach had potentially saved UK industry over £300Million. Fundamentally AMIS provides a benchmarking service that allowed sites within companies to appreciate where they stand in terms of effectiveness, compared to similar sites in a similar business sector, on the worldclass stage. Many UK and International companies have used the service to support their asset management development programmes. You may not know the MCP has been recognised with a Queen Award for Enterprise, 2016 for business growth and success worldwide. The AMIS database is the well we use to back up our claims. At our current position with more than 4500 assessments completed we can profile the stages of sites on the journey to asset management excellence. It is clear that a significant number of sites are not in control of maintenance, some have gained a measure of control, a number are trying to make the journey and precious few succeed. Because there are fewer site reporting beyond control... we argue..in conclusion...that the majority of companies do not look after their assets.

CARING FOR YOUR ASSETS Not only in business but in our personal lives assets must be cared for. Consider this from a health and wellbeing point of view. We know that if an athlete is to become world class, care must be taken of their body condition, tone and skills, such that, on the day of the competition the subject is fit for purpose

and able to compete to be the best. Considered in personal transport terms. We all understand that, if we depend on a mode of transport, e.g. a car, then it makes sense to attend to whatever is required that ensures the transport will be reliable whenever needed. We do not take the risk. Considered in finance terms. When we own a property we know that when it comes to selling we have to demonstrate that we have cared for its condition as much as possible. A sensible householder will have had a programme of maintenance that presents the home in the best light. So, why do so many companies let this logic evaporate when it comes to their business assets? Businessmen often believe they sound productive when they trot out the old mantra ‘sweat the asset’. Great, but what really happens? Short term it may appear a productive benefit has been gained. In the mid to longer term the risk to under performance is often ignored. Where is the logic? Why do business leaders override the longer term asset care logic that is evident in their private lives?

WHY DO COMPANIES NOT LOOK AFTER THEIR ASSETS? Here are a few thoughts: Maintenance is considered a cost rather than an investment Shortterm thinking....ignore maintenance now because it will be someone else’s problem when I am promoted Engineers are unable to persuade companies to make the right refurbishment /replacement decisions because they do not have the data for the defendable business case. Output is an overriding imperative and so do not stop for maintenance but be able to fix it quickly when the inevitable happens. Production think that if a preventative maintenance (PM) schedule is completed on time there will never be a failure. All failures must be engineering failures. These attitudes will conspire to asset management becoming nothing but a breakdown service. They will lead to a downward spiral of effectiveness where reliability slowly reduces and no amount of push, shove or bullying will improve the situation. We need to look to senior management for leadership and a way out of this situation.

IS THERE HOPE? Yes...ISO55001 is a game changing opportunity. Since the introduction of PAS 55 in 2004, its relaunch in 2008 and the subsequent arrival of ISO55001 in 2014 the interest in and awareness of asset management is growing. For the very first time we have a standard for Asset Management and businesses are beginning to take note. Some of the key reasons are:

- FM service providers know how relatively easy it is for the clients to request in contract tenders that they can demonstrate the ability to conform to the new standard. - Capital intensive companies are thoroughly aware that the regulator is expecting compliance to the new standard - Manufacturers in general have welcomed the attention created by the introduction of ISO55000. It provides a rationale for asset management to be considered an essential pillar of any world class business model. - There is widespread belief that ISO 55001 and asset management will be as important to future business leaders as ISO 9001 (Quality) and ISO 14001 (Environment). That’s a game changing situation. This all adds up to a rising demand for companies to demonstrate their competency in a management compared to the standard.

BUT IS COMPETENCY ENOUGH? Many companies, during an AMIS assessment, state their requirement is to be a company of natural choice for their customers and to do that they seek to be considered excellent at all they do. A display of competency compared to the ISO standard is not enough. The AMIS challenge explains what world class looks like and recommends the steps to be taken to achieve world class ambitions. The true goal of every company, or site within a company, can be signalled by the most seniorperson involved stating what he wants from the assets in order to be excellent. “I want the highest possible equipment, building and people reliability”

RELIABILITY IS THE KEY To achieve this it must be understood that excellence depends

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WATER SYSTEMS LEADING THE MARKET IN WFI AND CLEAN STEAM

on the 3 major elements of asset management being properly applied. The diagram below shows the relative importance of these 3 elements as they contribute to overall reliability. How equipment is used and operated is the prime activity. The contribution to reliability is estimated to be between 40 – 50 %. It is essential that companies understand this and put in place programmes to ensure operators are considered key to equipment reliability. The choice of equipment is vital for optimum life time cost for using and maintaining the asset. Get it wrong and we deduce for AMIS data that typically 20% of the annual maintenance budget spent papering over the cracks from poor investment decisions. Finally, if the first 2 elements are not excellent there is no amount of maintenance effort that can overcome the effects of poor operations and bad CAPEX decisions. Test this logic considering the choice of a vehicle. Bad drivers = unreliable vehicle Wrong choice of vehicle for the task = unreliable vehicle Good operator care + the ‘right’ equipment + optimum maintenance = reliable performance

HOW DO BEST PRACTICE COMPANIES SET OUT THEIR PLAN TO LOOK AFTER THEIR ASSETS? The answer lies in the strategic appreciation of the role of asset management in the business plan. ISO 55001 explains this as the ‘Asset Management System’ devised to explain to an investor how the asset will be cared for throughout its life. My simplified explanation of this is shown in the picture below.

Veolia Water Technologies, the leading supplier of pharmaceutical water systems, has now installed more than fifty clean steam and Water For Injection (WFI) systems from its highly successful Polaris range. The standard Polaris™ CSG units produce from 50kg/h up to 10,000kg/h of clean steam at up to 6barg for autoclave steaming and SIP. All models can be supplied for steam or electric heating and are available as horizontal or vertical to suit installation space. They also include an integrated thermal degasser for non-condensable gases removal, which is in compliance with HTM 2010, 2031 and EN285. Polaris™ MED uses the latest high efficiency, multiple effect distillation technology for WFI production. The dry column design, using falling film technology and utilising a baffle system, has been designed to maximise droplet separation to ensure excellent decontamination performance and optimise heat transfer to provide high efficiency and rapid startup. Polaris™ VCD is a mechanical vapour compression still, which can produce hot or cold WFI in facilities where steam supplies are either limited or not available. Featuring three-stage non condensable gas removal and FDA approved compressor seals, Polaris VCD is one of the most efficient products of its type currently available. Both Polaris™ MED and Polaris™ VCD are available in standard models covering the range 50-15,000 litres per hour of WFI and the choice of Siemens or Allen Bradley PLC, means simple interfacing with existing SCADA and BMS systems. The entire Polaris range is designed in accordance with GAMP, cGMP, ISPE and FDA guidelines and will meet the product quality specifications of all of the major pharmacopeia, including the USP and Ph Eur. For more information on Polaris and other products for pharmaceutical and healthcare applications visit www.veoliawatertechnologies.co.uk/processwater/markets/Pharmaceutical/polaris/

WIRELESS CRANE OPERATION WITH DEMAG INFRARED CONTROL - System features active range limitation - Eliminates risk of radio system interference - Practical inductive charging station

The Asset Management System is the formal recognition that looking after assets makes logical business sense. The policy and strategy documents must be part of the business strategic plan. With these in place engineering and operational teams can confidently pursue the adoption of the body of asset bestpractice knowledge and seek the levels of reliability so easily demanded by leadership. Is not an easy journey, the scope for thoroughly applied asset best practice is enormous and it will take a company several years to absorb, adopt and achieve the high standards required for reliable performance. The AMIS journey has been too much for some sites and companies. The reward experienced by those who have completed the course and sustained the processes and behaviours required is testimony to the value of asset management for all successful businesses. Those companies that do not look after their assets and choose not to change face a grim future. They are dinosaurs that will die!

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Terex Material Handling’s new generation of Demag DIR infrared (IR) remote controls provides crane operators with a viable alternative to conventional radio controls. The Demag DIR range incorporates a variety of innovative features for the reliable and efficient control of material handling systems. One of the principal advantages of the Demag DIR system over radio controllers is the considerably shorter range, of some 40 metres between the transmitter and sensor(s), which is of benefit when the operator wants to limit the distance at which the crane can be controlled, for safety reasons. This specifically limited range ensures that operators are always in close proximity to the equipment, providing a clear view of the lifting and moving process. There is no risk that the IR control system will be influenced or impaired by radio systems and the IR offers no potential for interference with other radio controls. The Demag DIR’s rugged hand held transmitter housing is based on the design used for Demag radio controls, meaning that users will be familiar with the controller layout and can use the same keypad concept for both transmission methods The high contrast bi-colour display provides a clear overview of the device and warning information, which affords the highest level of safety. The integrated vibration alarm and stop function conform to Category 3, Performance Level ‘d’ to the relevant standard EN 13849-1. For more information contact Demag Cranes Components Ltd, Banbury, Oxfordshire Tel: 01295 676100 · Fax: 01295 271408 E-mail: bnb-help@terex.com Web: www.demagcranes.co.uk

ASSET FINANCE ENABLES TECHNOLOGY INVESTMENTS TO SUCCEED IN THE FOURTH INDUSTRIAL REVOLUTION By Gary Thompson, Head of Business Development region North Technology and Digitisation atSiemens Financial Services (SFS) UK The manufacturing world is under fundamental change. This is marked by the digitalisation of production processes and the integration of the Internet of Things (IoT) which form the basis for increasingly intelligent and highly efficient manufacturing systems.

he development of digital, or “smart”, factories has been driven by the installation of widespread sensors in the physical manufacturing environment. These sensors link the physical and virtual reality, enabling enhancement of production economics through real-time performance data analysis. As with previous periods of innovation and development triggered by, for example the rise of steam power, the use of electricity and the development of digital technology and the internet, the world is once again witnessing an industrial transformation. These new dynamics have been identified as the “Fourth Industrial Revolution”. (1) This opens many new opportunities for manufacturers to add value to their products and services. Research by the McKinsey Global Institute (2) suggests that on a global scale, the growing interconnectedness of equipment and machinery via the internet - IoT - may have a potential economic impact of as much as $11.1 trillion (£7.6 trillion) per year in 2025. Among the physical environments in which these systems are deployed, factories are expected to reap the greatest share of economic gains with up to $3.7 trillion (£2.5 trillion) per year. These gains are believed to come from productivity growth, enhanced energy efficiency and maintenance savings. Manufacturers can therefore reap significant financial benefits by investing in the Fourth Industrial Revolution. Companies in the sector have already recognised this opportunity. In a recent study by Siemens Financial Services (SFS) (3) , major manufacturers across the world reported a need to invest in new ‘generation technology in order to manage four key sector challenges. Firstly, respondents felt an urgency to increase production capacity and flexibility to meet changing demand and drive sales. Secondly, manufacturers are under pressure to enhance client service quality while reducing production costs. Additionally, respondents reported that they are striving to improve competitive positioning by providing higher quality products and a broader product range, whilst optimising efficiency, cost control and manufacturing agility through automation and digitalisation. The ability to acquire new equipment, upgrade existing machinery and invest in new software and hardware solutions is therefore a decisive factor to ensure a competitive positioning within the sector. Access to the appropriate form of equipment finance is an important prerequisite for manufacturers wishing to grasp the benefits of Industry 4.0. (4) As a consequence, firms in the sector are increasingly diversifying their financing techniques and using a range of financing tools over and

above traditional sources such as loans. The digitalisation of the manufacturing industry also creates an expectation of more, and more frequent, upgrades and enhancements to the existing technology landscape, including software upgrades. Therefore, in order to remain competitive in the global markets, manufacturers need to find sustainable ways to invest in acquiring as well as renewing new-generation technology.

sales and marketing initiatives, opportunistic acquisitions, partner promotions and other tactical growth projects. The more capital that is unlocked, the more that is available to invest in growth initiatives.(5) As well as extending the available volume of financing, the speed and ease of the financing decision and arranging asset finance allows manufacturers to act fast to seize market opportunities.

CONSIDER THE FUNDING...

BALANCE THE FINANCING TO KEEP AHEAD...

Against this background, various forms of asset finance are seen as an important investment facilitator. They can accommodate the total cost of ownership approach to technology acquisition. In addition to the technology price, individually tailored finance solutions are also able to cover other costs such as installation. This gives a high level of transparency and allows the business considering the financing to appropriately assess the cost-benefit ratio of the acquisition right from the start. Solutions such as leasing and lease purchase offer reliable financial planning and contribute to the calculation of production cost per unit. Payments can also be arranged to align with expected cost savings or improved productivity delivered by the newly acquired technology. In effect, the costs for the technology acquisition or upgrade can be offset by the financial gains generated by the deployment of the equipment. Investments in next generation technology can therefore take place in a financially sustainable way. This new era of industrial production is characterised by rapid innovation cycles with new business opportunities continually emerging. Manufacturers have to remain financially flexible and retain their ability to react to unexpected market developments, technology advancements and new investment opportunities. Businesses are therefore increasingly looking for financing solutions which offer a high level of flexibility to fund investments. Asset finance solutions can include the exchange or upgrade of leased equipment within pre-defined periods. Specialist financiers combine capital markets expertise with a sound understanding of the funded technology and the dynamics of the manufacturing sector. They are therefore in a unique position to structure complex financing solutions and ensure beneficial outcomes for their client. Equipment and technology finance has now achieved strategic status. This is reflected in the growing importance of financing techniques that release capital from being “locked” in technology acquisition. Instead, they make that working capital available for, among other things, new product development,

As the world of manufacturing is once again transforming, it appears that it is no longer sufficient to just make the best products in order to stay ahead of the game. Companies who are able to efficiently gather high-quality data and use it to create innovative digital service offerings will be the most competitive. (6) Consequently, manufacturers are increasingly recognising the need to invest in machinery, equipment and technology that support the integration of IoT applications. Additionally, the digitalisation of the shop floor requires an advanced IT infrastructure and solutions for data management to make proper use of the increasing quantity and quality of data. Many manufacturing businesses however (SMEs in particular) lack the necessary expertise to assess whether a new application will create the desired return on investment. Specialist financiers with extensive technology and industrial knowledge can help companies make the right investment decisions and, at the same time, offer them appropriate funding solutions. In its early stages, the new industrial era presents manufacturers with a unique chance to reinvent themselves and take advantage of an abundance of new opportunities. For companies that successfully manage this substantial change, rewards lie ahead. More than ever, access to flexible and reliable funding plays a decisive role in establishing and maintaining a competitive positioning for manufacturers both large and small. With indepth sector knowledge and technology expertise, specialist leasing providers are well-positioned to provide customised financing solutions to ensure that manufacturers are able to grasp the benefits of the Fourth Industrial Revolution. 1 World Economic Forum, The Fourth Industrial Revolution: what it means, how to respond, January 2016 2 McKinsey Global Institute, The Internet of Things: Mapping the Value beyond the Hype, June 2015 3 Siemens Financial Services, Driving Digitalisation and Automation, Fall 20155 Siemens Financial Services, Investing In Success, Spring 2016 4 Siemens Financial Services, Investing In Success, Spring 2016 5 Siemens Financial Services, Investing In Success, Spring 2016 6 The Economist, ‘Does Deutschland do digital?’, November 2015

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SCADA COST-EFFECTIVE TOUCH PANEL SCADA PACKAGE Products4Automation (P4A) has packaged its Vision 600 series IPCs with Movicon 11 SCADA/HMI software to provide a highly cost-effective, ready-to-run and simple to deploy touch-screen SCADA solution. The solution combines the powerful Movicon 11 SCADA software platform with Vision 600 Intel Celeronbased touch panels running Windows 7, delivering fully featured SCADA with high resolution graphics, powerful alarm management, data recording, historian, trend analysis and recipes as well as control of machines and processes. The package delivers a top quality, fully featured SCADA hardware and software solution at entry level prices. This enables companies to deploy a full SCADA implementation locally to machines and processes for visualisation and control. Further, because Movicon is a hardware-independent platform deployable at all levels, users can easily migrate to larger implementations of Movicon on more powerful hardware as an application increases in size or complexity. Thus investment in the Movicon/Vision package is effectively future-proofed. Movicon 11 has a full range of inbuilt tools, including comms drivers for all standard connection hardware (no drivers are required to communicate with another Movicon system) plus a data historian which is usually a bolt-on item, at no extra cost. It offers an all in one development environment for managing HMI, SCADA, soft logic and statistical production data analysis applications. This helps reduce development times and ensures the delivery of powerful, open, flexible and easy to maintain solutions. It can also have a web client added for remote access. Products4Automation is packaging Movicon 11 on a number of different Vision 600 touch panels, in screen sizes ranging from 7in to 21in.. It has all the flexibility and cost advantages of an independent solution, but with guaranteed quality and EU based development and technical support. For more information contact Products4Automation Ltd : Sutton Coldfield, West Midlands Tel: 0845 077 3858 Email: paul@p4altd.co.uk Web: www.products4automation. co.uk

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DRIVING FORWARD ENERGY EFFICIENCY Across industry, electrical drives account for the lion’s share of electrical energy consumption and from 1st January 2017, all electrical motors will be subject to minimum levels of efficiency. This requirement is the next step towards energy efficiency under the ErP Directive and affects a huge 70 per cent of the commercial market. Here, Mark McCall, marketing manager at Newey & Eyre, looks at the options available to ensure compliance.

n the UK, in 2014, chemicals were the largest industrial energy consumer, responsible for 14% of total consumption, followed by food, drink and tobacco at 12%¹. These, among other industries, are already challenged to curb their energy consumption under Climate Change Agreement (CCA) schemes; voluntary agreements which enable businesses to receive discounts on the Climate Change Levy. A number of process industries have umbrella CCA sector commitments which set out energy efficiency targets, giving them a target saving to be achieved by 2020 from the base year 2013. For the food and drink sector, the target is an 18% reduction with 17% for plastics, 13.6% fo r brewing, 7% for bakers and paper manufacturers and 6.1% for ceramics. Huge steps have been made in CO² emission reduction in the UK, but our industrial sector still ranks in the top three offenders for carbon emissions in Europe, alongside Germany and Italy.²Designed to help tackle this, the ErP – Energy-related Products – Directive applies across products that use energy or have an indirect impact on energy consumption sold in the European Economic Area and the next wave of its requirements targets electric motors in the industrial setting. Electrical motors are widely identified as one of the largest consumers of energy worldwide. According to the Sustainable Energy for All (se4all) initiative, there are six product areas that will collectively account for around 55% of global electrical consumption by 2030 and one of those is motors. Use varies by sector but the impact of electrical motor usage can be significant – in plastics processing, for example, approximately two thirds of energy costs are a result of electric motor usage. Reducing this usage has the potential to be beneficial not only in broad climate change terms but also for the bottom line of individual businesses so the attention focused on drives by ErP could be seen as a wake-up call to significant energy cost savings.

CONSIDER THE CHANGES... The requirements of the directive are that, from 1st January

ANOTHER CHOICE..

example, in many fan and pump applications, efficiency gains of between 20% and 70% can be achieved. Other benefits also include increased motor longevity, reduced maintenance and a reduced risk of motor and machinery damage during start up, running and shutdown. Traditionally, VSDs have generally been specified when part of a larger or more complex control system, chiefly due to a gap in the market for an enclosed direct online (DOL) product that incorporates the simplicity of a DOL installation and the benefits of a VSD. For example, we have developed the Newlec EcoStart which is an energy-efficient enclosed motor starter that offers all of the benefits of a VSD which combined with an IE2 motor can be ErP compliant. In many instances, motors are over-rated for their application and the speed can be reduced overall to delivery energy savings. As an out-of- the-box solution, EcoStart is supplied to run at85% motor speed which immediately provides up to 40 per cent electrical energy savings .Additionally, it can be set to operate precisely to the requirements of the individual application. As an example of the potential savings, with a 4kW motor with an EcoStart motor starter, set to run at85%, in a system that is operational for 12 hours a day, 250 days a year, with an electricity cost of12 pence per kW/h, the user could expect to save £836 per annum on energy bills with a payback period of 1.5 years. The specific application will determine the choice of motor, with the higher costs of higher efficiency motors being offset by the ongoing savings that can be made in energy costs with the correct choice. ErP compliance gives engineers the baseline in terms of the minimum permitted efficiency and creates the opportunity to deliver solutions that can lead to lower running and energy costs, reduced maintenance and overall system downtime.

Alternatively, significant savings can be achieved by using an IE2 motor with a VSD, which as well as delivering energy savings can offer shorter payback times. In many applications, particularly centrifugal fans and pumps, compressors and material handling, the energy savings alone provide a conclusive argument for the incorporation of a motor with a VSD. For

¹ Department of Energy & Climate Change report Energy Consumption in the UK 2015. ² www.ec.europa.eu/eurostat/statistics-explained/indix.php/Consumption_ of_Energy. Visit the brand new website here www.neweyandeyre.co.uk and remember to bookmark the new

2017, all squirrel cage motors with a rated output of 0.75 to 375kW must either be supplied as an IE3 motor or as an IE2 motor with avariable speed drive (VSD). Choice of drive engineering is dependent on the application. Where fixed speeds or lower switching frequencies are involved, traditional motor starters offer the more energy efficient solution, whereas VSDs are more appropriate for applications with variable speeds or frequently alternating loads. IE3 premium efficiency fixed-speed motors will deliver the energy savings that tick the regulator box. They are, however, characterised by a number of properties, including higher starting currents which means that it is particularly important to use high-quality switchgear and protection components with the correct trip pattern and with a switching duty specifically designed for the IE3 motor being used. IE3 motors achieve the required energy savings, but can be more expensive to purchase leading to a longer payback time. Fixed speed motors operate most efficiently when their load equals, or is slightly greater than, the rated capacity. If motors are larger than needed for their applications, they will not reach the design load so will not run at optimum efficiency. Accurate motor sizing is therefore essential in order to achieve true energy efficiency. Fixed speed control is appropriate in applications where load demands maximum motor speed or mechanical constraints do not permit speed variation. Low voltage switchgear in a well-designed system can achieve significant energy savings, but these relate directly to the amount of time the motor is switched off. This can either involve the simple expedient of switching systems off when they are not needed, or designing an intelligent system incorporating techniques for determining precisely when the motor needs to be operational.

Authors notes

PROCESS INDUSTRY INFORMER July 2016

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Solids Handling & Processing Supplement

January - February 2016

LIVE AND LEARN When you stop learning you stop living – an axiom of obscure origin but nonetheless more relevant today than ever. Learning for learning’s sake can be very rewarding if intellect and pressures of daily life allow. Learning to enable career progression is no doubt laudable; learning to keep one step ahead is equally beneficial. But what is really worth learning and how do we know that what we are absorbing is relevant, accurate, well informed, unbiased and even truthful?

THE NEED TO KNOW

Many successful companies have been founded by people with good ideas for a product orservice; somebody perhaps with a particular skill for design, project management communication or marketing, amongst many others. Whilst the company is small the other necessary but less developed skills could be acquired by the proprietor, at least to the level needed for the fledgling organisation to operate. A century or more ago the speed of communication, for example by letter or courier on horseback, allowed time to think and consider actions, time for discussion, with only a limited possibilities. Such a blissful situation is not the lot of the modern factory owner, engineer or manager. New technology (laboursaving devices all….!!) brings with it a truly huge volume of required knowledge in order for life’s participants to succeed in any business enterprise. Indeed, a snapshot of the range of knowledge underpinning the products and services offered by the solids and bulk handling and processing industries may be gleaned from the ensuing pages.

HELP AT HAND

However, for companies manufacturing and installing these products and services, as well as users processing equipment with their kaleidoscopic variety of applications, help is at hand. Actually it has been at hand for around 35 years in the shape of an engineering trades association founded and still run by industry professionals, giving their time and expertise voluntarily for the betterment of British industry – this unsung hero is SHAPA.

LEARNING TO SUCCEED

From the very beginning in 1982 the Association has existed to produce and disseminate high quality relevant technical, commercial, legal and marketing intelligence in a lively and engaging manner. A little look at this year’s programme of events will demonstrate this ambition of living and learning. Earlier in the year the 8 th Annual SHAPA Digital Marketing Workshop was presented. It’s hard to believe that this event is now 8 years old, but such is the pace of change and rate of uptake of all things electronic, that its future is now assured. New ideas and platforms, commercial uses for social networking sites, ways to advertise effectively and economically – all clearly laid out with updates arising from progress since the last workshop in 2015. New subjects for this year included Content Marketing enabling more traffic to be directed to your own website. Google AdWords advertising was reviewed with fresh ideas, as well as selling in LinkedIn. This annual workshop is for anybody wishing/to promote their company by means of digital marketing in an entertaining, hands-on and extremely useful session. Not every company principal is a financial whiz-kid. As alluded to earlier all sorts of people start and run companies. In our industry they are likely to be engineers and innovators. But, along with the fun part comes the vital need to keep finances in order. Profit and loss accounts, appeasing the taxman, even avoiding prosecution are all beneficial occupations to preserve peace of mind. Clearly it is important to monitor the financial health of the company as a whole. In May this year SHAPA presented a Financial and Commercial Awareness Workshop, the first of its kind in the developing world of SHAPA learning opportunities. Specifically aimed at those managers for whom finance was not their primary skill, the seminar set out to de-mystify the processes and jargon of financial accounting. One session concentrated on analysing financial information, describing such terms as “ratio trends” and how to apply “ratio analysis”. Delegates gained a better understanding of their own particular financial objectives and learned how to assess the financial implications of their day-today decisions. They discovered how to make better use of resources allocated, but crucially they left with greater confidence through focused knowledge. Coming up in November is another new course, to develop and hone negotiation skills. It is clearly important for supplier and client alike that satisfactory contract conditions are agreed, for the safety and security of all parties involved. The course will cover subjects such as structuring negotiations, how to deal with all kinds of developing scenarios by means of role playing, as well as demonstrating how to apply these skills in practice in the workplace. Good negotiation skills will ensure that any business relationship, whether internal or leading to new contracts, will get off to a good start with an identifiable structure to cover all eventualities as the relationship proceeds.

HOT TOPICS

! n O s i e r u ss e r P The

NEW High Pressure Rotary Valve

REWARDING SUCCESS

All in all, SHAPA takes on-going learning and education at all levels very seriously indeed. So, what about the rewards for success? This year’s SHAPA Industry Awards were well supported and the results, in five categories now including an Individual Award and SHAPA Customer of the Year have been well documented. Morale boosting and commercially uplifting, the Awards will, we are sure, go from strength to strength. In challenging times SHAPA and all its member companies have risen to the challenges to promote a good future, whatever the political climate. The pages of this supplement will demonstrate some of the expertise and commitment that is the hallmark of our manufacturers and suppliers.

The DMN-WESTINGHOUSE HP valve with specially designed inlet is very suitable for handling granular formed products under a high pressure of maximum 3.5 bar g. The valve has a very important advantage in air leakage: the special conﬁguration of body, rotor and seals does not only protect product against degradation, it also does not allow any axial air leakage.

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

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

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

360° video

COMPONENTS FOR BULK SOLIDS HANDLING

On a quite different tack the Association will hold a further ATEX seminar, slated for Januarynext year. This is a constantly relevant topic, with many newer engineers encountering its ramifications for the first time. The seminar will tackle categorisation with zoning, T rating, SIL and ignition temperatures – some jargon here, but all will be explained to those who attend. Information will subsequently be disseminated to all SHAPA members following the event. Total cost of ownership is an old chestnut, but a very important consideration for all SHAPA members and their clients. It is well known that the capital cost of plant is only part of the story and all wise engineering purchasers will probe operating costs, planned maintenance and repair costs, set against WESTINGHOUSE the costs of unplanned downtime. Total life span and depreciation are obviously part of the mix too. All of this is being addressed by the Technical Committee and new information will be placed presently on the SHAPA website.

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DUST EXPLOSION PROTECTION – 10 COMMON MISTAKES IN A PROCESS FACTORY

Kevin Spiess from BS&B shares insights on what mistakes to avoid when protecting your facility from dust explosion risk With years of experience in providing protective solutions for dust explosion risk, BS & B Safety Systems has visited and surveyed factories in every process industry all over the world. While owners are making the effort to comply with DSEAR and ATEX regulations and ensure their staff’s safety, the execution of preventive measures has not always been correct. Many facilities share common problems when it comes to the installation of protective equipment. In some cases,they inadvertently omit to place fail-safes where necessary. Here are 10 cross sector examples of the most regularly encountered errors when it comes to protecting against dust explosion risk. 1. ISOLATION OF CONNECTED EQUIPMENT IS OVERLOOKED If an explosion vent is fitted to a dust collector, there must be isolation of the dirty inlet duct and isolation of the clean air outlet duct when it returns to the process area. This is necessary because the explosion could propagate along these ducts causing other safety risks to people and equipment. 2. DON’T FORGET TO PROTECT BUCKET ELEVATORS Bucket elevators are high risk equipment because they have many possible ignition sources. What’s more, they are connected, so if one is the source of ignition, a primary explosion caneasily spread to the other processes. The risk is further exacerbated via secondary explosionwhich causes further damage to other items of equipment. 3. EXPLOSION VENT INSTALLATION ERRORS By all means fit an explosion vent, but make sure it’s done properly and that it’s the correct size for your process requirements. Failure to do so will result in a variety of dangerous health and safety risks. • The possible leak of combustible materials from an incorrectly fitted vent results in burning materials being expelled at high pressure. The path of the flame becomes a secondary risk zone, both indoors and outdoors. The reach of a flame ball bursting from an incorrectly installed vent is typically between 10 and 30 metres long. • Another common oversight is not

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factoring in changes of the manufacturing process being used in relation to the size of vent required. If the materials that you are processing have changed and have a higher KSt and PMax value, the force of explosive pressures may increase. Check and recalculate (if necessary) the vent area required and make sure your vent is correctly sized! Vent ducting must be properly calculated and designed so that the flame path can escape freely to a safe area. In the past vent ducts have been installed and added to. There are strict guidelines when it comes to designing explosion vent ducts. Correct size and length of ductwork is key to the efficient performance of a vent. Ensure that your vent discharge path cannot possible endanger nearby personnel. If there ishazard due to explosion venting (expelling pressure and flames) then that area must beclearly indicated with signage and cordoned off. Do not obstruct the explosion vent path. DO professionally install a properly designed vent and don’t try and make your own. The performance will be erratic and certainly unsafe! Once your vent is correctly installed ensure it is regularly inspected and that the inspection records are visible.

4. ELECTRICAL GROUNDING AND BONDING NOT IN PLACE Electrical sparking in a dusty environment is a recipe for disaster. Ensure that grounding wires are not broken or unconnected. If there is piping across a flexible connection, make sure it is well bonded. These considerations are particularly significant when dealing with dusts that have a low ignition rating – it wouldn’t take much to cause a fire or explosion. 5. BAD HOUSEKEEPING Arguably the most logical activity but the most overlooked - cleaning the dust away. Dustaccumulations in the ceiling spaces, beams and walls can fuel an explosion to the point ofdestroying the facility. Make sure your employees know where the accumulation ‘hot spots’are and keep them clean. Do not attempt to move dust with an air spray. It just creates adust cloud which is a secondary explosion risk hanging in the atmosphere. 6. DUCTING AND PIPING NOT SAFE Weak explosion ducts can ease the path of an ignition to a destructive result. The strength of explosion vent ducts should be calculated so that they can withstand the maximum pressure of a vented explosion (Pred). Avoid long horizontal runs of duct work which attract uninterrupted building up of dust.

7. SILOS AND STORAGE BINS INADEQUATELY PROTECTED Venting is often the most appropriate preventive measure for silos because of the potential explosive pressure that can build up inside them. Vents should be placed on the top of the silo or on the sides at a height above the contained material. • Correct vent area sizing is critical so that the vent is large enough to prevent damage from explosive pressures. Silos need to be able to withstand venting pressures. Reduce the length to diameter ratio of the silo. Designing a larger diameter means that the vent area requirement will decrease significantly. • Don’t forget to test the material to be stored or handled and determine its KSt value. The KSt will inform the size of vent area required in your silo. 8. NO MANAGEMENT OF HOT PARTICLE RISKS Identifiable sources of sparks and other hot particles can and should be detected and redirected or extinguished in situ. The installation of spark detection and suppression systems rapidly and safely eliminates this risk. 9. UNPROTECTED DRYING EQUIPMENT Fires and explosions occur in dryers quite frequently. Depending on the type of dryerexplosion protection can be achieved by venting, spark detection, isolation, suppression ordesigning them robustly enough to contain an explosion. 10. ABSENCE OF RISK MANAGEMENT Putting risk management strategies into play can mitigate mishaps on the factory floor. Forexample, if installation of safety equipment is not based on measurable and current process requirements, your facility will be under-protected. Similarly, before the installation of safety equipment, carry out a combustible dust test and there after review your combustible dust classifications (KSt and Pmax levels) at regular intervals as process operations and materials change. This provision should be incorporated into Management of Change procedures. For more information on BS&B Safety Systems explosion protection solutions visit: www.bsbipd.com.

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

HOW DOES A ROTAVAL ROTARY VALVE REDUCE CHANGEOVER TIMES BY 75%?

RotaVal’s Fast Clean rotary valves have transformed production efficiency for A Schulman, the international manufacturer of plastics, resins and masterbatch. With a simple, ergonomically efficient mechanism for cleaning the valve at product changeover with only a single tool required, RotaVal Modular Fast Clean valves require only four minutes per changeover, a reduction of up to 75% over A Schulman’s previous equipment. A Schulman have gained an incredible 2-3 hours of production time per month at their Gainsborough production site. Cleanliness in production and the ability to guarantee that no material residue carries over when products change is a critical factor in A Schulman’s high-quality manufacturing process. At the same time, production pressure in a busy factory is ever-present, and it is vital that downtime is minimised. At every changeover, the process is purged, and that includes dismantling and cleaning the rotary valves. A Schulman identified that this was a bottleneck in their production processes and contacted RotaVal for a solution. RotaVal’s Modular Fast Clean valves are easy to work with, with patented RotAlign and bottom mounted sliding rails the valve rotor to slide out to be easily cleaned then slide back in with the minimum of fuss. All the operator needs to do is release the air supply and undo a few bolts, easily accomplished with a single spanner. As Michael Ingall, A Schulman’s Production Manager, put it, “The previous gate valve used a lot of tools and was time consuming. With the aid of the RotaVal quick release we have saved a lot of time and money” He was echoed by Production Supervisor Richard Hodge, “Time saving is 12-15 minutes and, with the amount of changeovers we have, it’s a fantastic saving.” Time saving is not the only one benefit. A Schulman have also identified that they are enjoying better quality control, with no operator errors. Richard Hodge went on, “A fantastic invention in what we do. Less risk of injury, it’s so swift to do, and clean.” Minimal downtime, with better quality control. Increased productivity that’s safer and easier for the operators. Also, savings can seriously mount up a site with 20 Fast Clean valves and ten changeovers per week would see an improvement of around 2600 production hours. For more information and a video filmed at A Schulman showing exactly how easily Fast Clean technology works in practice, see RotaVal’s website www.rotaval.co.uk

PADDLE BLADE MIXERS – MIXING AN ENVIRONMENTALLY SAFE SOLUTION FOR FCC ENVIRONMENT FCC Environment have installed two 7500 litre JR Boone Horizontal large scale paddle mixers in their Knostrop Treatment Plant in Leeds to treat and stabilise APCR waste from a network, of incinerators. Chosen for their robustness and reliability, the new mixers are now processing 25,000 tonnes per annum producing a stable material for safe landfill. Air pollution controlled Residue is generated in the flue of large energy from waste processes such as FCC’s Eastcroft plant in Nottingham and is typically a powder mix of calcium hydroxide and sand. The powder is created when hydrated lime is introduced into the flue to remove atmospheric pollutants including heavy metals and hydrogen chloride. FCC Environment’s Knostrop plant takes in the resulting powder, using the JR Boone mixers to mix in acidified water and produce a ‘sludge’ that is safe for disposal to landfill. High percentages of silica sand in the mix makes the process very abrasive, so the JR Boone mixers need to be very tough. The Paddle blade Mixers are fitted with wear-resistant mixer arms and blades, with the number of moving parts minimised. Two identical mixers are in place at Knostrop, between them processing around 20 tonnes per hour of waste material. The short length to diameter ratio of the mixers ensures that mixing is completed in the shortest time possible, while the ‘omega’ shape of the mixing vessel makes sure that all material in the mix is fully entrained by the blades, so every part of the powder is treated. This project was first set out as long ago as 2010, and initial material trials were carried out in 2013, Ian Martin, FCC Environment’s General Manager at Knostrop stated: ‘Our customers’ incinerators are running constantly and we need to be able to process the waste on a continual basis. Any stoppages here run the risk of stopping the upstream process. He went on. “We identified the JR Boone mixers quite early on in the project and chose them because they are tried and tested and very robust. We worked with JR Boone on pilot plant, fine tuning motor sizes and looking at the way the equipment performed with different material densities’. The Paddle Mixer is a very versatile machine also used as a processor-producing compounds with variable amounts of shear heat and under vacuum e.g. 100M HPBM for investment casting manufacturer Clan Ceramics (more information available on request). JR Boone also produce high shear Delta Blade mixers, low shear Helical Blade mixers and very low shear Rotary Drum Mixers for a wide variety of industrial applications. Mixers are available for test for each type of machine to demonstrate the clear advantage in choosing Jr Boone mixers and blenders for your process. For more information contact John R. Boone Ltd, Congleton, Cheshire. Tel: 01260 272894 Fax: 01260 28112 E-mail: sales@jrboone.com Website: www.jrboone.com

Prevention Venting Isolation Suppression

EXPLOSION HAZARDS LTD

YEARS

FOR ALL YOUR EXPLOSION SAFETY NEEDS www.explosionhazards.com +44 (0)1925 755153

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

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THE RISING TIDE OF SUPER SEAWEED

Tipped as one of the superfood trends of 2016, seaweed is packed with minerals, vitamins, fibre, omega 3 and protein, often being added to food as a nutrient boost. Claims that it can prevent colon cancer, control blood glucose level and aid digestion make it of significant dietary and health interest whilst sustainable farming and harvesting methods have led to seaweed’s recognition as a ‘futurefood’ as well as a superfood. The fibrous, wet and often sandy or gritty, seaweed is however difficult to process with costly and time consuming drying times. To reduce the drying process seaweed is often chopped to facilitate more rapid, less nutrient destructive drying processes. For many years processing experts Hosokawa Micron Ltd have offered processing solutions to alginate producers across the world. To meet the demands for milled, freshly harvested seaweed Hosokawa Micron Ltd has developed a two stage system comprising of a Prebreaker and Vertical Disintegrator. This low energy system offers uniform particle size reduction of wet or moist seaweeds for further processing, which offers higher levels of availability compared to conventional hammer mills. Once the friable materials have passed through the initial size reduction (Prebreaker) stage, they are transferred directly to the Hosokawa Micron Vertical Disintegrator to be further reduced to a uniform particle size. Designed for the reduction of fine to coarse, wet, moist or dry materials, the Hosokawa Micron Vertical Disintegrator provides automatic and continuous separation of disintegration resistant materials with redirection through the system from the exclusive secondary discharge. Uniform particle size is achieved as materials are subjected to repeated impact and attritional force from the high speed rotating hammers, and carried by centrifugal force through a perforated sizing screen. The vertical screen frees itself of product instantaneously during processing, which is ideal for products with a high moisture content. Barry Walmsley, Product Manager, Hosokawa Micron Ltd says, ‘The sturdy system, can operate at 12- 20 t/h. It is low noise and delivers product in a narrow particle size distribution, resulting in higher yields and less effluent. The Disintegrator is designed to withstand corrosion caused by the low pH often involved in the process and erosion caused by the natural inclusions which determines a predominant use of higher abrasion resistant materials of manufacture.’ For more information contact: Hosokawa Micron Ltd, Runcorn, Cheshire. Tel: +44 (0) 1928 755100 Fax:+44 (0) 1928 714325 Email: info@hmluk.hosokawa.com Web: www.hosokawa.co.uk

THE WOLFSON CENTRE FOR BULK SOLIDS HANDLING TECHNOLOGY HAS DEVELOPED A NEW COURSE The efficient processing of bulk materials to obtain a high quality end product is at the heart of the vast majority of industrial activity undertaken in the UK. However, how many engineers actually understand the fundamentals of the processing steps (size reduction, particle formation/agglomeration, grading, blending, etc.) that they are required to interact with or to specify. In order to help engineers better understand the characteristics and limitations of different types of ‘value adding’ plant. The Wolfson Centre has developed a new course that is intended to present the range of equipment types, their mode of operation and which applications are best suited to their use. The course is aimed at engineers that a new to industry or established engineers that would like to refresh their understanding of the subject. For more details of this and other courses on offer, go to the web site of The Wolfson Centre for Bulk Solids Handling Technology at University of Greenwich, www.bulksolids.com

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PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

PROCESS INSTRUMENTATION – A LEVEL PLAYING FIELD?

By Richard J Farnish, CEng MIMechE - The Wolfson Centre for Bulk Solids Handling Technology In recent decades, inventory monitoring systems for silos and bunkers have improved in terms of technology and quality. Such equipment types can be employed to offer indications of material volumes held in storage for equipment that cannot be readily inspected visually. Thus such systems can improve Health & Safety (i.e. no staff access to assess inventory) but also allow the adoption of fully automated processes. Common types of equipment used to monitor storage equipment include radar, ‘dipping’ probes, level probes and load cells. The effectiveness of these approaches is largely dictated by the nature of the installation – with particular emphasis on the discharge behaviour of the silo/hopper/ bunker that is being monitored. The flow pattern that develops within the vessel is key to the level of performance achievable, and in this respect it is important for the reader to understand what can develop. The two main discharge behaviours that can develop in silos and bunkers are as shown in the figures 1 & 2 below, which illustrate these flow patterns in the context of conical silos, but the principles are equally applicable to bunkers. Fig 1: Core (funnel) flow Fig 1, illustrates a discharge behaviour called core flow, where the bulk particulates d i s c h a r g e preferentially down a vertical channel above the outlet. The bulk particulates are fed into the flow channel from the top free surface and the product around the walls remains static until the level descends to the point where it becomes the top surface and discharges. If this discharge behaviour is present, then it can impact on the process in several ways: • The vessel will operate on a first-in, last out stock rotation (which can result in the unpredictable appearance of aged or different material on the process line if the inventory is maintained at a high level for a significant length of time). • An increased variability in bulk density throughout the discharge cycle of the bin may become apparent due to variations in particle packing due to variability in residence time before discharge (recalling that the vessel will draw down freshly introduced material). • If the material blend is subject to surface effect segregation (i.e. tends to separate in such a way that fines enrichment occurs in the central region – whilst the periphery of the vessel demonstrates a lack of fines), then initial discharges from the store will be fines rich (correlating to high bulk density or blend

imbalance) whilst the final stages of the discharge will tend to feature a higher coarse content (low bulk density or blend imbalance). By default, this discharge behaviour is most likely to be found in most processes and equipment types. Fig 2: Mass flow Fig 2 illustrates a discharge behaviour called mass flow. By contrast this type of discharge is arrived at by designing the vessel/equipment to suit the measured flow characteristics of the worst case material to be handled. If this discharge behaviour is present, then the following benefits can be derived: • The vessel operates on a first-in, first-out basis and as such maintaining a high inventory level does not affect the residence time of material being discharged. • Stagnant regions of material are eliminated. • The inventory is drawn down evenly through the equipment – thus providing a degree of recombination of radially segregated bulk particulates. • Discharge can be sustained reliably without resorting to discharge aids. The above (brief) descriptions summarise the principle differences in discharge behaviour between the two types of vessel geometries. It should be borne in mind that although the illustrations show conical type vessels, these discharge characteristics can be found in all other shapes and sizes of equipment. Considering core flow (as this is the default flow behaviour in process plants) it can be appreciated that accurate monitoring of inventory can be problematic for a variety of reasons. The characteristic ‘crater’ that forms during discharge can present issues for radar or ‘dipping’ probes, in that the point at which the respective reading is taken may only represent a height at a single surface radius – thus some calibration would need to be undertaken to allow for the actual gradient (and hence volume) within the vessel. This approach would be further complicated if the material changes (i.e. the gradient may steepen or become more shallow) and introduce an error. Equally if the vessel is prone towards rat-hole formation (i.e. the flow channel empties, but material does not flow into it), then the diameter of the rathole and its height would represent missing ‘capacity’.

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

FURTHER MORE... Such problems of inconsistent surface profile can also develop if the vessel is subject to regions of time consolidated material (cliffs) that occur asymmetrically. Level probes may be considered as an approach to overcome these short comings, but their operation can also be compromised by the characteristic presence of long term resident material on the flanks of the cone into which the probes intrude. This is particularly an issue if the material being stored is cohesive, in which case ‘tuning fork’ type probes will simply indicate that they are covered – even though the vessel has discharged what contents can be reclaimed by gravity (often leaving substantial regions of ‘dead material’ if discharge aids have not been adequately maintained). ‘Paddle type’ sensors can also be vulnerable to build ups of cohesive materials that have consolidated and can, in some cases, simply excavate a ‘cavern’ resulting in a signal indicating an absence of material – despite quantities still being in place. Load cells can also issue spurious information in the event that the vessel contains long term resident material that cannot self-drain. In such cases, it has been known that some companies progressively ‘tare’ systems through a year in order to only monitor ‘live’ capacity (thankfully not with a food grade product!). In contrast if mass flow discharge behaviour is obtained, inventory control becomes a considerably simpler and more reliable proposition. Under such circumstances, the surface profile (the shape of which will be dictated by the bulk materials and the filling method) is likely to be highly repeatable and even throughout the vast majority of the discharge cycle to empty. This makes the detection of the surface and any subsequent initial calibration of systems much simpler and more likely not to require ‘tweaking’ over time. The establishment of a full cross-sectional flow will also avoid the potential problems of rat-hole formation and long term stagnant regions. Thus level probes mounted on the walls of the vessel will actually ‘see’ the true inventory as the level reduces. Similarly, load cells will not need to take account of an unknown and growing mass of long term resident material (all of the inventory will ‘live’ during discharge operations). SUMMARY

In summary, it is widely recognised that without effective monitoring of inventory levels processes can be extremely vulnerable to short falls in feed stock or spillages through over filing of bulk and day bins. However, the influence of the storage equipment discharge pattern is seldom taken into account when selecting monitoring systems – and yet a lack of consideration of this factor is often at the root of a range of process problems (of which monitoring is only one!).

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NEW DMN-WESTINGHOUSE HIGH PRESSURE VALVE BEATS AIR LEAKAGE At the Powtech DMN-WESTINGHOUSE has presented its newly designed HP high pressure rotary valve. This valve has a very important advantage in air leakage: the special configuration of the body and rotor does not only protect product against degradation, it also does not allow any axial air leakage. This means that this valve has an air leakage reduction of one third against other standard high pressure valves. The DMN-WESTINGHOUSE HP rotary valves with specially designed inlet are very suitable for applications in the metering and pneumatic conveying of granular formed products under a high pressure of maximum 3.5 bar g. The configuration of the body, rotor and seals has been specifically developed to minimise degradation of the product which runs through it, whilst retaining the best possible pocket filling efficiency. The HP valves are supplied with a 316 stainless steel body and aluminium end covers, in order to have maximum protection against wear. The standard full end disc rotor is made of 316 stainless steel and has 12fixed blades. Due to the state of the art manufacturing facility, a high accuracy and tight rotor clearances can easily be attained. The end covers have outboard bearings, lubricated and sealed for life. The special construction of the shaft sealing guarantees the lowest air leakage. All models offer optimum venting through the large vent hole, so a maximum product flow into the vented pockets is guaranteed . DMN-WESTINGHOUSE fits SEW drives as their standard. The HP valves are available in 3 consecutive sizes from 200 - 300, covering a capacity range of the rotor from8.3 - 30 litre per revolution at 100% filling. The standard models are suitable for handling products up to a temperature of +80°C and a maximum pressure difference of 3.5 bar. DMN-WESTINGHOUSE have been designing and manufacturing rotary valves and diverter valves for bulk solids handling for more than 45 years. Offering tailor made solutions to the global food, dairy, plastics, (petro)chemical, pharmaceutical, mineral, power and biomass industries, our range comprises a number of universal components suitable for many applications. Additionally we supply components that are USDA Dairy Accepted, pressure shock resistant to 10 bar, flame proof, ATEX 94/9/EC compliant, EHEDG Type EL Class I compliant, etc. For more information Contact: Tonneke Krempel-Caspers, E-mail: t.krempel@dmn-nwh.nl Tel: +31 252 361 800 Web: dmnwestinghouse.com

FULLY INTEGRATED PACKAGING SYSTEMS FROM COPERION – THE COMPLETE RANGE FOR WEIGHING, BAGGING AND PALLETIZING Coperion and Coperion K-Tron are system and equipment suppliers, including extruders, feeders, components, pneumatic conveying and packaging. Coperion’s complete packaging solutions for a variety of industries like plastics, chemicals and food, are easy to operate, very flexible, adaptable to a wide range of products and easy to maintain. Coperion’s packaging equipment is specially designed for free flowing granular bulk materials and includes all required features to reliably manage bulk density variations and cross contamination. These machines combine all functions like weighing, bagging, marking, qualifying and palletising in one single unit. The innovative and modular designs for bagging and palletising are ideal for end of the line material weighing and packaging. With more than 40 locations, 2500 employees and numerous representatives world wide, Coperion and Coperion K-Tron can respond quickly and offer local support where it is needed. For more information contact: Coperion K-Tron Great Britain Ltd, Unit 4 Acorn Business Park Heaton Lane, Stockport, SK4 1AS United Kingdom Tel: +44 (0)161 209 4810 E-mail: info@coperionktron.com Web: www.coperionktron.com and Web: www.coperion.com/ packaging

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PNEUMATIC CONVEYING PERFORMANCE Dynamic Air offers 16 different pneumatic conveying concepts: Each system has its own unique set of operating characteristics for pressure, conveying line velocity, efficiency and performance. Because each and every material to be conveyed reacts differently under a given set of operating conditions, it is critical to match the system operating characteristics to the material to be conveyed in order to achieve the most desired conveying performance and to provide the best value. Dynamic Air’s 16 different pneumatic conveying concepts have the ability to convey at almost any conveying velocity desired to suit a given material to be conveyed. We can convey many materials with conveying velocities as low as.25 m/sec. using our HDP 6000 dense phase pneumatic conveying system and, using our LDP 2000 dilute phase pneumatic conveying system, we can convey at velocities well over 35m/sec. Plus our conveying capacities range from just 100kg of material per hour up to 400 tons per hour and conveying distances exceeding 1500 m in length. For more information contact Dynamic Air Ltd, Milton Keynes, Buckinhamshire Tel: 01908 622344 E-mail: sales@dynamicair.co.uk Web: www.dynamicair.com

BARTON’S SPACE SAVING SILOS Sanko Gosei Automotive Systems has saved considerable warehouse space and significantly reduced raw material costs by installing two aluminium, plastic granule storage silos supplied by Barton Fabrications. The two 3.5m x 12mhigh silos are used to store polypropylene granules used in the company’s automotive parts moulding processes. The50 tonne storage vessels are bulk filled from road tankers and replace large plastic sacks and cardboard Octobins previously used on-site. As part of the installation, the two Barton silos were fitted with load cells and telemetry system. This allows real-time visibility of stock levels and usage by both Sanko Gosei and the raw material supplier, which in turn simplifies management of the company’s plastic granule consignment stock. Commenting on the benefits of the decision Two Barton silos installed at to move to silo storage, James Bradley Sanko Sanko Gosei’s Skelmersdale Gosei’s Production Engineering Manager site said: “As part of our Kaizen process, we were tasked with removing waste from our warehouse. We identified two materials as high use with good potential for improvements in materials handling and storage. The decision to install two storage silos has allowed us to save significant warehouse space. Additionally, we have reduced both fork lift truck movements and the need to dispose of plastic storage sacks &amp; cardboard Octobins. “We have also lowered direct materials costs by buying in bulk and our surcharge / transport costs are less. We are absolutely delighted with the new Barton silos and were very happy with the whole installation process” The Sanko Gosei project is the latest Barton Fabrications installation that supports the supply of plastic moulded parts for the UK’s automotive industry. For more details on Barton Fabrications’ silo solutions, contact Mark Barton:Tel: +44 (0) 1275 845901 E-mail: sales@bartonfabs.co.uk Web: www.bartonfabs.co.uk

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

EFFECTIVE, INNOVATIVE EXTRACTION

MHEA ANNOUNCES BULKEX16 The Materials Handling Engineers Association is proud to announce the dates for its annual BULKEX conference. BULKEX16 – to be held again at the prestigious Harrogate International Centre, will take place on the 5 th and 6 th October. The two-day event is aimed at professionals, organisations and academics from across the bulk materials handling world. Michael Kaye, the new President of the Materials Handling Engineers Association, believes the 2016 event will build on the success of BULKEX15 and will be the biggest and best event in the MHEA’s 78 year history. Those wishing to make extra impact can take advantage of a BULKEX16 sponsorship package. From ‘Headline’ gold sponsorship and silver sponsorship to bronze sponsorship, hospitality ;and paid-for advertising, BULKEX16 will offer a range of sponsorship opportunities to suit all budgets. Companies looking to exhibit at the event or to find out more about sponsorship, can contact BULKEX16 event’s team on 01787 226995 (ask for Teresa or Julie). For further information please visit the BULKEX16 website at www.mhea.co.uk/bulkex16

Dust Control Systems Ltd specialises in providing dust and fume extraction solutions across many industries, including major projects in solids handling, food and beverage, pharmaceuticals, vehicle manufacture, and the waste recycling sector. Saving energy and increasing production efficiency, while ensuring a safe working environment, are key requirements of most processes and the company’s reputation has been built on its ability to provide the most suitable and cost-effective solution, whatever the project. DCS aim to improve their customers’ profitability by providing the best in current filter technology, significantly reducing energy usage with the Ecogate ® extraction optimisation system, and ensuring that expectations are met by focusing on system reliability. The DCS commitment doesn’t end there, but extends through lifetime service programmes customised to meet customers’ specific needs. To assist companies with compliance on COSHH Regulations, DCS also offer comprehensive LEV(Local Exhaust Ventilation) testing and examination packages that include inspection and service to ensure extraction systems continue to comply with regulations. For more information contact Dust Control Systems Ltd, Tel: 0800 040 7116 E-mail: sales@DCSlimited.co.uk or visit www.DCSlimited.co.uk

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

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Guest Article

IMPROVE MANUFACTURING

FLEXIBILITY

By Richard Lockwood, Business Development, Manager Food, Matcon Ltd The increasingly complex and challenging nature of the recipes that consumers demand today mean manufacturers need to adapt in order to survive. How can manufacturing methods be improved to satisfy these customer needs whilst also balancing product quality, safety and production costs? A modern Lean philosophy combined with the right technology can revolutionise profitability and the agility of manufacturing to quickly react to changes in market demands. In this article, we examine how a production system using Intermediate Bulk Containers (IBCs) can offer total recipe flexibility, reducing lead times and controlling Inventory levels.

SO WHAT IS YOUR WEAKEST LINK? In-line process systems by their design are linear – the raw materials enter the process in the Formulation Area before the final product is delivered out of the far end of the process line. No matter whether it is a 500kg or 10 ton production run, of a particular recipe, the same approach and the same equipment will have to be used. The problem here is that the process line will only be

again whilst Packing is completed. This results in an inadequate OEE (overall equipment effectiveness) rate both for individual equipment as well as the process line as a whole. With ever increasing consumer demands resulting in recipe proliferation, this means that ever more frequent recipe changes further destroy the effectiveness of this conventional way of processing. So much down-time is spent ‘cleaning’ between recipe changes, particularly where cross-contamination is a real risk. In an attempt to keep all the processes moving, some companies resort to creating large quantities of WIP/WIQ (work-in- progress/ work-in- queue) which is costly to store and runs the risk of going to waste.

INCREASE EFFICIENCY BY 300% An efficient way to work is to apply a parallel processing approach whereby batches are handled through the ‘process line’ all at the same time. Does this sound alarming from a safety standpoint? It shouldn’t do if the appropriate technology and a well system design is used. Parallel Processing means separating off the process steps (decoupling) so that Formulation, Blending, Packing and Cleaning take place simultaneously. IBCs (Intermediate Bulk Containers) are used to transport materials throughout the production processes, which enables them to operate independently and be continuously fed with

Separate Mixing

as effective as its weakest link. There are typically vast arrays of processes that happen along the way, from dispensary & mixing, to sieving packing, and in some cases, more complex processes such as granulation and drying are also involved. It is almost impossible to have all these processes completely synchronised, so as a result, there is a lot of waiting time between one process and another. Mixing and Packing stand idle whilst Formulation of the recipe takes place. Then the Mixer remains inactive

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IBC Blender

product, giving good OEE rates. The IBC itself becomes the blending vessel so there is no product contact with the blender, which means no down-time for cleaning between recipe changes. In fact, IBCs are cleaned off-line so do not disrupt the manufacturing time and process line flow. Some IBC systems have high containment levels as the system remains fully closed at all times so there is no risk of cross-contamination or dust generation, which in combination with the fact that no product comes into contact with the blender, means that several different recipes can be processed at the same time without compromising safety – a key benefit By adopting the parallel processing concept, rush orders can easily be fitted in to the production schedule, enabling rapid response to customer demands. OEE rates can increase from a very low 15-20% to 75-80%, generating significant additional revenue per annum. The right IBC system offers a Lean solution ensuring ‘right first time’ production, reducing scrap and waste and reducing the cost of the final finished product. With an additional contribution towards Sustainability goals through reducing waste.

A STAGED APPROACH TO PROCESS IMPROVEMENTS If you are not in a position to make a full-scale switch to an IBC System in one go, it is certainly possible to take a ‘staged approach’. The modular nature of the design allows for equipment to be added into the system as the need arises. Typical changes made by our customers have been to: • Decouple mixing from packing - this can double the capacity of either or both pieces of equipment in these areas. No longer does packing and blending have to wait for each other to complete their processing, but by decanting the mixed product from the fixed Mixer into an IBC, it means that the Packing lines can be continuously fed with product whilst the new batches are formulated and mixed. This rapid emptying of the Mixer results in reduced turnaround times and increased throughput. • Decouple raw material batching/dispensing from mixing – decoupling these operations typically increases available process time (and thereby efficiency) by some 50% or more. Formulating recipes into IBCs offline then using these to fill the fixed Mixer speeds up the loading process significantly. • Replace static mixers for premixing - high volume

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

Guest Article

production lines benefit operationally from pre-mixing the micro and minor ingredients. Static mixers have exceptionally poor OEE in this application, often involving double bag handling for both filling and emptying such mixers. An IBC Blender can be used to create a pre-mix offline. The IBC can then be used to dose directly into the fixed Mixer. A Matcon IBC contains the unique Cone Valve technology which ensures the mix does not become segregated on transfer due to product being discharged with mass flow not funnel flow. • Replace static Mixers with IBC Blending - By installing an IBC Blending System, all idle time is eliminated. Recipe formulations are prepared offline into IBCs then taken for blending. Because the IBC is the blending vessel there is no need to clean-down between recipes so any recipe can be run at any point in the production schedule. In fact, multiple recipes can run at the same time without risk of cross-contamination. Packing lines are continuously fed with product, with one IBC Blender able to supply up to 4-5 packing lines, allowing for different packing formats to be accommodated in one batch run.

THE MARKET IS MOVING ON, ARE YOU? Both large multinational manufacturers and smaller SMEs have embraced IBC system design. A leading spice blends contract manufacturer is now able to hygienically handle their portfolio of over 1,000 flavouring mixes and achieve a consistent 3 day ‘make to order’ regime without creating costly inventory by utilising an IBC system.

Premixing using IBC’s

Bakery manufacturer British Bakels installed an IBC System to produce their high variety, low volume product lines which sits alongside their fixed mixing system that is producing the high volume, low variety lines. This additional line has cut cleaning time between recipes from 480 to 70 man hours, released £175,000 of cash due to less Inventory, reduced labour costs by25%, cut manufacturing time in half as mixes with fat are done as ‘single-stage’ mixes and enabled the company to expand their product range to meet changing consumer tastes. Indeed, the IBC- system has enabled British Bakels to develop their gluten-free range of bakery products. Simon Dawson, Operations Engineering Manager said “we can now offer an enhanced product range, better flexibility of pack sizes, along with significantly enhanced quality assurance and customer service.” Hero, an Infant Nutrition manufacturer now uses IBC Blending to add micro/minor ingredients as a pre-mix. They had been using a horizontal ribbon mixer to blend the pre-mix and whilst the actual blending time was just minutes, the ribbon blender had to be supervised by an operator, took hours to fill and empty and demanded 1-2 hours for a full-clean down. This resulted in the pre-mixing stage being painfully slow and labour intensive with large amounts of down-time between different batch runs. The system limited production capacity and flexibility. The answer was to use IBC Blending for the pre-mix, which removed the need for cleaning the ribbon blender between batches, thereby dramatically increasing capacity and eliminating the bottleneck issue. They were able to double their production capacity, whilst achieving a 30% reduction in stock, save 1000 man hours of cleaning and reduce lead times. If you have a wide portfolio of recipes or need to produce smaller batch runs, tailor-made to your customer’s needs it might be worth considering what an IBC system could offer you.

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

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Guest Article

HEAT:

THE FORGOTTEN ELEMENT OF ANAEROBIC DIGESTION By Matt Hale, International Sales Manager, HRS Heat Exchangers Anaerobic digestion (AD) produces many valuable and useful products, including biogas (which can then be turned into heat, electricity or biomethane gas) and digestate, a biofertiliser rich in nutrients and organic matter. However, many farm AD plants also produce incidental heat, which can be captured and used within the AD process or for other on-site operations. Wasted heat is becoming increasingly important, not only from an economic point of view, put also politically. In the UK the Renewable Heat Incentive is the key policy driver to encourage the utilisation of heat from renewable sources, including incidental heat from the AD process, while some European countries now specify targets for the use of heat from AD plants.

SOURCES OF HEAT

Surplus heat produced by biogas combustion in a combined heat and power (CHP) unit is the most common heat source within an AD plant. Other processes which result in residual, usable heat include: • Digestate pre-heating • Digester heating (especially in summer when less heating is required) • Pasteurisation (either before or after digestion) • Electricity generation (e.g. via CHP) • Biogas upgrading to biomethane (heat is required for the process, but up to 75% of it can be recaptured and reused) • Digestate concentration For example, a minimum temperature of 70oC may be required for pasteurisation, leaving 30-40oC of ‘left over’ heat, which has historically been wasted to the atmosphere. This heat could instead be put to good use elsewhere within the AD process. Equally, heat left over from concentrating digestate could be used within pasteurisation.

WHAT IS A HEAT EXCHANGER?

Heat exchangers take heat from one process or place and transfer it to another. In practice, they allow the heat from a liquid or gas to pass to another liquid or gas without the two having to mix together or come into direct contact. Common everyday examples include domestic radiators (which transfer heat from a boiler to a room) and car radiators (which take heat away from the engine). Heat exchangers are used for numerous applications, including space heating; cooling; air conditioning; sewage treatment; food processing; and in chemical industries. Increasingly, their potential role in the anaerobic digestion sector is being recognised, with more plants specifying their inclusion at the design stage or retrofitting them, either to improve overall process efficiency or to use heat which would otherwise be wasted.

TYPES OF HEAT EXCHANGER

There are different types of heat exchanger and it is important that the right type is selected for a particular application. Two of the most common types in use today are Plate Heat

Exchangers and Tubular Heat Exchangers. However, within these broad categories there are many different models and refinements and it is important to understand what is being offered. It is therefore advisable to consult a specialist who can explain the benefits of different types and perhaps offer different solutions. For example, viscous fluids such as digestate can quickly foul tubes and surfaces. For this reason, scraped surface heat exchangers are usually recommended, as they will constantly remove such fouling. However, another option is to use a tube design, which will minimise fouling in the first place. HRS corrugated tube heat exchangers are designed so that the constant swirling of the fluid in the tube prevents sediment and clogging. Whichever system is proposed, it is important to compare running costs, including maintenance and cleaning, over the full life of the plant – downtime caused by regular dismantling or cleaning can quickly eat into any capital savings made at the time of purchase.

POTENTIAL USES FOR HEAT IN THE AD PROCESS

So, having identified a source of heat, what can be done with it? There are a number of options with the AD process, including: preheating feedstock, which can help to speed up the digestion process or improve gas production; for pasteurising, for example to meet PAS 110 requirements for digestate or to ensure crop hygiene; and to improve the quality and reduce the volume of digestate. Using surplus heat in an HRS Digestate Concentration System (DCS), for example, can reduce digestate volumes by around 60%, bringing significant savings in storage, transport and application to farmland, while retaining all the nutritional benefits. Finally, using waste heat to upgrade biogas to biomethane, for use as a transport fuel or for injection into the gas grid, is also becoming increasingly common and helps to fulfil AD’s potential as a diverse energy source. What’s more, depending on the exact technology used, as much as 75% of the heat used for biogas upgrading can then be recovered.

OTHER USES FOR HEAT

Captured heat can be used almost anywhere, provided that it is economically and practically feasible to transfer it. Even

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

low temperature water can be used to reduce the amount of additional heating required, for example by a boiler. There are many uses of heat at an AD plant whether it’s farm or food based. For farms, heat can be used for space heating of greenhouses and polytunnels to drying crops or biomass fuels. Many livestock buildings require heat, particularly for pig and poultry production, and where farms have diversified to create office or business centres there is often the scope to install district heating systems. And at a food plant, heat can be used for space heating and cooking, to heating liquids to aid processing as well as pasteurising and sterilizing foodstuffs. In other parts of the world more unusual uses for heat have also been seen, such as aquaculture for fish production; further electricity generation through the use of Organic Rankine Cycle (ORC) technology and Kalina Cycle low temperature generation systems; or transporting heat in containers which utilise latent heat storage technology. With careful planning and a long term approach which considers the full life of an AD plant – not just initial purchase prices – the individual heat loads of each process within an AD operation can be greatly reduced by using recaptured heat, resulting in improvements in both efficiency and product quality.

AN ENDLESS CYCLE?

It may be tempting to think that you can keep recapturing the heat used over and over again, but unfortunately, this isn’t possible. However, what is possible is to reuse some of the leftover heat to improve operational efficiency. Systems which do this, such as an HRS digestate pasteuriser, can often deliver efficiency savings of 40% or more compared to traditional pasteurisers without heat recovery. With careful planning and a long term approach which considers the full life of an AD plant – not just initial purchase prices – the individual heat loads of each process within an AD operation can be greatly reduced by using recaptured heat, resulting in improvements in both efficiency and product quality.

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

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PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

Guest Article

NEW SERIES-E IRIS DIAPHRAGM VALVE FROM MUCON Those of you that have utilised Mucon Iris Diaphragm valves over the past sixty years they have been on the market, will have doubtless noted that, at least in the manually operated form, it is possible to vary the diameter of the valve’s orifice almost infintiely between fully closed and fully open. Over this period Mucon has developed and launched a number of powered versions of the Iris Valve including the well known Series-E Iris Diaphragm Valve. Historically, in order to both control and monitor the position of these powered valves they have been fitted with open and closed limit switches and one, or perhaps two, intermediate position switches somewhere in between; often referred to as the ‘trickle’ position. More recent developments including the Series K2P and A2P Iris valves have improved the ability to vary the diaphragm orifice still further by providing a pulse generator switch; offering the end user the ability to programme up to thirty positions between fully open and closed. Once programmed, the controller can utilise any 4-20mA or 0-10V input signal to give direct, closed loop, control over the open diameter of the valve orifice. When this control module is used in conjunction with a powered Mucon Iris Valve, feedback from a weigh scale can be used to slowly close the valve as it approaches the target weight or in the case of a mill the feed rate can be controlled in real-time, based on an interpretation of the load on the drive motor. The module also monitors torque and can be programmed to gently push to a closed position whilst protecting the motor from damage; we believe this will allow us to apply electrically powered Iris Valves to applications like big-bag neck choking, amongst many others. If you want to know more about this story or the products and services offered by Mucon you can contact us in the following ways: Tel: +44 (0)1625 412000 E-mail: sales@mucon.com Web: www.mucon.com

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

STARCLEAN BELT CLEANING REVOLUTION ARRIVES ProSpare has launched a new, unique product which tackles the challenges of belt cleaning in a completely different way to traditional belt scrapers. FE Schulte Strathaus & Co KG have been at the heart of changing the way conveyor belts are cleaned across Europe, but their ground breaking new system has not been available in UK or Ireland - until now! ProSpare are pleased to announce that a new Distribution Agreement was signed at Bauma, the worlds largest construction equipment exhibition, officially appointing ProSpare as sole stocking distributor for Starclean belt cleaning systems in UK and Ireland. Starclean conveyor belt cleaners are recognised as a huge leap forward in belt cleaner design: Twist-swing solves the problem Separate Starclean blade segments are tensioned onto the belt individually using the ingenious “twistswing” design. Optimum belt contact pressure is maintained as each blade segment automatically compensates for different wear rates independently of the others. The result is a gentle cleaning action which is more effective, protects belts and reduces blade wear rates. Fastest, simplest maintenance Starclean quick-release tensioning devices combined with quick-change, slot-in blade design has changed belt scraper maintenance forever. Likened to a F1 pit stop, in-house site staff can carry out maintenance in minutes without the need to call in expensive specialist contractors, leading to substantial savings. James Bullock, MD of ProSpare commented: “Through our close cooperation with TBK Group, we have been growing sales of conveyor components such as Spill-Ex skirt sealing, Friflow Impact beds and Centrax belt trackers, but we were repeatedly asked for belt cleaning solutions. Starclean completes our range perfectly and we now offer a strong one-stop conveyor belt solution. We are very pleased to have teamed up with one of the most respected belt cleaner manufacturers who offer a market leading product which ideally complements our existing range”

If you experience belt cleaning problems, more information about Starclean belt cleaners or the rest of their conveyor components range can be found on the www.prospare.co.uk

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MILLING TECHNOLOGY SELECTION FOR PARTICLE SIZE REDUCTION By British Rema The selection of the most appropriate milling technology for a particular application is not always straight forward and the most appropriate answer is not always the most obvious. Failure to identify feasible alternatives can be extremely costly over time. Identifying these alternatives often requires trials, not theory, and a potential purchaser of either equipment or processing services needs to ensure that their chosen supplier can advise and conduct trials across the appropriate range of alternative techniques. The controlled reduction of the particle size of solid materials is a process required in many industry sectors, and is applied to an astonishingly wide range of materials from inhalable active pharmaceutical powders through food ingredients and fine chemicals to large-scale mineral processing applications. Not surprisingly, there are different technologies available on the market to meet these challenges, exhibiting different combinations of capability and cost (both capital investment and running costs). Some tasks can be carried out using more than one technique, the choice becoming a trade-off between the required performance (usually expressed as an output particle size distribution and throughput) and cost. Some materials require different techniques depending on the input particle size and/or shape, and the inexperienced can be surprised to find that the same material chemistry-wise may mill much less efficiently (or not at all) on a particular mill type in one physical format (eg extruded product) when the same mill type was quite effective on a different product format. Handling heat sensitive materials, such as polymers with a relatively low softening point(typically a function of its chemical composition, molecular weight and glass transition temperature), can also be problematic, but the cost implications of failing to recognise that the conventional cryogenic milling solution (1) may not actually be required for the particular task in question can be profound.

majority of milling applications in one form or another are as follows:

AIR MICRONISERS Air micronisers (or “jet mills”) are used to grind a wide range of materials, particularly where the feed material is already relatively fine. The technique relies on particle-on- particle impact to break down the material, having been introduced into what are very high speed air jet streams inthe body of the mill. There are two types of jet mill: (i) a spiral flow jet mill which is commonly jet mill which can handle harder materials (up to 10 on the Mohs scale (3) with classification achieved by means of a high speed rotor.

ROTARY IMPACT MILLS Rotary impact mills, also known as beater mills, use high-speed rotors with a rotor tip velocity of up to 120 m/s. Grinding takes place through the impact of the powder particles on the rotating and fixed grinding surfaces. Typically used for softer materials of up to 3 Mohs hardness, an impact mill provides an operationally cost-effective solution when hardness and particle size parameters fall within its range.

ASSESSING THE TASK

BALL MILLS

As a supplier of a wide range of equipment and an experienced operator of all the equipment types in our own plant as a contract processor, in our experience there are three key pitfalls to be avoided: 1. Don’t take the specification for granted – the first step with customers who arrive armed only with a numerical specification (eg “d50 < 12 microns”; or “100% < 50 microns”) (2) of this specification. Not only are there different definitions of what, say,“d50” means, but different measurement systems can also yield very different results. 2. Don’t over-specify the end product – having established that a particular particle size distribution of a material has the required functionality in application, it can be worthwhile exploring its specification limits. Sometimes a relatively small relaxation of one parameter can have a substantial impact on the milling performance or efficiency and can, in extremis, enable the switch from one technology to another. Working with an unnecessarily stringent specification might suit the equipment or service provider as it will be more costly, but it is not in the best interests of the customer, and some careful work to define what the specification limitations truly are can pay dividends in the long run. 3. Don’t presume you know the answer – try it! Be sceptical of a supplier who quickly and confidently tells you what the right solution is going to be.

Ball mills, and other forms of tumbling mills such as tube mills and rod mills, comprise a cylindrical shell slowly rotating around a horizontal axis, partially filled with a grinding medium(such as ceramic or steel balls) to which the material to be milled is introduced. Typical in the ores, minerals, paints and general chemicals industries, ball mills can be designed to operate continuously (fed at one end and discharged at the other), or on a batch basis. Each of these mill types can then be combined with external classifier stages, with or without feedback, to create an overall process that is as efficient and cost-effective as possible.

TECHNOLOGY TYPES There are several different underlying technologies used for milling, and then a multitude of variations and hybrids. The common underlying technologies which, between them, address them a

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CASE STUDY In expanding its operations to the European market, a global manufacturer supplying resin powders for use in composites and membranes for the aerospace, electronics and other hightech industries, approached British Rema to address its milling requirements. These end applications demanded a highly-regulated quality control environment and the customer had previously used cryogenic grinding followed by a screening process to achieve the particle size distribution. Although ultimately achieving the required results, the use of liquid nitrogen required complex enclosed systems and the application of stringent health and safety procedures. Rather than presume to replicate the existing methodology, British Rema recognised that, in this particular case, cryogenic milling may have been unnecessary, and British Rema’s solution was to use its classifier mill, albeit especially adapted for the purpose. Classifier mills are a type of rotary impact mill (referred to above)

which have the benefit of being a single machine with an integrated impact mill and classifier in the one housing. The CLM mill is commonly used for multi-stage, closed loop grinding and is ideal for products with properties of a more challenging nature and/or requiring a tightly controlled particle size distribution (see figure 1). This process achieved the desired particle size but, importantly, processing costs were significantly reduced. In addition, the stringent health and safety precautions associated with theuse of liquid nitrogen were no longer required.

CONCLUSION The selection of the most appropriate milling technology for a particular application requires experience, trials and an open mind. A failure to identify feasible alternatives can be extremel costly over time. Unnecessary over-specification of the finished product can also lead to higher costs than necessary, and a close, collaborative working relationship between customer and supplier is needed to develop the optimum long run solution to any particle size reduction project.

Figure 1 – British Rema Classifier Mill

The classifier mill works on a four stage process as shown in the diagram: Stage 1 The material is introduced into the mill via the primary air feed where the material is mixed with air, thereby minimizing the risk of agglomeration. Stage 2 The material enters the grinding chamber where grinding takes place in the same way as a conventional rotary impact mill. The secondary air inlet further aerates the product and provides the option to introduce chilled air if the material has a low melting point. Stage 3 The milled material passes into the classifier wheel. Material of the desired size passes through whilst oversize particles are rejected and pass to the next stage. Stage 4 The rejected oversize material passes to a separate section of the grinding wheel where it is ground separately from the in-feed material and then once again directed to the classifier wheel.

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

TWO NEW KEY APPOINTMENTS AT BRITISH REMA Powder processing specialist British Rema has announced two new appointments which will further strengthen the company’s service to customers. Dr. Richard Mellor has been appointed Technical and Quality Manager, joining the company with years of experience in the development and supply of new materials. James Bell has been named Engineering and Safety Manager and brings extensive experience gained in the health and safety arena for a number of wellknown organisations. Dr. Mellor has both a scientific grounding in, and a practical experience of, powder application. He will work closely with British Rema’s in-house design engineers and trialling and laboratory facilities to optimise customers’ powder specifications from both a functional and processing point of view. He has previously worked on supply and development projects throughout the world including for the defence departments of the UK and the USA. Until recently he was Technical Director for Purification Products where he was instrumental in the company receiving the Queen’s Award for Export. Mr. Bell joins British Rema from a blue chip company where he was responsible for fire and emergency safety across four of the company’s manufacturing sites. He previously spent 24 years in the Royal Navy as an air traffic control specialist. At British Rema he will be responsible for developing internal process improvements in both health and safety and engineering, including the implementation of preventative maintenance programmes that are integrated into the overall supply chain management systems of British Rema’s core aerospace customers. For more information contact British Rema Process Equipment Ltd. E-mail: info@britishrema.com Web: www.britishrema.com

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. The new device has an ultra-wide dynamic range, which means even foaming, turbulent product surfaces, condensation, or antenna build up have little or no effect. 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

Made in Britain

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

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BULK BAG LIFTING FRAME WITH ADJUSTABLE ARMS Flexicon has introduced a new bulk bag lifting frame with telescoping arms that accommodates bulk bags produced in an increasing range of sizes. The lifting frame is optional on all BFC models of Flexicon’s BULK-OUT ® discharger line, and available for up to two tonne capacities to replace conventional lifting frames of any make or model of discharger that employs a hoist to position and suspend bulk bags. The telescoping arms can be adjusted using clevis pins and safety clips to a range of settings to accommodate bulk bags from 81 to 119 cm square at the upper sew seam. This adjustability also allows the lifting frame to work safely with rectangular bags. Available in carbon steel with durable industrial coatings or stainless steel to industrial or sanitary standards, the adjustable frames are equipped as standard with Flexicon’s patented Z-CLIP™ strap channels that hold the straps securely while allowing rapid insertion and removal. Other dischargers offered by the company include BFF models with a lifting frame for forklift loading of bulk bags, low-profile BFH half frame models that require a forklift or plant hoist to suspend the bag during unloading, and BFX split frame unloaders that allow loading of the upper frame on the plant floor, and then forklifting it onto the sub frame within several centimeters of the ceiling. The company also manufactures bulk bag conditioners, bulk bag fillers, flexible screw conveyors, tubular cable conveyors, pneumatic conveying systems, bag dump stations, drum/box/container tippers, weigh batching systems and engineered plant-wide bulk handling systems with automated controls. For information contact Flexicon Europe Ltd, Whistable, Kent Tel: +44 (0)1227 374710, E-mail: sales@flexicon.co.uk, Web: www.flexicon.uk.com 16sp

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

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