Process Industry Informer May 2016 by Process Industry Informer

www.processindustryinformer.com

MAY 2016 Volume 12 No.3

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

SRVs

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

CONTENTS. 4-5 News & Events 6-8 Applications 8 Lubricants 9 Drives & Controls 9 Inspection & Vision Systems 13 Health & Safety 13 Spectrometers 18-22 Fluids & Liquids Handling (incl. Pumps & Valves) 37 Process Control 39 Heat Transfer & Energy 41-45 Process Measurement & Instrumentation 47 Products & Services Suppliers Directory

WHY E-COMMERCE IS NOW A MUST HAVE IN AUTOMATION

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

25 BPMA News

MARGINAL GAINS

SAFETY RELIEF VALVES: PURPOSE & FUNCTION

DOING YOUR LEVEL BEST

WHY YOU DON’T ALWAYS NEED A WELL OILED MACHINE

EFFICIENT STEAM FILTRATION HELPS INDUSTRY

EFFICIENT DATA ACQUISITION

SPEED CONTROL EVOLUTION FOR THE INDUSTRIAL & DOMESTIC SECTORS

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MAKING THE CONNECTION

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

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NEWS & EVENTS CHANCELLOR ANGELA MERKEL & PRESIDENT BARACK OBAMA VISIT RITTAL STAND AT HANNOVER MESSE 2016

US President Barack Obama and German Chancellor Angela Merkel paid tribute to the extraordinary innovation and commitment to future talent development shown by the Rittal company during a recent state visit .

Both the corporation’s new “Blue e+” generation of cooling units - which set new standards for energy efficiency – and its ongoing investment in young trainees impressed the President and Chancellor Merkel on the opening day of the Hannover Messe 2016. The USA was selected as this year’s partner country for the Hanover expo, which is now the world’s leading trade fair for industrial technology. Rittal currently equips some of the largest data centres in the world. “We are Europe’s number one provider of engineering software, and we want to keep on growing,” says owner and CEODr. Friedhelm Loh, who also highlighted to both leaders theimportance of software and data in future industrial production. The US President showed considerable interest in the new Blue e+cooling unit, commenting at one point; “This is a fine company!” Chancellor Merkel, meanwhile, appeared particularly enthused by the Friedhelm Loh Group’s commitment to training young, up-and-coming, talent and she also spoke warmly of Rittal’s determination to integrate refugees into its regular training programme – a first in Germany. Rittal in the United States Rittal has set ambitious goals for itself in the United States with plans to double its sales in this important market over the next few years. “We have been active in America for more than 30 years, and are particularly proud that 85 percent of our products are made in the USA”, stressed Gregg Holst, President of the Rittal Corporationin the United States. Rittal currently employs 750 members of staff at its US operations, which are headquartered in Chicago. Further information at Web: www.rittal.co.uk www.friedhelm-loh-group.com, or on twitter @rittal_ltd.

BABCOCK WANSON COMPLETES MAJOR EUROPE WIDE REBRAND Babcock Wanson, a leading international supplier of products and services for industrial boiler houses and process heating needs, has undergone a complete rebrand to represent and support its position in today’s marketplace.

The new brand maintains links to the company’s proud heritage but shows Babcock Wanson as the modern, forward thinking group of international companies that it has evolved into. The bison logo, which has been part of the company’s branding for more than 50 years, is indicative of business with power and drive that forges ahead has been redesigned to appear even stronger and fitter for the future. The new stylised bison is actually combined with the tail of a comet to indicate both movement and energy; it’s an unusual idea but one that has worked well due to the contemporary nature of the new design. The new Babcock Wanson colour scheme consists of a bright eye catching blue which links to the previous blue colour scheme, limited use of black plus a fresh new orange to represent power and heat, as well as a connection to the environment and earth. Chris Horsley, Managing Director of Babcock Wanson UK, comments on the rebranding exercise: “Our new logo has been designed to express Babcock Wanson’s core values; which are to think and act on a long term basis, to focus on efficiency and to help our customers make the best choice to meet their needs. We also wanted to convey the history and pedigree of the company as this is an important indicator of Babcock Wanson’s expertise and knowledge of the marketplace. “Furthermore, the Europe-wide companies that make up the Babcock Wanson group are now more closely aligned than ever before, so it is important we better show ourselves to be an international and united organisation. “Each component of the rebrand has been carefully selected to represent our desire to be recognised as a reliable, modern and forward thinking company that works with its customers to a common goal.” Research on the direction of the new branding was undertaken across Babcock Wanson’s European operations. For more information contact Babcock Wanson on Tel; 020 8953 7111 or Email: info@babcock-wanson.co.uk or Web: www.babcock-wanson.co.uk

EMERSON ENHANCES DIGITAL WHITELEGG MACHINES PRESENTS VALVE CONTROLLER SOFTWARE TO MAJOR PRESENTATION AT DRIVES & CONTROL SHOW INCLUDE PROFIBUS PROTOCOL The addition of DTM software extends FIELDVUE™ instrument’s monitoring and diagnostic capabilities and enables Emerson to support an installed base of 32 million PROFIBUS devices.

Emerson has enhanced the software for its Fisher™ FIELDVUE DVC6200 series digital valve controllers, which are now available for use by process industries with PLCs and PROFIBUS communications as the dominant protocol. The FIELDVUE DVC6200p digital valve controller with Device Type Manager (DTM) software supports control valve start-up, commissioning, and diagnostic activities. It has also been tested and integrated for use with multiple Field Device Tool (FDT) host systems. Industries including food and beverage, water and wastewater, pharmaceutical, pulp and paper, and metals and mining will find value in the FIELDVUE DVC6200p DTM instrument’s intuitive interface. Available in a variety of materials including stainless steel, the device comes with mounting kits to accommodate different actuators. Mounting kits can be re-used in upgrades to existing FIELDVUE instruments. For control valves located in critical or hazardous areas, the FIELDVUE DVC6200p may be remotely mounted to enhance its performance in harsh process conditions such as high-heat or vibration. Utilising Human-Centred Design concepts, the FIELDVUE DVC6200p DTM has several features that simplify control valve set-up and monitoring. Its intuitive set-up, auto-calibration, and simple tuning features save time during commissioning. With the failsafe option, users can set the instrument to hold its last value or position to actuator fail, based on control valve process needs. For more information about Fisher FIELDVUE products and capabilities, go to www.EmersonProcess.com/fieldvueDVC.

Together with partners, Schleich Gmbh, Whitelegg M a c h i n e s of Crawley presented a comprehensive array of advanced motor testing and condition monitoring equipment.

Spread across 6 workstations, visitors had the opportunity to view hands-on demos of both off –line and on-line motor testing and analysis. The range on display included the portable Motatest 2, an economic and multifunction tester for many AC and DC tests for motors and windings up to 375kW. For testing operational (online) motors the Dynamic Motor Analyser monitored the motor, power supply and load with automatic calculation of efficiency, torque, performance, harmonics, transients and many more. Also suitable for variable speed drive motors. This year sees the launch of the MTC2 Surge Tester offering partial discharge testing to EN60034-18-41 and incorporating a voltage analyser which measures the rise time and voltage at a motor’s terminals. The new MTC3 is the only Fully Automatic Production Tester, fully configurable and incorporating, amongst other tests, Surge, AC testing and partial discharge. The market for electrical white and brown good’s testing is addressed by the new GLP2 Basic, a highly flexible multiple tester for safety and operational integrity in production, lab, test bench and QA environments. Whitelegg are UK and Ireland sales and service and calibration agents for Schleich.

For more information contact Whitelegg Machines Ltd, Crawley, Surrey. Tel: 01293 526230 E-mail: info@whitelegg.com / Web: www.whitelegg.com

PROCESS INDUSTRY INFORMER May 2016

NEWS & EVENTS TRANSDEV WAS THE POWER IN MOTION AT DRIVES & CONTROLS 2016

TransDev exhibited at the bi-annual Drives & Controls 2016 Exhibition at the NEC in April. Our

stand at 40 square metres provided us with the perfect platform to showcase what we do and how we help a wide audience of OEMs, trade, distributors and end-users. This was the first time for several years that TransDev have exhibited and we enjoyed meeting customers old and new, as well as those who wished to learn more about our 50 year old business. New branding and comprehensive literature redesigns were on show alongside exciting hands-on product displays, including an exclusive Continental belt driven electric bike as well as a six axis robot from ST Robotics featuring SYNCHROCHAIN pulleys and belts. As the UK member of MULCO (the organisation representing major PU brands) visitors saw world class PU belt technologies from German manufacturers, such as BRECO and ContiTech. We also showcased new brands such as BRECOFLEXmove®, CONTI-V® FO Pioneer and our own Transflex rubber belts. We were delighted to showcase a new product from our partners ContiTech®. CONTI FO Pioneer Timing Belt Raw-edge V-belt from ContiTech: more power, longer service life. Raw-edge V-belt on basis of ethylene propylene diene monomer rubber (EPDM) Our Special Belts were on display and took centre stage on the stand. These are manufactured at our factory in Poole and cover everything from special profiles and flights to backed belts, draw-down belts, jointed and extra wide belts. The possibilities, like some of our belts, are endless and we are experts at delivering the most complex belting solutions, within microns of pitch accuracy. Chain brands such as Wippermann, TYC and Witra® plus hardware, gears, sprockets and pulleys all ensured that customer’s power transmission and conveying needs were fully covered in one place. As a major pulley, gear and sprocket manufacturer we can discuss standard and custom requirements and can work with customers to develop drive solutions for a vast array of applications. NEW TransDev Range Catalogue Visitors to our stand also browsed our new Range Catalogue via an installed iPad, with some stronger visitors taking on a copy there and then! ‘The Beast’ as it has become known is our biggest Range Catalogue ever at 864 pages. For more information contact TransDev, Poole, Dorset. Tel: +44(0)1202 675 555 E-mail: gdale@transdev.co.uk Web: www.transdev.co.uk

PROCESS INDUSTRY INFORMER May 2016

BYWORTH BOILERS WINS QUEENS AWARD A leading boiler manufacturer has won a queen’s award for enterprise in innovation for its market leading unity boiler management system, based on ABB control equipment.

Byworth Boilers, based in Keighley, West Yorkshire, produces a range of boilers for industries such as pharmaceuticals, brewing and distilling, food and beverage plants as well as facilities like hospitals and schools. The company and its customers were faced with the challenge that boiler controls use a variety of third-party instrumentation and control products, making it difficult to put together a compatible system. Jason Atkinson, Control System Engineer for Byworth Boilers, says: “Instead of using different instruments to measure individual parameters such as water and steam pressure, the boiler house needs to be treated as a complete integrated process. No boiler manufacturer was offering this sort of system but it was something our customers were asking for, so we decided to look for an integrated solution that we could package as a complete product for our users.” Byworth chose the ABB Freelance system, comprising ABB AC700F controllers and S700 I/O units and DIGIVIS, a human-machine interface that runs on standard Windowsbased PCs. With training and support from ABB facilities in Stone and Minden, Byworth software engineers developed Unity, a control system that gives customers a more efficient and configurable boiler house. As well as obtaining information from a PC, data can be accessed from the Cloud, allowing managers to see boiler performance on a tablet. Byworth’s engineers can also monitor customers’ systems remotely and advise on corrective action or maintenance. Capable of handling dozens of simultaneous I/Os, Unity is suitable for any boiler house, from control of a single boiler to complex multi-boiler, multi-fuel installations incorporating waste heat and composite boilers. Using ABB components allows Unity to communicate over Modbus or TCP/IP, simplifying cabling and dramatically cutting costs and installation time. Says Atkinson: “Having better control makes the customer’s plant safer and more efficient, as well as reducing emissions. “We won the Queen’s Award through two years of team effort to produce Unity which, as a product, is the first of its kind and represents a whole new approach to managing boiler plants safely and efficiently. “The support we got from ABB was second-to-none on this project. We also had a swift response to our queries and excellent help in developing the software.” For more information please contact: ABB Ltd, Warrington, Cheshire Tel: +44 7515 196801 E-mail: anders.forsberg@gb.abb.com

FREE-TO-ATTEND PROCESS NETWORKING SEMINAR MANCHESTER, JUNE 29 This highly practical seminar addresses the key issues arising from the use of digital communications technologies in process and hybrid industries. With 50%

of the seminar time dedicated to live demonstrations and most of the remainder taken up with practical advice based on actual experience, the programme will be of great value to Instrument Technicians/Engineers, C&I Engineers and System Engineers involved in design, operation and maintenance of modern process plant. Covering the use of PROFINET, PROFIBUS and IIoT in key application areas such as Pulp & Paper, Chemical, Utilities, Pharmaceutical, Oil & Gas today, it focuses on the practical aspects of using PROFIBUS in process industry applications from system design and hazardous area considerations through to maintenance and fault-finding. The seminar is ably presented by specialists from PI UK member organisations. Attendance is free of charge to pre-registered delegates from the User community, i.e. companies that own, operate, design, build or maintain process plant. The event will provide delegates with an excellent networking opportunity and the ability to speak to our experts whom, we promise, will not force you to buy anything. Subjects covered include: • Introduction to the basics of PROFIBUS and PROFINET • PROFINET in Process • System design for the Process Industry • Functional Safety in PROFIbus and PROFINET ... and more If you’d like to learn how to simplify your PROFIBUS or PROFINET process application … don’t miss this one-day Practical Aspects of PROFIBUS and PROFINET in Process Seminar. Places are limited so don’t delay – book today! For more information and to register Email admin@uk.profibus.com

OBITUARY It is with deep regret that the AUMA Group announces the death of Ian Sully, a former M a n a g i n g Director of its UK subsidiary, AUMA Actuators Ltd.

Ian passed away on 15th April 2016. He was a devoted husband to his wife Lindsey and loving father of two sons Kyle and Callum. He was passionate about his work for AUMA: he joined the company in 1985 and, after a short break from the organisation, he returned as a Technical Sales Representative. Ian was promoted to Sales Manager of AUMA Actuators Ltd in 1992, and subsequently to MD in 1996. From 2011, he continued his support for AUMA in a technical and sales advisory capacity. Everyone who knew Ian was impressed by his knowledge, expertise, commitment, energy, passion and wicked sense of humour. He was extremely driven, and his achievements extended beyond growing AUMA in the UK, where his support to staff and customers was second to none. He achieved many sporting accolades including Iron Man events, where his infectious enthusiasm led to many colleagues being persuaded to participate and large sums of money being raised for charity. Ian will be sadly missed by his family, colleagues and customers.

APPLICATIONS CHOPPER PUMPS HELP FORD MOTOR TO IMPROVE WASTE HANDLING The Ford Engine plant in Dagenham is not the type of site you usually associate with an application for a VAUGHAN chopper pump as these powerful, heavy-duty pumps are more likely to be found operating at sewage treatment works around the UK.

However, motor manufacturing, like any major process involves its own unique solids pumping challenges. For example, how to handle the difficult combination of swarf, cutting oils and coolants being collected from huge CNC machines operating on engine and transmission manufacture. The origins of the application began in the late 1990’s when Vaughan Co. supplied an initial trial pump to a Michigan based OEM filter systems manufacturer. The pump was to be tested to see how it would perform against the conventional method of handling waste material and coolant collected from CNC machines. The design and operational characteristics of the Vaughan pump provided an effective, all-in-one combination of shredder and pump which could handle all the ingredients of the machine waste, affectionately known as ‘pump backs’ in the industry. After 4 years of validation and ongoing collaboration between Vaughan, the filter systems engineers and Ford Motor Company’s transmission and coolant specialists, Vaughan succeeded in being chosen as the preferred type of pump for the waste handling applications. Fast forward to 2005 and Vaughan’s Huntingdon based UK distributor P&M Pumps became involved with the supply of 74 bespoke design V3M ‘pump back’ pumping systems for similar waste handling applications at Ford’s UK engine plant sites at Dagenham and Port Talbot. These pumps were supplied from Detroit and then the packaged system was fabricated and built in the UK by P&M Pumps. They were then shipped to the German CNC manufacturer for eventual delivery and installation at the Ford UK sites. Today, approximately 175 Vaughan pumps are, in the words of Ford Motor Company’s engineers, “performing flawlessly” on the waste handling pump applications associated with their huge machine tool process. Through their experiences at numerous UK waste water treatment and manufacturing sites, P&M Pumps have been able to demonstrate that Vaughan Chopper Pumps are an extremely effective option on the most challenging solids pumping applications. For more information contact P&M Pumps, Sawtry, Huntingdon. Tel: 01487 830123. | E-mail:matt@pumpmix.co.uk | Web: www.pumpmix.co.uk

ADDISON ACCELERATES THE PRODUCTION OF MICRON’S HYGIENIC PIPE REDUCERS A fully automatic Imet Sirio 370 AF-NC circular cold saw from Addison Saws is enabling Micron Stainless Steel Hygienics Ltda. of Swadlincote, Derbyshire, to accelerate production of its stainless steel pipe reducers.

A long-established supplier of high quality concentric and eccentric reducers for the dairy, brewery and hygienic processing industries, Micron required a solution that would speed-up the cutting of 316-grade stainless steel tube and, in doing so, free-up machine operators for other manufacturing processes Slicing cutting time “Prior to purchasing the Imet Sirio from Addison Saws, it was taking as long as one minute to set-up then cut each component from 1.5-inch to 4-inch diameter tube using our old semi-automatic saw,” comments Micron’s Managing Director, Michael Nemec.

Streamlining sawing process “Our new Imet Sirio automatic saw easily accepts the 20-foot-long stainless steel tube lengths we use and has reduced cutting time to just 20 seconds per part,” he adds. “Furthermore, its 99-program memory is proving particularly useful, streamlining the cutting process further through the input of cutting lengths and the number of cuts required.” As Micron’s manufacturing process favours flood cooling, as opposed to mist spray cooling, cut components are collected in a hopper for drying overnight, prior to deburring and finishing the following morning. For more press information contact: Addison Saws Ltd. Tel: +44 (0) 1384 264 950 Email: news@addisonsaws.co.uk www.addisonsaws.co.uk

VIBRATION PROTECTION FOR SMALLER CRITICAL PLANT I m p r o v i n g efficiencies, reducing energy consumption and eliminating downtime has never been more important than in today’s highly competitive industrial

environment. Whether generating power, pumping essential fluids or driving process equipment, it is vital to monitor machinery dynamic behaviour and protect processes from the disruption and expense of unscheduled downtime. As a consequence continuous protection and monitoring is an essential requirement for critical rotating plant across every industry sector. However, the cost of sophisticated protection systems can be difficult to justify for smaller machinery operating on less critical applications, although the requirement for monitoring still needs to be addressed. The solution is cost-effective and compact machinery protection monitoring devices such as those developed by condition monitoring specialist SENSONICS. A good example is their DN26 G3 protection monitor which provides practical and affordable protection for smaller plant and equipment such as, pumps, fans, motors, centrifuges, turbines, or any item of small to medium industrial machinery. A recent project success for the DN26G3 is the Boasteel Zhanjing Steel plant in China where over 90 modules are utilised with Sensonics sensors to monitor critical plant. These include the main exhaust fans in the blast furnace, the vaporising fans in the continuous casting line and de-dusting fans in the steel making and sintering unit; providing vibration protection to over 30 fans in total. The Zhanjing plant has a first phase capacity of 9MT per annum and is one of the most advanced steel plants in China with low emissions and high energy efficiency. The high-performance Din Rail mountable DN26 G3 unit is capable of monitoring two channels of bearing vibration, shaft vibration, or shaft position and offers fully programmable signal conditioning with a range of measurement algorithms and sensor options. In addition the DN26 G3 offers a dedicated speed monitor channel which can also be utilised as a phase reference for harmonic analysis of the vibration signals. The unit is designed for optimum flexibility; as a universal module (single hardware platform) it is field upgradable and can be programmed for any of the measurement options detailed above. It is available with mains voltage or +24Vdc power supply options. The sensor interface is programmable to accept IEPE type accelerometers / velometers, proximity probes (API 670 standard), and active / passive speed probes. All sensor signals are available via a buffered interface which provides the option of further detailed analysis if required. Three alarm relays are available as standard (expandable to up to seven relays via a digital interface), one dedicated to indicate module and sensor integrity, the other two relays are fully programmable across the alarm criteria selected. All three input channels measured values are available via a 4-20mA interface. The unit is available with Ethernet communications as standard, permitting configuration either locally or remotely through the inbuilt web server and offering Modbus over TCPIP for connecting measured data to other plant wide systems. The DN26 G3 features a built-in intuitive colour LCD display and menu drive facility providing various display modes including an alarm historian with real time logging capability. For more information contact, Sensonics Ltd, Berkhamsted, Herts. Tel: +44 (0) 1442 876833 Email: sales@sensonics.co.uk / Web: www.sensonics.co.uk

PROCESS INDUSTRY INFORMER May 2016

APPLICATIONS A BESPOKE ENGINEERED SOLUTION ALLOWED A NEW DEIONISATION PLANT TO BE INTEGRATED INTO AN EXISTING SYSTEM Veolia Water Technologies has supplied a deionised water system to Jaguar Land Rover’s Halewood factory. The new, bespoke

engineered system, which can deliver up to 90m3/h of deionised water, replaces the 40 year-old ion exchange plant at Halewood which was reaching the end of its life. To ensure a perfect bodywork finish on all Land Rover models, high purity deionised water (conductivity <0.5µS/cm) is used at all stages of painting from phosphating through to final electro-coating. Average water consumption is almost 30m3/h then, when baths are being dumped and re-filled, this can increase by a factor of three for short periods. Veolia’s project management team reviewed the existing plant and concluded that the raw water, degassed water and treated water tanks, along with the effluent neutralisation system, could be retained and designed a bespoke ion exchange plant, based around a standard triplex Rapide Strata 45+ with HiPol polishing, to produce deionised water of conductivity 0.1µS/cm. The skid-mounted plant, together with its dedicated control panel, featuring a Siemens graphic display and Ethernet interface to Jaguar Land Rover’s network, was installed in a new plant room. This provided continuity of production by allowing the existing plant to continue in operation until the Strata 45+ system had been commissioned, ensuring that there was no interruption to the deionised water supply and keeping the paint line running. Veolia’s well-proven Strata+ uses the latest short-cycle, counterflow regeneration technology with layered beds. This design improves chemical usage efficiencies and reduces waste water, achieving long-term cost savings and helping to reduce Jaguar Land Rover’s water footprint.

For more information contact Veolia Water Technologies, Tel: + 44 (0) 1628 897000 | Web: www.veoliawatertechnologies.co.uk

PROCESS INDUSTRY INFORMER May 2016

LIGHT DAWNS FOR A CRYPTOSPORIDIUM PROBLEM atg UV Technology, the UK’s leader in ultraviolet disinfection systems, has been awarded a contract by Trant Engineering, for Portsmouth Water.

The contract covers supply and installation of UV units for Cryptosporidium inactivation at two water treatment works: Eastergate and Westergate. Both are 20Ml/d borehole works and each site will be provided with fully atg UV units for Cryptosporidium inactivation automatic duty and standby atg destined for Portsmouth Water UV UVLW 16800 20 UV reactors. The reactors, which are third party validated to US EPA UVDGM, feature atg UV’s multi-lamp, high output, ultra-efficient 800 Watt Amalgam UV lamps. This is a new technology offering significant cost savings compared to traditional UV lamps. The contract, which is due for completion by mid-2017, will be Portsmouth Water’s first UV installation. The required 4-log inactivation of Cryptosporidium will be achieved by a validated UV dose of 40 mJ/ cm2, and this will be maintained over the full range of works flow by monitoring UV intensity in each reactor and automatically adjusting the dose. The atg UV UVLW range uses the very latest in Amalgam UV Lamp technology and flow efficient, in-line, L-shaped UV reactors, designed to provide optimum flow distribution and hydraulic performance. As one of only a few available products capable of treating water with UV transmittance as low as 55%, the atg UV UVLW range offers a solution for small, medium and large capacity drinking water and water reuse projects. For more information, please visit www.atguv.com/UVLW

For more information contact atg UV Technology, Wigan, Lancs. Tel +44 (0)1942 216161 | E-mail info@atguv.com | Web www.atguv.com

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. Mark says “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.” 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. To gain a similar operating temperature from traditional water- or steam-based systems would require a pressure of 85 bar. And while Rebellion Beer Company prefers to operate its thermal system at lower temperatures of around 135°C to ensure a quality product, for many processes where high process temperatures are required, thermal fluid heaters are an ideal source of heat. 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. Commenting for Fulton, Doug Howarth explains : that unlike steam, thermal systems provide useable temperature with very little pressure and a variety of cost savings should therefore be expected. The additional control provided by thermal systems also allows multiple, easy and accurate temperatures throughout a single system that can also include cooling. There are also no freezing hazards, they provide rapid start up and shutdown with minimal heat losses and there’s no requirement for blow down or condensate losses. “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.” says Doug. Fulton’s thermal fluid heat transfer solution is now used throughout Rebellion’s brewing process. From the brewhouse, where liquor (water) is heated to 66 degrees for the mashing-in process and wort is boiled with hops for 90 minutes; to heating the brewhouse and fermentation tank CIP system. Fulton’s highly-efficient FT-C thermal fluid boiler offers a compact, fuel-fired, 4-pass heater design capable of operating at temperatures up to 345°C. The system is designed to provide high-fluid velocities and low-film temperatures for improved longevity. The system’s compact footprint also means it could be skid-mounted, accommodating ancillaries such as circulating pump, expansion tank and related pipework, to minimise the floor space required for installation. Summarising, 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 oiland 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 call Fulton on Tel.: 0117 972 3322, | Email sales@fulton.co.uk | Web: www.fulton.co.uk.

LUBRICANTS AS EASY AS ONE, TWO, THREE “TOP THREE TIPS WHEN CHOOSING YOUR INDUSTRIAL GREASE” The Lubricants and Fuel Additives Innovation Platform of global water, energy and maintenance solutions provider, NCH Europe, has compiled a handy SlideShare that looks at the three vital characteristics engineers should consider when specifying their industrial grease. The SlideShare can be downloaded from NCH Europe’s SlideShare page.

Exploring some typical industrial applications, the SlideShare looks at the everyday problems that heat, friction, loading, rust and corrosion cause for machinery and equipment from bearings and motors, to gears and tools. Covering the traditional problems with existing greases and reasons they fail, this guide also explains additives and features that allow a good grease to perform in extreme conditions such as hot and cold temperatures, heavy loading, wet and steamy conditions and indoor and outdoor environments. “Most people know that 70 percent of mechanical wear occurs on cold startup,” explained Mark

Burnett, VP of the Lubricants and Fuel Additives Innovation Platform of global water, energy and maintenance solutions provider, NCH Europe. “What most people don’t know is that this can cause long term damage including cold-welds, pitting and particulates. “In turn, these problems can lead to foaming, oxidation and the buildup of acidic compounds and sludge. Because the encroachment of rust and corrosion is a slow process, ineffective lubrication of machinery and equipment can bring your whole plant process to a halt - not something that can be easily fixed. “We’ve developed this SlideShare as it’s a vital resource to give engineers and plant managers valuable insight when it comes to choosing the right grease for their application.” The guide targets sectors including industrial automation, food and beverage, process control and steel mills, as well as general industrial machinery. The SlideShare can be downloaded from NCH Europe’s SlideShare page.

PROCESS INDUSTRY INFORMER May 2016

DRIVES & CONTROLS CENTA ROLLS OUT NEW MAINTENANCE-FREE ROTATIONAL COUPLING FOR LARGE MILLS & PROCESSING PLANT Diesel engine drives specialist, Centa Transmissions, has unveiled a high performance, low maintenance shaft-to-shaft flexible coupling that eliminates vibration and noise from heavy duty mechanical power transmissions in large industrial mills, processing plant and mining machinery.

The CENTAFLEX-BL is a heavy duty, maintenance-free and robust rubber roller bearing design, which makes it more cost-effective to install and operate than the steel gear coupling it is designed to replace. It is ideal as a maintenance replacement product or a component for

OEMs. Typical applications include compressor drives, crushers, conveyors, roller plants, mining, quarrying, sugar plant, flour mills, paper mills, steel mills and many other heavy industrial applications. Centa manufactures and supplies flexible couplings, shafts and other power transmission products to suit any diesel engine-driven industrial application where the elimination of misalignment, vibration and noise is required. For more information contact Centa Transmissions Limited, Shipley, Bradford Tel: 01274 531034 E-mail: post@centa-uk.co.uk Web: www.centa-uk.co.uk

PROCESS INDUSTRY INFORMER May 2016

INSPECTION & VISION SYSTEMS FLUKE ANNOUNCES PRICE REDUCTION OF TWO PROFESSIONAL SERIES IR CAMERAS Fluke announced in February a reduction of over 20% in the manufacturer’s recommended price of two cameras in its rugged Professional Series of Infrared (IR) cameras, the Ti300 and Ti400, based on the previous list price.

The Fluke Ti300 and Ti400 IR cameras feature LaserSharp® Auto Focus which offers laser speed and accuracy when focusing on a designated target. A built-in laser distance meter calculates and displays the distance to the designated target with pinpoint accuracy. They feature a high resolution LCD touchscreen to clearly see what is being measured and to quickly navigate the menu with one hand. The recently announced high-end Ti450 IR camera, in the same series, takes focusing to a higher plane with MultiSharp™ Focus. All three of the Professional Series IR cameras are compatible with Fluke Connect and all three feature Fluke IR-Fusion® technology with AutoBlend™ mode to detect problems faster. Optional telephoto and wide-angle lenses offer extra detail from near or far. *Within the provider’s wireless service area and subject to the plan’s pricing and other terms. For further information contact Fluke UK Ltd, Northampton, Northants Tel: 0207 942 0700. Fax: 01603 256 606. E-mail: industrial@uk.fluke.nl Web: www.fluke.co.uk

WHY E-COMMERCE IS NOW A MUST HAVE IN AUTOMATION & CONTROL ENGINEERING By Tony Young, Director at CP Automation Automation and control engineers aren’t renowned for buying components online. Despite being able to interface a PLC with a control system on another continent, using nothing more than a secure connection and a Web browser, we have always distrusted the idea of choosing and purchasing a drive, motor, resistor or encoder online and having it delivered without first being able to physically ensure that it meets our requirements.

owever, this attitude is changing. It will inevitably become an industry relic, alongside Thomas Watson’s claim that there will never be a global need for more than five computers and the 1876 Western Union internal memo that read, “This telephone has too many shortcomings to be seriously considered as a means of communication”. At CP Automation we can appreciate that in the 21st century everyone wants to buy solutions to their problems and not just components. We also know that solutions engineering requires site visits, design engineering skills and an in depth understanding of the technologies involved. But sometimes, just sometimes, people don’t want to buy a solution. They might want to buy a PLC (Programmable Logic Controller) that is identical to the one that has just gone down or an inverter with exactly the same footprint as the one that has just died and they want the product delivered as soon as possible. This is where online buying fits into the automation industry. The rest of CP Automation’s business is about solution engineering but the online shop provides a quick answer to a quick and fully understood problem. Undoubtedly, e-commerce represents a huge opportunity for industrial manufacturers and distributors. However, implementing an online trading platform is not without its challenges. Setting up a platform for industrial automation e-commerce is both time and cost consuming. The task of inputting and consistently updating product data can be daunting, especially considering the rapid pace of change in the sector. New regulatory compliance requirements, the increasing page of product development and problems concerning product obsolescence have been known to challenge the sector’s ability to keep e-commerce platforms in line with market demands. One could argue that a legacy of strong, personal relationships has also hindered many suppliers and distributors from embarking on a more aggressive e-commerce strategy. Having successfully operated for years without an online trading platform, many suppliers will disregard e-commerce as an unnecessary expense. The reality is that with the rise of the online and with Generation Z engineers entering the workforce, e-commerce platforms will only increase in popularity.

RELATIONSHIPS REMAIN, BUT COMMUNICATIONS CHANGE...

THE

MEANS

However, just because younger engineers have a clear preference for the online and tend to shop around more, it doesn’t mean there is no place left in industry for long-term collaboration. Trusted industrial automation suppliers are still seen as gold dust, but even the best companies need to adapt how they communicate with their customers. Alongside the option to enquire or purchase online, industrial automation specialists could easily take advantage of other digital communication tools that allow immediate communication. Generation Z is notorious for preferring instant messaging to phone calls, so an industrial automation supplier that can tap into the potential of instant messaging and deep learning tools could secure a significant share of the market. However, while this approach could work for a straightforward task like finding a part replacement as soon as possible, commissioning more complex projects or system upgrades would continue to require the face-to-face interaction and site visits it always has. This proof that online buying is now becoming an important issue in automation and the wider engineering industry is borne out by the number of online engineering shops that have been launched in the last few years. These businesses are not just outlets for existing engineering companies but complete operations in their own right that sell only online. We are moving rapidly towards a situation where simple components, which can’t be bought online, are losing visibility in the marketplace. The question is when did this trend begin? Some of the largest players in industry have had online shops for several years now, but privately they will admit that those shops have been producing minimal sales until recently. Clearly there is a new wave of younger engineers joining the workplace every year and this is a contributing factor. Our apprentices and graduate engineers have been born on the Internet and this has a fundamental effect on their buying habits. As the most experienced engineers start considering retirement, younger engineers are likely to abandon the traditional model of purchasing industrial parts from trusted, long-term suppliers and shop around on the web instead.

I think we can trace the origins of the phenomenon further back though. For some time, automation businesses have been reporting that enquiries have been arriving fully formed and ready to convert. The customer now knows what they need to buy, what the part number is and all of the crucial specifications. Most customers will be familiar with the tedious task of calling multiple companies in a desperate attempt to find the right product. However, for organisations with high costs for production downtime, this time-consuming task isn’t a viable option. Online purchasing provides the ideal solution for a faster turnaround.

COMPARE FROM ANYWHERE... Today, customers are able to compare the product to key competitors without ever picking up a telephone because all the necessary information is available online. Having stock on the shelf is not enough to truly support urgent customer demands, you have to actively market the products in all buying mediums to succeed. If the supplier’s website isn’t up to scratch, the information is available from a news site, a partner site, a directory, an online catalogue or exhibition or a social media profile or blog. In fact, when CP Automation was sourcing a product that would allow electric motor users to return braking energy to the grid, thereby taking advantage of feed in tariffs, we started our search online. By the time we met our ultimate supplier, we knew all about RevCon, our regenerative braking product. We were a great example of the changing buying pattern in our own industry. It’s in this changing buying pattern that I believe we can find the routes of genuine e-commerce taking place in automation. The widespread availability of information means that we do not always need a salesman promising to send a data sheet that never arrives. It’s a small step from having all the information at your fingertips to clicking ‘buy now’ and providing your delivery address. Personally, I don’t believe that the truly significant, solutions-based orders will be placed via e-commerce in the short or medium term. There needs to be a quantum shift in online technology before that happens. But for quick and easy component level sales, e-commerce is now taking place in our industry.

EFFICIENT DATA ACQUISITION THROUGH INTELLIGENT MEASUREMENT TECHNOLOGY IN PRODUCTION DEVELOPMENT As the requirements for production automation constantly increase, these requirements, combined with short cycle times mean automation solutions must process an increasingly greater number of measuring values ever more rapidly. Bernd Knoll, International Product Manager of HBM looks at what this means for modern data acquisition and further discusses possible solutions with decentralised intelligence, which is increasingly being used within industrial measurement technology.

ince integrating sensors and instruments with components in production lines and test systems is the only way to enable dynamic models to be implemented, a new breed of data acquisition systems (DAQ) have been developed to fulfil the arduous demands placed on industrial data acquisition. With performance, flexibility, ease of use and integration top of the list, latest models have been designed to undertake measurement data acquisition, subsequent data processing and transmission to a higher level controller, at very high speeds for example, sample rates of up to 19.2 kHz, for all channels. Parallel to this, data acquisition with very high precision, of up to 0.05% accuracy class is also guaranteed through measuring amplifiers with a high resolution of 24 bits.

popular as a communication protocol in automation technology. The result of this growth means that simple field buses such as CAN or PROFIBUS have now been replaced with DAQ systems, which support real-time Ethernet protocols, such as EtherCAT, PROFIBUS or Ethernet/IP, all of which allow very fast transmission of large amounts of data, in real time. Furthermore, as the measured signals can already be processed internally by the amplifier and evaluated in real time, this means that these DAQ systems can therefore effectively implement some of the tasks, directly in the amplifier, which would otherwise be taken over by the high-level controller, such as mean value

COMMUNICATION WITH THE AUTOMATED ENVIRONMENT As the number of measurement channels and choice of interfaces depend on the respective task in the application, modern DAQ systems comprise a basic device that can be variable equipped with plug in cards for flexibility, which is a key factor. The first slot is reserved for a communication card that enables integration with a higher-level automation system whilst additional slots are also available for amplifiers with 4 channels each and combined input/output cards. Different modules are also available with measuring amplifiers for strain gauges (SGs), which can be used for analogue inputs and outputs, and for digital outputs, which enables the most frequently required physical quantities to be measured, such as force, torque, pressure, strain and temperature. All modules are supplied with voltage via the DAQ basic device and communication with a PC or operating unit can be used for configuration or visualisation via fast Ethernet, which enables transmission of all measurement data up to 100 Mbit/s. In addition, most basic devices are also equipped with a USB interface which can be used, for example, to save configuration to a USB stick for later retrieval. The connection of peripheral units, such as hard drives or barcode scanners, can also be used to save quality data and to include component identifications in this data.

VIRTUAL CHANNELS Measurement technology in industrial applications must seamlessly integrate with the communication protocols of the automation system, and as data volumes and speed requirements continue to grow, Industrial Ethernet has become increasingly

At this stage it is also worth mentioning the importance of frequently monitoring machine parameters in large and complex machines and systems in order to minimise standstill times. By implementing a system, machine errors can be quickly detected, minimising unplanned and costly downtime. Another classic application case for measurement systems, such as the PMX from HBM, is the industrial test bench set up, where complex components are tested for their maximum loading capacity and practicality. Over the last few years, Industrial Ethernet has become prevalent as a communication medium in this sector. Equally as important, the same applies for checking the quality of finished products at end-of-line test benches. Storing the quality data acquired here in a database also poses increased requirements for the communication architecture of the measured technology systems. Incorporating high measurement accuracy and long term stability, the PMX data acquisition and control system from HBM is suited for use in production lines and industrial test benches and enables professional and precise application of force, torque, vibration, pressure, strain, temperature, voltage, current, frequency, speed, angle of rotation, rotational direction and many other quantities

VISUALISING & OPERATING CONCEPTS

determination, peak value acquisition and other mathematical calculations. In addition to the measurement channels offered by the latest range of DAQ systems, users can also benefit from the systems socalled virtual calculation. Featuring powerful signal processors, specifically designed for this purpose, which can perform calculations at the required speed, all measured values and the derived values calculated in the virtual calculation channels can be transmitted in real time, with up to 10 kHz to the machine and system controller. Decentralised, intelligent measurement technology is also another important feature which needs to be taken into consideration. Particularly important for applications with a very high degree of automation, in order to reduce failure frequency and the system load on the controller, typical applications for such decentralised measurement systems can be found in production applications, such as the monitoring of presses, such as tablet and powder presses through to sheet metal presses, commonly used in the automotive industry.

Moving with the times, when it comes to new browser technology, users and system operators are familiar with smart devices and use them on a daily basis. In line with this, modern DAQ systems incorporate the latest measurement test and measurement technology which offers convenience and ease of use. Standardised interfaces also provide convenient access to all device parameters for configuration, operation and analysis, via any internet compatible terminal device, meaning users can comprehensively implement applications on mobile devices and cloud solutions in line with Industry 4.0.

PRACTICAL ANSWERS AT YOUR FINGERTIPS Offering a plethora of opportunities, potential applications range from simply utilising a smart phone or tablet as a mobile display for a measuring device, through to controlling networked test benches in a company network, and even monitoring remote wind turbines via the internet. In addition to simply visualising data, modern technology now allows customers to conveniently and quickly employ control elements, such as buttons and switches for operator actions, such as start, stop or trigger.

PROCESS INDUSTRY INFORMER May 2016

HEALTH & SAFETY STI DEVELOPS MECHANICAL SAFETY INTERLOCKS FOR HARSH ENVIRONMENTS NS range suitable for cement, concrete, asphalt and steel industries.

Industrial safety specialist SERV Trayvou Interverrouillage (STI)has developed a range of mechanical interlocks for heavy-duty applications or aggressive environments. The NS range relies on trapped-key technology and is suitable for use in industries such as cement, concrete, asphalt and steel, as well as tyre manufacture and maintenance in the rail industry. The NS range’s bolt and latch locks are made from copper-brushed aluminium with stainless steel covers. The corrosion-resistant properties of aluminium enable the range to withstand harsh operating conditions. There are no intermediary components between the NS range’s key and bolt; the key drives the bolt directly. A broken key will prevent the bolt from moving, while a defective bolt will trap the key in the lock. This important feature ensures that personnel are immediately warned of any fault affecting either the key or locking mechanism, keeping operators safe. Interlocks whose intermediary components between the key and bolt are faulty could allow staff to turn the key without moving the bolt. If the bolt stays open after the key has been released, an operator could potentially restart a machine while a colleague is still present within a dangerous area. For more information contact SERV Trayvou Interverrouillage S.A.S.1 Ter rue du Marais 93106 Montreuil CEDEX, France Tel: +33 (0)1 48 18 15 15 | Email: pr@servtrayvou.com | Web: www.servtrayvou.com

SPECTROMETERS OCEAN OPTICS ENHANCES CAPABILITIES OF NIRQUEST SERIES SPECTROMETERS Now feature replaceable slit design and internal shutter option Ocean Optics has enhanced the NIRQuest series of small-footprint, near-infrared spectrometers. All NIRQuest spectrometer models now come with a replaceable slit design as standard, increasing measurement flexibility with easy user changes in the field. Additionally, the option of adding an internal shutter is now available to more effectively manage light throughput and dark measurements in experiment setups. The NIRQuest is a robust, reliable spectrometer with a fast response time and good optical resolution over 900-2500 nm to suit applications from moisture detection and chemical analysis to high-resolution laser and optical fibre characterisation. Slit size is one of the determining factors in the optical resolution of a spectrometer. The choice inevitably involves design trade-offs: a larger slit increases throughput, but at the expense of optical resolution; a smaller slit yields higher optical resolution, but decreases throughput. The flexibility to adjust the width of the slit helps eliminate these trade-offs by granting users the ability to adapt spectrometer performance in the field, without the need for recalibration. Shutter type is another mechanism to configure a spectrometer for maximum performance in a given application. The NIRQuest’s new internal shutter option is useful for applications where placing an external shutter is difficult, such as emissive setups and probe-based measurements. Internal shutters are also more convenient for applications where light intensities change, requiring users to dynamically adjust integration times and renormalise the spectrometer. The internal shutter improves signal throughput in the set-up and allows for shorter integration times for an equivalent level of signal. Operation via software makes shutter control as simple as a few keystrokes, with no extra components or cabling to contend with. The NIRQuest series includes several models of preconfigured spectrometers, each optimized for the best response within a specific wavelength range. A custom model is also available for users who want to select the ideal combination of optical bench components, including gratings, slits and filters for a particular application. External hardware triggering functions allow users to capture data when an external event occurs, or to trigger an event after data acquisition.

For more information contact Ocean Optics Geograaf Tel: +31 (0)26 319 05 00 Email: info@oceanoptics.com |Web: www.oceanoptics.com

PROCESS INDUSTRY INFORMER May 2016

SPEED CONTROL EVOLUTION FOR THE INDUSTRIAL & DOMESTIC SECTORS THE ELECTRIC DRIVES REVOLUTION by Anna Jensen

Speed control is the perfect solution for providing unobtrusive and essential efficiency optimization. In industrial and production sectors across the globe, electric motors ensure reliable and effective operation. Millions of these motors are controlled by AC drives. In fact hardly any aspect of daily life can be managed without drives. Electrical drive technology holds enormous potential for reducing energy consumption, since 65–70% of all electrical energy consumed is used to run electric motors. The number of installed AC drives is ever-increasing. The growing demand reflects trends towards optimized processes and lower production costs, and more efficient use of expensive energy.

here are three significant milestones in the history of drive technology: • The invention of the DC motor in 1833 • The invention of the three-phase motor in 1889 • The first series of mass-produced variable speed drives in 1968 (the VLT® drive from Danfoss). Since the launch of the first mass-produced variable speed drive, rapid technological evolution has taken place. In line with the global spread of automation and the number of motors with variable speed control, the production of drives has virtually exploded. Danfoss production facilities in Graasten, Denmark, 1968

APPLICATION-OPTIMIZED DRIVES

NEW MILLENNIUM, NEW DIGITAL POSSIBILITIES

Manufacturers soon realized that the need to reduce energy consumption while reducing costs was becoming a top priority for their customers. Remaining innovative and producing variable speed drives that meet these requirements became paramount for leading manufacturers in this field. Approaching the new millennium, drives experts realized that the vast possibilities offered by information technology enabled integration of more features in to an AC drive. The demand for customized and application-optimized drives was on the increase.

At the turn of the century Danfoss established an early foothold in digitalization, introducing an advanced IT system into the supply chain. Since then, assembly has been digitally controlled from the moment the customer defines the features for his specific drive, on line. These specifications determine which components are included in the customized drive: printed circuit boards, enclosure type, EMC filters, user interface, software, fieldbus, and options. From a limited number of choices of each element, thousands of different drives can be configured. After assembly, each customized drive is tested in the factory before shipping. This build-to-order approach means that customized drives are built and shipped within hours. Even manuals are printed ondemand in the language specified by the customer, and shipped with the drive, ensuring manual content is always up to date. In 2006, this setup was awarded the Frost & Sullivan Award for Product Innovation.

FROM LARGE ANALOG DEVICES TO COMPACT MODULAR SYSTEMS In response to forecasted market conditions and industry trends, Danfoss technicians focused on identifying the separate elements in the architecture of standard drives and the internal communication between them. These individual elements make up the modular approach that Danfoss has always used as the foundation for creating the next generation of drive series across their product range. This modularity reduces the cost of development and time to market. The same philosophy has always supported the unique supply chain setup adopted by Danfoss Drives. Modularity enables the manufacturer to produce drives in high volumes and in numerous variants, for use in a multitude of applications in many industrial sectors.

MOTOR & SYSTEM INDEPENDENCE Modern drives can now be easily combined and fitted to multiple motor technologies and PLC systems originating from numerous suppliers. This motor and control independence enables users to obtain systems perfectly matched to their needs. It also facilitates easy and low cost system expansion and adaptation of drives to a modified plant design or new processes. In recent years, there has been a major trend towards increasing the intelligence in the drive. Many functions previously handled by a central controller are now migrating to the drive, becoming built-in functions in majority of cases. User-specific adaptations are now possible with freely programmable extensions and EMC measures are now classed as essential by most customers. As a result, low-harmonic drives, devices with active front ends, and active filters that mitigate harmonic distortion for a whole set of motors are now crucial elements – especially because power levels now extend to several megawatts, even with low voltage devices.

ENGINEERING TOMORROW WITH ENERGY-EFFICIENT the coming decades. For AC drives, the potential is enormous and includes: DRIVES

efficiency. This adaptability will become increasingly important with widening diversity of new motor technologies.

Drive technology is taking on another important duty for the future: using energy efficiently. Variable speed drives are the first choice for energy-efficient solutions. They control pumps for reliable water supply and wastewater treatment, they run air conditioners, ensure reliable operation of conveyer belts, safeguard the power supply of cargo ships, and ensure that you arrive safely on the fifth floor. In all these applications, they achieve considerable energy savings and optimize processes. Legislators now recognize this capacity. The Ecodesign Directive is the legislative framework that sets requirements on all energy-related products in the domestic, commercial, and industrial sectors throughout the European Union. The main goal of the directive is to improve the energy efficiency of products throughout the EU and here variable speed drives play a pivotal role. This trend will expand to the world’s legislative boards over the coming years, and we will see an increasing demand for accurate control and measurements of energy consumption.

ENERGY STORAGE AND HYBRIDIZATION

Danfoss ensure that all requirements regarding accuracy, hygiene & compact size are met

PROCESS OPTIMIZATION FOR ACCURACY, QUALITY, AND RELIABILITY Today’s production facilities are often textbook examples of optimization. Speed control of motors according to changing needs improves process control, which is essential to ensure high quality of the product produced. Accurate control has positive effects on efficiency, material usage, environmental emissions, and production yield. At the same time, facility managers have strict requirements for dimensions, heat emissions, cleanable surfaces, communication integration and ease of service. A recent major trend is towards increasing user friendliness and drives dedicated to and optimized for specific applications. Another important and growing development in the marketplace is the OEM philosophy. Customization for OEMs means that customers and suppliers are collaborating more closely than before to find the optimal match of products.

DIGITALIZATION DRIVES DOWN OPERATING COSTS The era of digitalization has long begun and our dependence on data, analytics, and the cloud will develop dramatically in

• Predicting customer problems and solving them before they start • Enabling OEMs to run their applications even better • Leveraging data utilization to reduce costs for the customer • New services drawing upon analysis of big data For at least 30 years, software dedication of drives has been implemented to create drives dedicated to specific fields of application, for example HVAC. A dedicated drive operates software including a set of features relevant to the application, for example in safety, minimization of wear, and compatibility with relevant fieldbus protocols. With digitalization developments, AC-drive programmability is enhanced with improved connectivity, data gathering and analysis abilities, moving towards more customizable solutions. The AC drives of the future will order their own spare parts, and predict process-level malfunctions and maintenance needs before possible costly breakdowns. These trends bring data handling, intelligence, and learning as totally new fields of AC-drive software functionalities; end-to-end communications, device availability, interoperability, and security on a wide variety of digital platforms. Digitalization will lead to significant and concrete savings via: • Decreased time to repair • Increased process availability • Enhanced remote support capability These developments do not mean the end of human interaction by any means. With increasing digitalization, the service network staffed by real people becomes a vital extension of the drive capabilities – users, management, service technicians, hotline, and account management. Service design will become the skill of creating the seamless flow between them, using different channels, different applications, and different devices.

ENERGY EFFICIENCY DRIVES DEVELOPMENT IN NEW MOTOR TECHNOLOGIES Driven by increasingly stringent legislation such as the Ecodesign Directive in Europe, motor manufacturers employ diverse concepts to achieve high efficiency in electric motors for industrial and commercial applications. New motor technologies will therefore continue to emerge. Although all motor technologies in the same efficiency class provide comparable efficiency at the nominal operating point, they differ in many aspects such as starting behavior or partial load characteristics. For users, the main impact of the wide variety of motor technologies is the need to find the right technology for each application in order to achieve maximum energy efficiency for the system, and win the associated savings. For each application, a different motor technology can provide the optimal performance characteristics. When the AC drive is compatible with all typical motor technologies, then the system designer is free to choose the optimal motor for overall system

The increasing development of hybridization involves equipping general processes and machines which with energy storage to upgrade performance and efficiency. AC drives contribute to the advantages of energy storage which include: • Peak shaving, removing the need to dimension systems to peak power demand • Optimizing performance by operating at the optimum point, avoiding over- and underload operation • Backup power, which removes the need for idle reserve running

FROM ENERGY CONSUMER TO ENERGY GENERATOR Processes which have historically been heavy energy consumers, will implement optimizations to create localized energy surpluses. An example is in water management, which consumes up to 40% of a European municipal budget. Raising the ambition level, this power requirement can be reduced to nil by 1. reducing motor energy consumption with the help of AC drives, 2. generating bio-electricity from sludge The ambitious wastewater treatment plant can potentially generate enough power to meet the needs of the entire water management utility: supply, distribution and treatment. On a global basis, 8% of the world’s energy is consumed in water management, so the potential is enormous.

OUTLOOK With their diminishing size, increasing capabilities, and growing intelligence, variable speed drives have become indispensable for both the industrial and domestic sectors. They are still not even noticeable to many of us in our daily life, as most of the drives in operation are performing their duties quietly in the background.In the present economic climate, reducing total lifecycle costs and optimizing system performance, without compromising on product quality, are now more crucial key factors in the early stages of the design process than ever before. Flexible innovations that continue to meet these needs will continue to be a major trend for the foreseeable future. Sources: IoT http://www.slideshare.net/VaconGroup/iot-for-automaatio-xxi-15vacon http://www.focusondrives.com/is-iot-an-opportunity-for-the-drivesbusiness/

“MAKING THE CONNECTION” HOW MANUFACTURERS CAN TURN INDUSTRY 4.0 TO THEIR COMMERCIAL ADVANTAGE

By Fabrizio Battaglia, Head of Manufacturing HSO Industry 4.0 is now underway and it’s already bringing radical change to the manufacturing value chain. One of the key enablers is connected manufacturing which is today helping to link all the components - from the supplier to the production line, reseller or distributor, and finally end customer.

anufacturers are already accessing information about the supply chain and their products through the Internet of Things (IoT). The new paradigm is enabling them to extend the connection to the end customer and start to feed back information assembled there to production to adapt the value chain.

REAPING THE REWARDS This new connectivity enables manufacturers to find out more about how their customers are using their products. And these developments are likely to have a profound influence on the way that goods and solutions are made in the future. Thanks to the change unleashed by Industry 4.0, manufacturers are already designing and developing products based not just on their own vision and expertise but also on customer feedback and an analysis of customer usage. Moving a further step forward, manufacturers can use that information to improve the product but embed it with services that both align with customer needs and deliver incremental revenue streams. It is an evolution of the whole design concept and it requires a complete mind-shift. Manufacturers no longer simply have to consider the shape, form and build of the product but they now also have to think about how best to embed services into the product too. Customer usage can increasingly be tracked and this knowledge shapes the ongoing development of the product. If a particular function is not being used at all, it can be removed. On the other hand, if a function is being used intensively, its capabilities can be developed further in the next release. In a sense, the customer is in charge, driving the evolution of the product based on the way they are using it. It’s also critical to have a feedback loop in place so that customer complaints can be fed back into the design and development process. If customers are complaining to customer service that a valve has broken, for example, then the design team also needs to be aware of it so that they can adjust the product accordingly.

HERALDING A NEW ERA The concept of connected manufacturing represents not just

a big change but also a major challenge to manufacturers. Their focus is no longer on simply creating a product and then selling it. Instead, they need to gather together and leverage information about how the product can be used and serviced. Doing this successfully necessitates crossdepartment collaboration. Working in silos is no longer an option. Moving to a connected manufacturing model is not easy. There needs to be a process of education put in place around the requirement for businesses to adopt a more service-led approach. Some manufacturers see this in fairly limited terms as being primarily concerned with putting a service contract in place and then tracking any assets that have been sold – often by employing approaches based on sensors and the broader Internet of Things (IoT). They may have developed a new customer service team or they may have extended their existing one. But often this team works in isolation, disconnected from the rest of the company and its partner ecosystem. Manufacturers need to ask themselves the key question: is their customer service team working as a siloed department, or is it really open to the customer and linked back to production, design and the wider supply chain? Many companies are not yet putting all of these key connections in place and coupled with this, many are not yet grasping all the opportunities that exist around the feedback loop referenced earlier and the ability to evolve the design with service in mind. This is at the very heart of the concept of connected manufacturing. Manufacturers need to first understand and accept this reality and then start modifying their processes and procedures to accommodate it. After all, it will be those businesses that understand the new connected manufacturing model and tackle the challenges outlined above that will succeed in the future and be best placed to take advantage of the opportunity to develop new solutions, upgrade existing ones and build sustainable new revenue streams that change the after-market process from cost to profit centre. Having an understanding of the challenge and a determination to tackle it is, however, not sufficient in itself. Manufacturers also need a clear view of the broader context. They need to know what their ultimate goal is - what they are looking to achieve - before they switch to the new model. They need to understand, for example, what markets they

want to target, what demand is likely to be and what KPIs are they going to put in place to measure achievement. And they need to have a talented team of people in post who can read and analyse information coming from the customer and then kick-start the development of new products and services that address this new insight into behaviours and preferences. And remember - all of this has to be part of an evolutionary process. A big bang approach simply will not work because the risk involved will be too high. If an organisation moves too early, they are likely to find that in fact they can’t change sufficiently quickly because they haven’t tested their plans properly and they don’t have a fully thought-through strategy in place. The capabilities enabled by this new connected manufacturing paradigm are today enabling manufacturers to transform not only the way they engage with customers but also their entire business model and approach. The days of the traditional ‘sell it and forget about it’ manufacturing approach look to be increasingly numbered.

SHIFTING TARGETS Manufacturers today can’t afford to adopt a purely salesfocused approach. Instead, they need to go further than that to draw on the data resources they have across the organisation and beyond in order to understand clearly how the customer is using the product and what they are looking to get out of that usage. They also need to develop a strategy to collect data and analyse it as well as putting in place of team of people capable of carrying that process out. And of course, it also means bringing in the right technology, typically including enterprise resource planning (ERP) to enable this vision to happen. With all of that implemented, manufacturers have a solid foundation to enable the delivery of value added services that allow them to build a long-term relationship post-sale, improve the user experience and tap into incremental revenue streams. It amounts to a transformation of the whole manufacturing landscape – and ultimately that is likely to be one of the greatest legacies of the new connected world that Industry 4.0 has ushered in.

PROCESS INDUSTRY INFORMER May 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves REDUCED POWER CONSUMPTION & OPTIMISED SAFETY PERFORMANCE FROM NEW IMI PRECISION ENGINEERING VALVE IMI Precision Engineering, an international market leader in pneumatic motion and fluid control technologies, has demonstrated its commitment to develop technologically advanced energy-efficient solenoid valves with the launch of a low power ICO3 valve from product brand IMI Maxseal.

Designed and certified for use in the most extreme environments, the valve is suitable for applications ranging from offshore platforms to shale gas extraction. With a power consumption of just 1W, the new IMI Maxseal ICO3-1W is ideally suited to solar powered applications while maintaining industry-leading reliability and performance. The new product boasts a <60ms changeover speed and a 5kg return spring – three times that of most other products on the market - which ensures 10x force friction ratio (FFR). The full range is certified to ATEX Ex d IIC T6-T4 (-55°C to +90°C) and has an IP66/X8 and Nema 4X environmental rating. Its operating pressure range is 0-12 Bar (pneumatic and hydraulic) with each fully balanced valve delivering leak-tight performance. To suit limited power applications, such as satellite platforms or shale gas, the range comprises of both 12V dc and 24V dc versions. The ICO3 range draws on the leading IMI Maxseal ICO technology from IMI Precision Engineering, whose inherent reliability characteristics have provided safe and reliable performance, even in the most arduous environments, across the globe for more than 50 years.

Andy Evripides, Sales & Marketing Director at IMI Precision Engineering, says: “We

are continually pushing the boundaries of valve and instrumentation technology and have an established reputation for high-performance products which operate across the oil & gas, petrochemical, chemical, and power generation markets around the world. This new valve has been optimised to combine minimal power consumption with optimised safety and all the key performance attributes the sector has come to expect from IMI Precision Engineering products.” IMI Precision Engineering is the new name for Norgren following a rebrand in 2015, and continues to engineer great solutions for fluid and motion control through its portfolio of flagship product brands including IMI Norgren, IMI Buschjost, IMI FAS, IMI Herion and IMI Maxseal. For more information contact IMI plc, Birmingham, Tel: 0121 717 3700 E-mail: info@imiplc.com Web: www.imi-precision.com

PROCESS INDUSTRY INFORMER May 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves NO MAINS POWER IS NO PROBLEM FOR RECHARGEABLE DRUM PUMP MOTOR Problem:

How do you transfer liquids from drums and barrels safely and cleanly when you have no electrical or air supply available to drive the pump motor and manual, hand-operated pumps are not an option? Solution:

A Lithium Ion Cordless Rechargeable Drum Pump Motor developed by drum pump specialists Finish Thompson (FTI) and available through MICHAEL SMITH ENGINEERS. The S6 12-Volt rechargeable 2-speed drum pump motor can be used with any of the Finish Thompson EF polypropylene, pure polypropylene/PVDF or stainless steel tube sets. The result is an extremely versatile and portable option for remote or difficult-to-access drum emptying applications. The The cordless design makes it easy to transfer fluids virtually anywhere, with maximum fadefree performance, equivalent to a corded AC powered motor. The latest Lithium ion batteries have a much higher energy density compared to nickel cadmium (NiCd) or nickel metal hydride (NiMH) batteries so the pumps can operate effectively for up to 50 minutes between charges. Also, Lithium ion batteries have no â&#x20AC;&#x2DC;memoryâ&#x20AC;&#x2122; effect which means they can be recharged at any state of their discharge. The S6 rechargeable drum pump motor has a solid-state electronic control circuit that monitors all aspects of the motor and battery pack to ensure reliable operation and longlife, while dual cooling fans help to improve the performance and life of the battery pack. Multiple charging options include 115 or 230 volt AC and for mobile applications an automobile or commercial vehicle 12 volt port option will suffice. For permanent charging locations, a moulded wall hanger is available which stores the charger unit internally. On the low speed setting, the pump / motor will run for approximately 50 minutes between charges and the high speed setting, it will run for around 20 minutes. The S6 Rechargeable Drum Pump Motor will be an ideal option for transferring fluids from drums, barrels and carboys where a power supply is not available, is too distant from the point of pumping, or where fluids need transferring in remote, isolated locations. For more information contact Michael Smith Engineers Ltd, Tel: 0800 316 7891 Email: Info@michael-smith-engineers. co.uk Web: www.michael-smith-engineers. co.uk/products/drum-and-barrelPeristaltic pumps for food flavouring pump/ef-series-cordless-rechargeabledrum-pump-motor.htm

Green PerisTalTic PumP

Verderflex

NEW

Vantage 5000

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

PROCESS INDUSTRY INFORMER May 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves AXFLOW LAUNCHES RANGE OF ELASTOMER COATED ROTARY LOBE PUMPS AxFlow has extended its range of positive displacement pumps with the introduction of the Boyser LB suite of elastomer coated rotary lobe pumps for flows of between 5m³/ hr and 130m³/hr.

The LB pump has been designed from the ground up following an assessment of products currently on the market with a view to producing an economical process quality pump with the best combination of design features. The LB range offers a combination of innovative features. Ergonomic rotors designed in conjunction with Universitat Autonoma in Barcelona, maximise the sealing face while allowing the passage of particles up to 50mm in size. The rotors can be coated in NBR (FDA), EPDM and Viton or supplied in AISI-410 and 316 stainless steel. Also to be noted is the unique intermediate chamber that isolates the pump head from the gear box, therefore avoiding any kind of cross contamination. The pumps utilise robust, high precision gears with self-aligned roller bearings that ensure that the rotary lobes deliver exceptionally high levels of accuracy and efficiency and use a range of process quality mechanical seals. Lastly, stainless steel axial liners incorporated in the pump chamber protect the pump casing, help to maintain the pump’s performance and are easy to replace, thereby significantly increasing pump life. AxFlow believes that the LB benefits from having the optimum design features that make it suitable for all but the most demanding process duties. For more information contact AxFlow Ltd, Ealing, London. Tel: 020 8579 2111 | E-mail: info@axflow.co.uk | Web: www.axflow.co.uk

EXTENSION TO QDOS RANGE OFFERS OPPORTUNITIES FOR UPSCALE TO HIGHER FLOW RATES & OPENS UP NEW, POWERFUL OPPORTUNITIES FOR PROCESS ENGINEERS · New Qdos 120 offers greater flow – and has no valves, ancillaries or gas-lock issues, thus reducing installation and maintenance costs · Reduced chemical costs through accurate, linear and repeatable flow · Provides extended operating life

Watson-Marlow Fluid Technology Group is proud to release the new Qdos 120, offering flows up to 120 l/hr at a maximum pressure of 4 bar, double the flow of existing models in the Qdos range of peristaltic metering pumps. This latest addition to the product range builds upon the core foundations of the WatsonMarlow’s design-thinking for the widely deployed Qdos suite of high-accuracy chemical metering technology. Qdos 120 - not only offers double the flow of other models (in comparison with Qdos 60), it delivers a step-change in performance and usability compared to conventional solenoid or stepper-driven diaphragm metering pumps. All models in the Qdos family are designed to eliminate the need for ancillaries, boost productivity, and cut chemical wastage due to its highly accurate, linear and repeatable metering. Powerful combination of features This powerful combination of core features offers significant benefits to process engineers in the water/wastewater, industrial and agri-chemical sectors. It is easy for customers to upscale to the higher flow rate of the Qdos 120 as it maintains the same common interface, connectivity and functionality of the existing Qdos models. Driven by market demand for pumps that offer low total cost of ownership (TCO) without compromise to performance or process quality, the Qdos 120 allows engineers, as well as skid manufacturers and packaged-plant designers, to overcome a host of issues associated with diaphragm pump technology, such as poor suction lift and the downtime resulting from blocked valves and gas-locking. The peristaltic operating principal of the Qdos 120 has been designed to deliver continuous, smooth flow for optimal fluid mixing, while high accuracy provides chemical savings and increased process quality. Safe, One-minute maintenance The combination of high reliability and low maintenance ensures minimal operational expenses. There are no valves or seals to clog, leak, gas-lock or corrode. Moreover, process uptime is maximised with no-tools maintenance and quick and easy pumphead replacement. In fact, there is only one consumable part on Qdos 120 pumps, the ReNu pumphead, which can be replaced in 60 seconds to return the pump to its as-new state. What’s more, the fully contained pumphead ensures no spillage or exposure to chemicals. Increased flow capability at development partner sitesAmong the many success stories emerging from customers involved in the validation of Qdos 120s product development, is a seed treatment company, which since adopting the Qdos 120 has enjoyed improved flow capability and accuracy at a higher viscosity. Previously, the company was limited to the chemical types it could run on its existing Qdos 60. In contrast, the 120 allows a single pump to cover all flow ranges, providing users greater flexibility with a single spare part inventory. Control options The Qdos 120 range includes a number of models offering different control functionality depending on customer requirements, extending from manual speed control models, through universal+ (manual, 4-20mA input/output, pulse), to remote and Profibus control options. For more information contact Watson-Marlow Fluid Technology Group, Falmouth, Cornwall. Tel: 01326 370370 E-mail: info@wmfg.co.uk Web; www.wmfg.com

PROCESS INDUSTRY INFORMER May 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves VIRTUALLY PULSE-LESS FLOW REMOVES THE NEED FOR PULSATION DAMPENERS The unique multi-diaphragm arrangement of Hydra-Cell metering & dosing pumps from Wanner is claimed to remove the need for pulsation dampeners in many circumstances.

Hydra-Cell pumps from Wanner have multiple, hydraulically balanced diaphragms in a single head, that operate sequentially, dramatically reducing system pulsation and the damage it causes. The cost of additional pulsation dampeners, along with ongoing costs of charging and maintenance is avoided in many instances and systems become more reliable. Pulsation is usually observed as noisy vibration in system components or rapid gauge fluctuation. This vibration can be a major problem, potentially causing component failure through fatigue or simply leakage in discharge pipe work due to pipe strain. The Hydra-Cell pump range can accommodate measured flow requirements from 1 to 6360 litres per hour at pressures of up to 172 bar with virtually no pulsation. Hydra-Cell pumps also exceed API 675 performance requirements in terms of repeatability, linearity and steady state accuracy. They are able to pump abrasives and liquids that contain solid particles and being seal-less, can pump hazardous liquids safely and can even run dry indefinitely without suffering damage. For more information contact Wanner International, Fleet, Hants. Tel +44 (0)1252 816847 Email: NHerrington@wannerint.com Web: www.hydra-cell.eu

A DIXON SOLUTION TO SAVE PIPEWORK & PRODUCT Dixon Europe are pleased to be launching a new product, the Dixon Hygienic Breakaway Check Valve, which is proving to be ‘the right connection’, potentially s a v i n g companies thousands. At a

recent trade show, an engineer from a well-known UK dairy company explained how a milk tanker had driven away from the loading bay before disconnecting the delivery hose costing thousands in replacement piping and install cost. Dixon’s Hygienic Breakaway coupling is a solution this problem. In such instance the coupling will break in two, separating the tanker from the loading bay. The 13kN break load bolts are the only items that will need replacing. The new Dixon Breakaway Check Valve is an innovative solution that is designed to eliminate product loss too. It incorporates the Breakaway Coupling and a Hygienic Check Valve. It acts as a single unit that has a diverted breaking point which will break at a determined break-load. Then the check valve will close protecting the loading bay pipe system AND avoiding product spillage. Designed with hygienic processing in mind, you can be assured that the breakaway conforms to FDA standards and is CIP capable; but, without the intricate workings and associated cost of similar products on the market.

For more information contact Dixon Group (Europe) Ltd, Tel: +44 (0) 1772 323529 E-mail: marketing@dixoneurope. co.uk |Web: www.dixoneurope.co.uk

PROCESS INDUSTRY INFORMER May 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves NEW DEVELOPMENTS FOR AMBITIOUS VALVE MANUFACTURERS BIFOLD AS THEY LAUNCH THEIR NEW INITIATIVE

The Bifold Store

Bifold Store is one of Bifold Group’s newest initiatives, incorporating their preferred range products with the emerging online market and the global acceleration of e-commerce. The preferred range includes a variety of the valves which Bifold Group provides with 48hr despatch. The range includes: Ball and Needle Valves, Check and Exhaust Valves, Flow and Volume Valves, Pilot and Mechanical Valves, Solenoid Valves and Medium Pressure Valves. Bifold Store is a way in which Bifold can offer a selection of products to you online, therefore creating a much more accessible and easy service. The Bifold Store has filter services such as ‘type of valve’ and ‘price range’ to make it easier to distinguish and locate products and navigate around the store. The Bifold Store is an easy way to access the products that are available via 48hr despatch time. The features on the web page make sure to spotlight popular products using a ‘Popular Categories’ section wherein customers can easily select products which are regularly bought. The Bifold Store also includes product images and descriptions along with their operational schematics in order to make product identification much quicker. The Bifold Store website also has easily identifiable tabs of the separate product ranges, again making navigation and accessibility around the online store easy and efficient. Accessibility is extended further via the various devices that the Bifold Store website has been made available to. Customers can access the website through a multitude of devices, including tablets, phones and computers. This means that products can be ordered in cohesion with the immediacy of the customer demand. There are over 500 products available in the Bifold Store’s growing catalogue, featuring a comprehensive selection of products from across the entire Bifold range. Once a customer becomes a regular buyer, they will acquire an account and purchase history which will be found under ‘My Account’. In this, customers can view their previous orders, current orders and can re-order the same items again without going through the basket process. All of the products on the Bifold Store are despatched within 48 hours from the point of order, incorporating Bifold’s new ’48 Hour Despatch’ initiative. This has been successful within the Bifold sales department and so implementing it on the Bifold Store will have the same effect in terms of efficiency. This again improves the accessibility of the products to the customers in conjunction with the other features of the website. If you are interested in the Bifold Store initiative, please visit www store.bifold.co.uk for further details and terms and conditions. You can also contact Bifold using the information below. Bifold are dedicated to maintaining the excellence of their products and their new facility confirms their commitment to shortening lead times and meeting customer demands. Bifold Group would like to take this opportunity to thank all their customers for their continued support. For more information contact Zoe Bancroft, Bifold Fluidpower Ltd, Tel: +44 (0) 161 345 4777 E-mail: zbancroft@bifold.co.uk Web: www.bifold.co.uk

HIGH-FREQUENCY RADAR LEVEL TECHNOLOGY ON THE RISE The introduction of VEGAPULS 64 begins a new age in radar measurement technology for liquids

VEGAPULS 64, the world’s first radar level sensor for liquids, operating at a frequency of 80 GHz, has instigated a radical new era in radar level measurement technology. Eighteen months ago a new sensor for the continuous measurement of bulk solids, VEGAPULS 69, was introduced with great success. This sensor also operates with a transmission frequency 3 times higher than the widely used 26 GHz frequency. “The market has shown that this technology is the thing of the future – since the market launch, over 10,000 VEGAPULS 69 level sensors have already been installed,” says Jürgen Skowaisa, product manager of radar instrumentation at VEGA Grieshaber KG, describing the success story of these increased frequency sensors. These instruments have proven their worth, especially on media with poor reflective properties, in production shafts up to 120 m deep, or in silos with numerous internal installations that generate strong false echoes. VEGAPULS 64 for liquid applications will follow this leap, also setting a milestone in measurement technology with its high dynamics and superior focusing. “Media with poor reflective properties, i.e. low dielectric constant, can now be measured significantly better than with previous radar sensors,” continues Skowaisa. Thanks to the vastly better focusing, the beam simply passes by internal tank installations or buildup. Interfering signals, which previously had to be filtered out with false signal suppression, now play hardly any role in the measurement process. “Moreover, it is now possible to use a much smaller antenna. Today we have process fittings with an antenna diameter of only ¾” – equivalent to the size of a £1 coin. The new technology also allows precise measurement of the level very close to the tank bottom. This opens up new perspectives in determining the level in small containers used in the pharmaceutical and biotech industries, as well as determining the amount of fuel left at the bottom of large fuel tanks. Measurement accuracy is +/-2 mm, even with a working range up to 30 m. The great success of bulk solids radar sensor VEGAPULS 69 and the current market launch of VEGAPULS 64 for liquids are setting the agenda for the future technological development of radar level measurement. Today, there is no way to surpass the performance of radar measurement based on an operating frequency of 80 GHz,” says Skowaisa with conviction.

For more information contact VEGA Controls Ltd, Burgess Hill, West Sussex. Tel; 01444 870055 E-mail: info.uk@vega.com Web: www.vega.com

CHOPPER PUMPS MEET THE CHALLENGE OF CORROSIVES

GRUNDFOS KEEP UP THE PRESSURE

The variety of waste handling applications which present specific challenges to pumps and pumping systems are many and varied although the aims and objectives (however tough the challenges) are usually the same; safe and reliable pumping 24/7 with minimal

maintenance.

Aggressive fluids, such as corrosives occur in many applications and a good example of where these have been pumped safely and efficiently with impressive reliability over many years is at a APHA (Animal & Plant Health Agency) research laboratory facility in Surrey, now sponsored by DEFRA. Vaughan Chopper Pumps were first supplied and installed at the research laboratory in 1997 by the Huntingdon based UK distributor, P&M Pumps. The pumps were CD4 Duplex (hardened) stainless steel pumps, fitted with special double mechanical seals in Hastelloy C and Kalrez construction. They also featured an external fluid barrier system due to the highly corrosive nature of the chemicals being handled, for example Sodium Hypochlorite with a concentration ranging from 15 to 20%. The pumps are typically handling flow rates of 18 M3/hr at heads up to 5 metres and are powered by 7.5 Kw motors running at 1450 RPM. Through their experiences at numerous UK waste water treatment and a wide range of manufacturing and processing sites, P&M Pumps have been able to demonstrate that Vaughan Chopper Pumps are an extremely effective option on the most challenging and varied solids pumping applications Further information contact P&M Pumps, Tel: 01487 830123

E-mail: matt@pumpmix.co.uk | Web: www.pumpmix.co.uk

The BM range from Grundfos is a family of high-pressure booster modules that are ideal for use in many situations such as boosting, liquid transfer as well as in systems that create circulation under a high static pressure. Their

compact design makes it easy to integrate the pump into existing piping systems. The pump is hermetically sealed; a design that helps minimising maintenance costs and insuring the pump delivers low-noise operation. This family of submersible pumps are characterised by their high level of resistance to aggressive liquids. Available in high-grade stainless steel AISI 904L, the BM boosters are corrosion-resistant and are thus well suited for operating in a range of applications including reverse osmosis systems, water supply systems, water treatment systems and industrial plants. The booster is built into a pressure sleeve, which makes it possible for the pump to deliver a high static pressure of up to 80 bar. With so many attributes and a great reputation for reliability, these modules have the answer to many boosting needs, check these out for yourself at www.grundfos.co.uk

PROCESS INDUSTRY INFORMER May 2016

SAFETY RELIEF VALVES:

PURPOSE & FUNCTION By Nick Smith - Marketing - Seetru Limited

The primary function of a Safety Relief Valve is the protection of life, property and environment. A Safety Relief Valve is a device designed to protect a pressurized vessel or system against overpressure should all other safety systems fail.

n overpressure incident is defined by any situation/ condition which would cause the pressure in a vessel or system to increase beyond its specified design pressure or maximum allowable working pressure (MAWP). A Safety Valve is designed to open and relieve excess pressure from vessels or equipment ...and then to reclose and prevent the further release of fluid, gas, or steam once normal conditions have been restored. There are a number of reasons why the pressure in a vessel or system can exceed a predetermined limit. A PI Standard 521 | I SO 23251 Sect. 4 provides a detailed guideline about causes of overpressure.

operating system automatically measures and calculates the bubble count / leak rate in a manner compliant with the requirements of API 527. The informative and comprehensive display: - Manages the test sequence  - Shows the bubble leak rate  - Provides a Pass / Fail Indication

SAFETY VALVE DESIGN: SELECTION

A Safety Valve is in many cases the last line of defence for a system or operation. It is vitally important that the Safety Valve is certified to, and capable of, operating at ALL times and under ALL circumstances. A typical example of this would be the event of power failure, when system controls are non-functional ...in this situation the sole source of power for the Safety Relief Valve must be the process fluid or substance itself. The Safety Relief Valve must open at a predetermined set pressure, flow a rated capacity at a specified overpressure, and close when the system pressure has returned to a safe level. Since reliability is directly related to the functionality and performance of the device, it is important that the design of the Safety Relief Valves is as uncomplicated and efficient as possible. NOTE: A Safety Valve has a singular purpose: Overpressure Protection and should NEVER be used as a process valve or pressure regulator).

Safety Valves are sophisticated instruments, to ensure their safe operation it is important that they are always dealt with by competent specialist engineers, this applies to their selection, installation and maintenance. The use of Safety Relief Valves across a very broad spectrum of industries and applications means that considerations with regards to design must be correctly evaluated. Valves need to be available with a large variety of options for construction materials, sealing materials, connections ...and must be able to tolerate wide variances in both pressure and temperature. We have been designing and manufacturing Safety Valves for over 65 years and have an extensive range of devices which have many National and International approvals such as US National Board (ASME Section VIII Division I) and of course the European Pressure Equipment Directive 97/23/EC, update soon to be to introduced under PED 2014/68 enabling European CE mark; and, Russian EAC (TR CU) Customs Union certification and declaration. This allows Seetru to offer their products into the global marketplace. The extensive ranges of products include Safety Valves in the key materials of construction including bronze, brass and stainless steels, Safety Valve Pressures: 0.2 bar g. 500 bar g. | Safety Valve Temperatures: 196° C +250°C.

SAFETY RELIEF VALVES: TESTING

SAFETY VALVE DESIGN: TECHNOLOGY

One of the critical quality characteristics of a Safety Relief Valve is its functional tightness, i.e. the tightness between the seat and the disc. On gastight safety valves, tightness is measured using the internationally accepted air bubble count test (also known as “Kellogg Test”) as per the API 527 standard (American Petroleum Institute Seat Tightness of Pressure Relief Valves). Seetru have developed an automatic, electronic system for recording the Kellogg Bubble Count; our trademarked ComputestTM fast

The generation of compressed gas has considerable cost and therefore reliability of safety valve performance is essential to the optimization of running costs. Where possible, the safety valve should provide reliable and repeatable leak tight performance up to the Safety Valve’s set pressure: elastomeric seals are particularly suited for this demand. It is also essential that the flow capacity of the Safety Valve matches that of the application: if the valve capacity is too low it may not protect the system and personnel adequately against overpressure; if the flow capacity of the valve is too large it may chatter (open and close quickly and repeatedly) in operation – this may cause damage and subsequently result in valve failure. In the early 1960s, Seetru pioneered the use of elastomeric seals in safety valves for use in the compressor industry across Europe. The key benefit of elastomeric seals in compressor applications is that they will seal fully, reliably and repeatably. It is, of course, necessary to select a sealing technology that is suitable for the duty: here, the seal material must be suitable for the temperature and medium, i.e. the compressed fluid and any other substances that may be contained in the fluid, such as lubricating oils or gas contaminants. While modern elastomeric seals have very extensive performance

The most common are: ·Blocked discharge  ·Exposure to external fire, often referred to as “Fire Case” ·Thermal expansion  ·Chemical reaction  ·Heat exchanger tube rupture

PROCESS INDUSTRY INFORMER May 2016

envelopes (temperature and chemical compatibility etc.), it may still be necessary to use plastic or metal sealing technology in order to deal with aggressive or difficult applications. Safety Valves have to be of the highest quality and provide a long term reliable operation solution. The company’s range of elastomeric safety valves for compressed air and gas applications incorporate proprietary compact design technology which is highly efficient and cost effective, and incorporates the exclusive Tutchtite® seal technology for repeatable bubbletight sealing performance. Another example of Safety Valve innovation is a range of specialist ultralow emission safety valves for refrigeration applications: these world leading safety valves are tested during assembly using gas spectrometry leak detection, to ensure leakage rates of less than 3 grams of gas per year.

SAFETY VALVE DESIGN: EVOLUTION Although generally speaking the design and manufacture of Safety Relief Valves is varied and remains driven by the individual requirements of specific applications, some manufacturers have developed multipurpose devices which aim to provide a more complete and practical solution.

In keeping with this, we have developed our own range (The LGS™ Safety Valve range) which incorporates all of our technological advances into a more versatile system. This Safety Valve range has been designed with a robust and reliable construction so as to be suitable for the widest possible range of industrial applications, while also achieving a broad variation in flow characteristics ...coping with both low volume and high relief operations. A ‘single trim’ design ensures that all components are common across Liquid, Gas & Steam applications.

SAFETY VALVE TRAINING It is worth mentioning that Seetru offer a range of training courses through its online division BEI Services (Blupax Engineering and Industrial Services). BLUPAXTraining (BEI Services: http://blupax. com/blupax) are able to offer a wide spectrum of specialist safety valve training courses. We offer personal development training at locations throughout the UK, subjects include: Safety Relief Valves, Safety Pressure Devices, Practical Workshop instruction.

WHY YOU DON’T ALWAYS NEED A WELL OILED MACHINE Paul Mitchell, managing director of Bowman International, explores how self-lubricating bearings can remove the burden of correct lubrication to help improve safety, cut costs and extend the lifetime of equipment.

ealing with OEMs, distributors and logistics companies, we understand more than most what customers need from a bearing. Whether it is a standard catalogue item or a special order, customers are wanting more and more for their suppliers to take responsibility for helping them to select the right bearing. In many cases this means addressing the three main reasons for bearing failure; bearing fatigue, making the wrong selection of bearing type and material, and incorrect lubrication.

AN ALTERNATIVE SOLUTION? Any engineer will know that the topic of lubrication – or tribology - is an extremely complex one. There are not enough words in this magazine, let alone on this page, to cover the subject in anywhere near the detail required to do it justice. However, one thing is clear; there are so many varying factors which influence the decision over how best to lubricate a bearing, it is not always an easy choice to make. Even once that difficult decision has been made, consideration must also be given to the ongoing requirement for lubrication. In many sectors it is either

difficult, cost-prohibitive or impossible to service bearings because of the environment in which they operate. In others it is the nature of the industry that busy operatives simply will not take the time to keep bearings adequately lubricated. Whether manual or automated, regular lubrication of process equipment to ensure performance and extend the lifetime can be expensive too. For some applications, the answer could lie in the specification of self-lubricating plain bearings. And there are now a host of proven solutions that can help keep maintenance to a minimum in even the most hostile of environments.

SELF-LUBRICATING SOLUTIONS Self-lubricating bearings are also referred to as graphite plug bearings, because they are lubricated for life with solid graphite plugs. Graphite is mechanically forced into holes into the bearing. A film of graphite is then transferred to the shaft as it begins to turn, offering continuous lubrication over long periods without maintenance. With the capability to withstand high temperatures up to 425°C (800°F) and cryogenic temperatures down to -200°C (-400°F), they are ideally suited for applications where no external lubrication can be provided, for high temperature applications where oil or grease would carbonise, and for bearings which will be immersed in water. This includes high temperature applications such as ovens, kilns, dryers and injection moulding machines, together with dry applications such as printing, textiles, food, cosmetics and

pharmaceutical machinery. Wet application would include submersed pumps, textile finishing, chemical processing, water turbines and lock gates – all of which are hostile environments and difficult to access for servicing, which clearly makes a maintenance-free solution hugely appealing.

REDUCING REQUIREMENTS Another option that is proving increasingly popular in a wide range of applications is to choose a different material that can prevent the need for lubrication. Bearings made from the latest, value-added alloys can deliver enhanced benefits, including the capability to take far higher loads and corrosion-free operation – thus giving longer life and greater reliability. Before such innovations in materials, designers were faced with the choice of utilising oversized bearings in order to take the required loads, which would add weight and take up more space to get the necessary load and lubricity level, or switch to hardened steel, which requires regular lubrication. Instead, the higher load and lubricity ratings delivered by new materials allow manufacturers to use smaller bearings with higher load ratings to save space and weight, or replace existing bearings and get a much higher load rating and longer life. It means longer lasting bearings and, in some cases, cost-savings too – a win-win situation.

EXTENDED CHOICE There are other options, of course. Leading suppliers can offer a wide range of lubricants with varying temperature ranges to meet specific requirements, whilst lubricant additives are also available to impart anti-wear properties in marginal lubrication conditions such as stainless steel shaft applications. Alternatively, wrapped PTFE lined bearings include a lead-free polymer fibres mixture layer, which effectively coats the mating surface of the bearing assembly to form an oxide-type, solid lubricant film. With lower wear, a low coefficient of friction and good sliding characteristics, it makes these bearings suitable for a wide range of applications where self-lubricating properties are hugely advantageous.

TAKE ADVICE Whatever your application, the most important thing is to speak to the experts. At best a bearing failure is a huge inconvenience, at worst it is extremely costly and potentially dangerous, so it is crucial to get it right. Whether you need to lubricate or can source a maintenancefree solution, the most important thing is to use a supplier that can take a holistic approach to all bearing types, materials and lubricants. Without that whole-market view, you could be missing out on efficiencies that you didn’t even know exist.

NEWS

MAY 2016

ON WARDS & UPWARDS… We are delighted to say that recently we have added three new members to the fold. Namely March May, based in St Neot’s where from they have been manufacturing & distributing high performance magnetic drive seal-less pumps for 40 years. Established in Bishop’s Stortford, DAB Pumps are recognised in the motor-driven water pump industry in which they have been operating in for 37 years. Our third new member is NOV, who, over a hundred years have been manufacturing pumping and mixing equipment & systems and can be found in Manchester.

2016 PUMP AWARDS… This year’s event was the 10th, held at The Heythrop Park Resort Hotel on the edge of the Cotswolds and was widely considered to be one of the best. As usual it was ‘staged managed’ by Touchwave Media who as usual did so as ‘smooth as silk’. Results can be seen inside…

BPMA NEWS… I’ve forgotten the number of year’s that I have been editing ‘the News’, but it must be at least 12-14 and I’m delighted to say that recently there has been an increase in the number of members participating and bringing their information to you, complimenting the BPMA’s press activity. We are always looking for ways to develop the BMPA News further and would welcome any feedback & suggestions – please email peterullmann@piimag.com

Installed Base - Everything from a single source We provide comprehensive customer care from a single source – and we can deliver this over the entire product life cycle. We offer an extensive range of pumps and valves for virtually every application, unique engineering expertise to fulfil every specific customer request, and tailored service and spare parts solutions. In other words, technology that makes its mark. • KSB Limited • 2 Cotton Way • Loughborough • Leicestershire • LE11 5TF • 01509 231872 • www.ksb.co.uk

Our technology. Your success. Pumps Valves Service •

•

BPMA 75TH TH ANNIVERSARY DINNER The Heythrop Park Resort Hotel Celebrating The Past, While Embracing The Future

This year the BPMA achieves an impressive milestone – three quarters of a century serving the British pump industry. From its humble beginnings back in 1941, whilst the UK toiled with the inherent difficulties of the second Word War, through the numerous economic peaks and troughs that have inevitably followed, and against an ever changing legislative landscape, the BPMA has been a constant source of support, guidance and information. To celebrate 75 years of unbroken service to both its members and the wider pump industry, the BPMA will be staging a special 75th Anniversary Gala Dinner. Held at the impressive Heythrop Park Resort hotel in Oxfordshire, on Thursday 6th October, the event promises to be the highlight of its year-long celebratory activities. Heythrop Park boasts a unique and luxurious venue set in 440 acres of stunning Oxfordshire Countryside. Dating back to 1710 this quintessential English country estate seamlessly combines elegance with style. Located on the edge of the Cotswolds, with Oxford on the doorstep, it is also close to Blenheim Palace and the picturesque Cotswold villages of Burford & Chipping Norton. The Resort also offers a championship 18-hole golf course, superb health club facilities, and exceptional dining. A glittering champagne reception, held in the main hall and accompanied by live music, will be followed by a stunning 4-course dinner with fine wine, and further musical entertainment direct from London’s West End. More music and dancing courtesy of the Swinging Little Big Band, will ensure a great time is had by all. Event Timings • 1.00pm - 5.00pm Arrival, Check-In and Leisure Time • 7.00pm - 7.45pm Drinks Reception in the Great Hall • 7.45pm - 8.00pm Move through to Dinner in the Enstone Suite • 8.00pm - 9.45pm - Anniversary Dinner • 9.45pm - 10.30pm - West End Musical Showcase • 10.30pm - Late - Dancing to the Swinging Little Big Band Prices Tables of Ten can be secured at £1000.00 + Vat (£200.00) = £1200.00 Individual Places can be secured at £120.00 + Vat (£24.00) = £144.00

Event Kindly Sponsored By

ATEX: EC GUIDANCE ON THE TRANSITION FROM ATEX DIRECTIVE 94/9/EC TO DIRECTIVE 2014/34/EU An EC Guidance document on the transition from the ATEX Directive 94/9/EC to Directive 2014/34/EU is now availablefrom BPMA. The new Directive does not bring about any changes as regards the scope, essential health and safety requirements and conformity assessment procedures. This document consists of a detailed FAQ section covering both horizontal questions (in line with the latest Blue Guide text) and sectorial ones (applicable to ATEX only) The key changes reflect the alignment with the New Legislative Framework (NFL) and mainly concern: · definitions (horizontal additions from the NLF) · more detailed information about the obligations of economic operators · more detailed requirements for notified bodies · updated references (presumption of conformity, CE marking) · simplified procedures for market surveillance · taking the contents and model of Declaration of Conformity (DoC) from the NLF · taking validity conditions for EU type-examination certificate from the NLF · practical transitional arrangements given for the DoC and the Directive numbering that needs to be stated (in accordance with the Blue Guide interpretation) To ensure that the transition to the new Directive is not too abrupt, the manufacturers are given the flexibility to indicate already today the following statement, as long as their product declares conformity with the Directive in force. This transitional arrangement can be applied to other NLF-Directives only too: “The object of the declaration described above is in conformity with the relevant Union harmonization legislation: Directive 94/9/ EC (until April 19th, 2016) and Directive 2014/34/EU (from April 20th, 2016)” Please note that this version of the Guidance is preliminary, due the ongoing drafting of the ATEX Guidelines and the pending publication of the Blue Guide.

BPMA GOLF DAY 2017 The 2017 BPMA Golf Day will be held at the

Heythrop Park Resort Oxfordshire

Thursday 25th May 2017

Tea, Coffee & Bacon Rolls at Registration 18 Hole Texas Scramble Team Competition with Buggies Individual Prizes Prize Giving Dinner Overnight Accommodation Breakfast on Departure

Only £199 + VAT Per Player

I/We would like to reserve Places at the 2017 event Contact Extra accommodation on the 24th

Company Email Rooms Invoicing January 2017

Fax Back: 0121 601 6387 Email: s.smith@bpma.org.uk Contact: Steve Smith 0121 601 6350

DELEGATE NAME

CITY & GUILDS BPMA COMPETENCY ELECTRICAL COURSE (3 DAY)

CITY & GUILDS BPMA COMPETENCY ELECTRICAL TRAINING COURSE (3 Day)

City & Guilds BPMA Competency Electrical Course BOOKING FORM NEXT DATE: June 21 - 23 - 2016 It is usual in many industries to find that companies have radically streamlined their maintenance and technical workforce departments. This puts pressure on company managers to use non-electrical personnel for routine electrical duties. This three day course is specifically designed to assist non-electrical employees to prepare themselves for cross trade working, and to help companies comply with the requirements of current legislation regarding the use of such people for minor electrical tasks. Course Objectives: After completing the course, students should be able to: • Recognise safe working practices (related to electricity in the workplace) • Work within the requirements of current electrical legislation (relating to topics covered) • Understand the fundamental principles of electrical energy • Perform routine electrical tasks at a basic level • Perform safe isolation of electrical circuits • Enhance their workplace skills • Relate to electrical circuit diagrams Who should attend: The course is primarily aimed at mechanical or un-skilled tradespersons that are preparing themselves for work upon electrical systems. The course may be of great benefit to companies that intend to employ non-electrical personnel to perform routine electrical duties, such as, lamp replacement or portable appliance testing etc. Prerequisites: Basic numerical and literacy skills are required. Topics Covered: • Health and Safety legislation (related to electricity in the workplace) • Basic electrical principles • Electrical power and units of measurement • Safe isolation of electrical circuits • Safe working practices • Electrical test instrumentation • Conventional circuit layout • Basic first aid (related to electrical hazards) • Electrical diagrams • Cable and wiring system

Next Course Date: 21 - 23 JUNE 2016

BOOKING FORM Delegate Cost : £450.00 + Vat Please complete all sections where applicable and then click the "submit" button at the bottom of the page Company Name: Address Your Name: Main Contact Email: Purchase Order No:

Authorised by:

21 - 23 June 2016

No. of Delegates

DELEGATE NAME

Course venue: British Pump Manufacturers Association Ltd, National Metalforming Centre 47 Birmingham Road, West Bromwich, B70 6PY

Amount

(J1, M5) (SatNav B70 6QE) Each day will consist of: A morning session from 0.900 - 12.30 pm (10.15 am start on the first morning) followed by lunch and :

Sub-total

An afternoon session from 1.30 - 5.00pm.

VAT @ 20% TOTAL:

There will also be refreshment breaks

PAYMENT OPTIONS IMPORTANT - PAYMENT MUST BE RECEIVED NO LATER THAN 7 DAYS PRIOR TO COURSE DATE CARD (MASTERCARD/VISA ONLY

INVOICE

CHEQUE Please make cheque payable to: "British Pump Manufacturers' Association and post with a copy of this form to BPMA, National Metalforming Centre, 47 Birmingham Road, West Bromwich, B70 6PY

Card No: Cardholder: Address:

Expiry:

Cancellations: Cancellation should be in writing Charges are as follows 0-7 days 100%, 7-14 days 75%, 14-21 days 50%. 21 days and above 0%

Security No;

Further details will follow once all registrations are received

Postcode:

Submit If you encounter a problem in submitting this form please email s.smith@bpma.org.uk

WASTE ELECTRICAL & ELECTRONIC EQUIPMENT DIRECTIVE DEVELOPMENTS In August 2018 the WEEE2 Directive will enter into force in the UK . Under the existing WEEE Directive in the UK it has been fortunate that other than Garden Pumps no other pumps have been included in scope. This first revision of the Directive has now brought in many products that were previously out of scope. To try and clarify if pumps will be in scope of WEEE2 the BPMA met with the UK government, BIS ( Business Innovation & Skills) who unfortunately advised the BPMA that they are overwhelmed with the amount of items that require clarification. To assist in making a decision in the UK for the Pump Industry they have now requested that the BPMA write its own position paper after assessing all the Commission Guidance documents for both domestic and non-domestic pumps. If BIS agree with the BPMA document then that will position for pumps in the UK . This gives the BPMA and its members an opportunity to control the situation on WEEE2 Even if the UK population agree to leave the European Union on the 23rd June 2016 it will be many years before the existing European laws are repealed , on this basis it has been decided to form a new BPMA working group to write the WEEE2 position paper for the pump industry. The first meeting of this working group will take place in July.

For further information relating to the BPMA please contact British Pump Manufacturers Association, National Metalforming Centre, 47 Birmingham Road, West Bromwich B70 6PY, UK Tel: 0121 601 6350 Fax: 0121 601 6373 E-mail: enquiry@bpma.org.uk or visit our website: www.bpma.org.uk The BPMA takes no responsability for the statements, claims or opinions expressed in this Newsletter 3

Launched 16 years ago, the Pump Industry Awards are now widely regarded as the industry event. Whether it’s recognising companies and individuals who go the extra mile or acting as a motivator to encourage more companies to fulfil their potential, the core values of the awards have not changed over the years. This year’s Pump Industry Awards Gala Dinner was held at the Crowne Plaza Hotel, Heythrop Park on the fringe of the Cotswolds on Thursday 10th March. The awards ceremony was the highlight of the evening, hosted by the enchanting BBC News Presenter Mary Rhodes and held in association with the BPMA and sponsored by Process Industry Informer, KSB, SPP Pumps, AESSEAL, WEG, Tomlinson Hall & Co and World Pumps. The 2016 finalists were awarded certificates on stage and the eight worthy winners announced and presented with certificates & trophies to the usual ‘unruly’ celebrations. After dinner entertainment followed with the hilarious Dominic Holland whose performance was greatly received by the guests.Finally and to round off the evening we held a charity raffle to raise money for WaterAid, we managed to raise a staggering £1800.00!

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

MEET THE WINNERS

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

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

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

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

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

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

WEG PRESENTS NEW FLEXIBLE & EFFICIENT GEARED MOTORS

BREWERY LAPS UP ENERGY SAVINGS

WEG, a leading global manufacturer of motor and drive technology, is launching the WG20, a new range of highly versatile modular geared motors that offer worldwide interchangeability and up to 96% energy efficiency across a wide range of industrial applications requiring precise and reliable power transmission. The new geared motor will enable users to increase the energy efficiency of systems in their plants significantly, reducing associated energy costs. Developed in cooperation with the companyâ&#x20AC;&#x2122;s subsidiary â&#x20AC;&#x201C; gear technology specialist Watt Drive - the WG20 comes in standardised mounting dimensions to suit both new and existing drive systems, ensuring ease-of-installation and flexibility when retrofitting. It is designed to cover virtually all international supply voltages thanks to internal voltage switching, which makes it easily interchangeable. Available in energy efficiency classes IE2 and IE3, the motors feature an advanced design, with the pinion directly mounted on to the motor shaft resulting in a two-stage gear unit (in place of the commonly used three-stage unit). Fewer stages means reduced friction, which translates into lower power and heat dissipation and thus more efficiency. Additionally, the improved gear geometry featuring optimised gear teeth and high quality ground gear parts ensure low-loss power transfer and low noise levels, along with reliable performance and extended service life. The compact gear unit design also has a positive impact on the required lubricant volume. The gear arrangement and the advanced housing interior allow the gear units to operate with a low oil level. The optimised oil fill level and low friction losses in turn prolong the life of the seals and extend the oil change intervals, therefore minimising time and costs associated with maintenance. The WG20 is built with helical, parallel-shaft and helical bevel gear units with rugged pressurecast aluminium housings and is suitable for most industrial applications requiring torque ratings between 50 and 600 Nm. International certifications further enhance the geared motor unitâ&#x20AC;&#x2122;s versatility, enabling users to operate it at 100 or 120 Hz with variable speed drives. For more information on WEG visit www.weg.net/uk.

When a well-known name in the brewery industry in the UK approached Grundfos Pumps to undertake an Energy Check on a part of their operation, they were sure they could help to deliver real savings. This is because Grundfos have been at the forefront of energy optimised pump development for years and take real pride in their achievements and their approach to sustainability. Finding out what energy savings could be achieved is straightforward as Grundfos provide a range of diagnostic tools such as an Energy Check and Pump Audit that will establish the current pump system performance. Not only that, but these tools also provide various post-analysis reports that include details regarding the potential savings and payback periods as well as the various pump options you could opt for. This is what happened in this particular case, when an energy check was undertaken which showed a potential energy saving of 148,645 kWh could be achieved by changing just 2 pumps. Better still, the payback period was just 6 months. The pumps were duly replaced with 2 x Grundfos NB 65-200 these reliable single-stage, standard bloc pumps. With their enviable reputation the Grundfos NB(E), are manufactured at ISO 9001 certified facilities, and today the range comprises of a complete series of close-coupled (NB family) and long-coupled (NK family) pumps that are compliant with DIN EN733 or ISO2858. All are nonself-priming single stage, centrifugal pumps with axial suction port, radial discharge port and horizontal shaft. The pumps have now been installed for some time and are delivering not only in terms of the promised energy efficiency, but also are proving to be very reliable as they continue to deliver optimised pumping operation. A particular key customer benefit in this instance is that the pumps can be automatically slowed down at weekends when production is not as high. This is a great way of saving additional energy and means these pumps are contributing towards their global energy reduction targets. All in all are supplying many good reasons for saying cheers. For more information or Literature request contact Grundfos Pumps Ltd, Leighton Buzzard, Bedfordshire. Tel: 01525 850000, E-mail: grundfosuk.com Web; www.grundfosuk.co.uk

The path to a greener future... Efficiency l Strength l Reliability Since January 2015, EU MEPS have stipulated that any new motors on the market ranging from 7.5 kW to 375 kW power output have to meet the IE3 efficiency standard or IE2 efficiency standard if used with an inverter drive. From January 2017 this will be extended to motors from 0.75 kW to 375 kW. Our inverter drives will work with new and existing motors to help you reduce energy consumption and meet legislation when used with an IE2 motor.

For a greener future www.weg.net

WEG also offer a complete range of IE3 and IE4 energy efficient motors both for safe area and hazardous area applications to WIMES. Watt Drive high performance gearboxes are built to withstand the toughest industrial applications meeting the demands for operation across different industries.

Individually, our gearboxes, drives and motors are amongst the most energy efficient available. Together they give you unbeatable levels of reliability and performance.

THE PUMP INDUSTRY – PAST, PRESENT AND FUTURE

The definition of a pump is a device which uses suction or pressure to raise or move liquids. Back in Egyptian times, 2000 BC, this meant a long suspended rod with a bucket at one end and a weight at the other. 1800 years later, in arguably the greatest invention of all time, Archimedes devised a mechanical method of lifting low lying water for irrigation and land drainage purposes known as the Archimedian Screw Pump. This method is still very much in use today. Mechanical pumps require power in order to operate, in 200 BC this source of power was the human hand. Animal, wind and water turbine power sources followed, thanks to the development of mechanical power transmission linkages. Steam engines became the main power source at the end of the 18th century, whilst gas and early oil dominated the 19th century. In 1790 Thomas Simpson coupled a reciprocating pump to James Watts rotary motion steam engine, to drive municipal water works pumps on the River Thames. This ultimately led to the formation of Worthington Simpson in 1917, which is now a part of Flowserve. In 1851 John Gwynne filed his first centrifugal pump patent. His early pumps were again steam engine driven but used primarily for land drainage. Allen Gwynne Pumps closed their manufacturing plant within the town of Bedford in 1987, which led to the formation of Bedford Pumps by former members of the pump department at W H Allen. The first electric motor driven pumps finally emerged in the early 1900’s. Whilst electric motors now dominate the pump industry, electricity cannot reach all locations and the diesel engine driven pump, with its high torque engine, still plays a significant role in today’s mobile pumping market.

VARYING PUMP OUTPUT AND PERFORMANCE Since Archimedes time there has been a desire to vary the output and performance of a pump. This was originally achieved by changing the rotational speed of the screw or by varying the depth of water over the intake of the screw. Both concepts still hold true today. In 1972 the Swiss engineer, Martin Stähle, invented the “Prerostal” system that much like the Archimedes Screw, varies the output of a Hidrostal screw centrifugal pump without changing its speed! 20” Environment Agency Hidrostal mobile pump driven by JCB Diesel Engine Archimedes and the modern equivalent Prerostal system Prerostal uses gravity to drive the pump inlet head, but with the addition of controlled pre-swirl through a specially designed pump basin. This system holds all the non-clog benefits of the Archimedes Screw but with the added advantages of a smaller footprint and lower power consumption and is a great example of how the pump industry tends to enhance and build upon successful designs and experience that have gone before.

All engine driven pumps can adjust performance by changing the shaft speed and or gear ratios on the drive train to the pump. With the fixed speed electric motor driven pump, adjustment to performance was initially possible through belt and pulley drives between pump and motor. This was not really improved upon until dual speed motors became commercially available from the late 1950’s on. It was not until the late 1980’s that the possibility to infinitely vary the speed and performance of an electric motor driven pump became commercially available to the wider market. This took the form of the variable speed drive or frequency converter.

DEVELOPMENTS IN PUMP TECHNOLOGY It could be argued that the main developments in pump technology have been driven by an end users application requirement (eg. to be able to vary a pumps output) since Archimedes time. This need was progressively met through the many changes to pump power/drive source as new technology became available and was adopted into the pump arena. The alternative to speed control was to throttle a valve or close a sluice gate. This however wastes energy across the restriction barrier to flow. The need to vary pump performance within an installation experiencing changing system characteristic’s, is not that new, the possibility to achieve this comprehensively however, is. Today improved motor and variable speed drive technology provide the solutions to varying load or demand patterns on pumping systems. Whilst this has opened up new opportunities it has also brought new challenges. The main one ensuring that the latest technology is applied appropriately, therefore delivering the best results that add value to a system, i.e. Whole Life Cost or Totex. A variable speed drive alone does not always guarantee optimal results in terms of efficiency, reliability or reactive maintenance. This can be apparent on some wastewater applications and systems with a high static head component to a duty point. Here a technology such as a Prerostal (perhaps with dual speed motors) will often deliver a better Whole Life Cost outcome.

The trend to better match pump performance to system requirements looks set to continue and probably intensify, particularly as we run out of options to improve product efficiency and look into the system to obtain further savings. Having said that we must not lose sight of the fact that not all systems require infinite variability in pump performance and sometimes a belt drive, dual speed motor, fixed speed motor or even the halfway house of a Prerostal system may be the most appropriate Totex solution where fewer set-points of performance are required.

WHAT’S THE FUTURE? We are all aware there is a limit to product efficiency. As we get closer to that limit, the magnitude of savings which pumps, motors and variable speed drives alone can realise, is decreasing. Perhaps the next generation of significant savings for pump users belongs to a wider pumping system optimisation approach? This would no doubt require a middle way, taking the right mix of the most appropriate technology combinations for given applications. By not just looking at the pumps in isolation, but aligning controls and monitoring to adapt and match performance to the more dynamic systems, a lower energy outcome should be possible with improved reliability from planned maintenance driven by monitoring equipment. The BPMA has offered members valuable guidance on many aspects of evolving pump efficiency, standards and testing for some considerable time, helping us all separate fact from fiction. BPMA is also currently actively involved in the developing scene of an “Extended Product Approach” which Europump are currently proposing. Beyond this we are then into the huge diversity and knowledge challenge of “System Optimisation”. Could the future of the BPMA lie more in the realms of optimum system integration for pumps as opposed to the ‘pump itself? Whatever the challenge may look like we can be assured the BPMA will continue listening to the members, balancing the arguments and representing the British Pump market needs successfully for many years to come. For further information please contact Andy Wilson, Business Development Manager for Hidrostal Ltd.

HIGH EFFICIENCY API 685 PUMP WITH INTERNAL VAPOUR MONITORING SOLVES HYDROCARBON APPLICATION CHALLENGES Sundyne HMD Kontro Supplies ZeroLoss™ and VapourView™ technologies to US Customer on light hydrocarbon application Experiencing operational and fugitive emissions issues with an existing mechanically sealed API pump application in Washington, USA, a pump user reviewed whether the application of a magnetic drive sealless pump solution would improve the situation. The application liquid, a highly volatile hydrocarbon, presented several sealing and operational challenges that would be overcome by the elimination of the mechanical seal. The proposed solution was a magnetic drive pump complying with the API 685 standard fitted with an engineered composite containment shell and internal flow regime monitoring. The engineered composite containment shell (ZeroLoss™) eliminates induction losses normally associated with metallic containment shells and provides much improved handling of volatile and heat sensitive liquids. It also provides a more robust solution for magnetic drive installations that might experience marginal system conditions. The containment shells are produced to comply with the 40 bar (580 psi) API 685 design pressure requirements and feature highly chemical resistant composite material that is tough, durable and robust. Non-invasive internal flow monitoring (VapourView™) was proposed to provide constant monitoring of the hydrocarbon inside the pump. Early detection of the presence of gas in the internal cooling and lubrication system is given, providing an early warning of adverse conditions that might impact the safe and reliable operation of the pump. One of the key features of the system is that it measures the primary cause of a potential problem (presence of vapour), and not a secondary condition such as change in power or temperature. Further, the system ensures correct priming and venting of pump is performed during start-up, a desirable feature, particularly on hydrocarbon applications. After consideration the user chose to implement the proposed magnetic drive pump solution. During the commissioning phase of the installation, the internal flow monitoring device detected a number of priming and venting issues that enabled the user to revisit their start-up procedures, ensuring these issues were overcome. After start-up the presence of gas was also detected inside the pump, which originated from the presence of vapour in the pumps suction pipeline, this condition was also corrected. By reviewing and applying the latest magnetic drive pump technologies, the user is now enjoying improved reliability and reduced fugitive emissions in this hydrocarbon pump installation. Full details of the GSP pump range and VapourView™ and ZeroLoss™ technologies can be found at www.sundyne.com/hmdkontro. For further information and literature, please telephone +44 1323 45200 or email vince.lee@sundyne.com.

BRDO & NMRO COMBINE TO SIMPLIFY REGULATION FOR BRITISH BUSINESS

SPP MAKES FURTHER INVESTMENT INTO DEWATERING BUSINESS

BRDO and NMRO brought together into a single BIS directorate from 1 April 2016. The Better Regulation Delivery Office (BRDO) and National Measurement and Regulation Office (NMRO) were brought together into a single BIS directorate from 1 April 2016 to focus on regulation and enforcement. BRDO were previously responsible for improving the way in which local and national regulators enforce regulations, saving money for business and taxpayers. NMRO operated as an Executive Agency within BIS, sponsored by BRDO, aiming to simplify technical regulation for the benefit of UK businesses. The new Regulatory Delivery directorate is led by BRDO Director, Graham Russell and reports to Small Business, Industry and Enterprise Minister, Anna Soubry. The directorate will work to ensure that the way regulation is enforced is proportionate and risk based. It will deliver existing functions such as Primary Authority, legal metrology and hallmarking policy, technical regulation and enforcement work. BIS Permanent Secretary, Martin Donnelly, said:

“Combining NMRO and BRDO will bring together policy expertise and practical experience. This will ensure that government policy is effectively delivered in ways that reduce burdens on business, save public money and properly protect people and communities.” The director of the new Regulatory Delivery directorate, Graham Russell, said:

“This is an exciting opportunity to raise standards of protection for vulnerable people and encourage businesses to grow, by improving the way we regulate in the UK. Combining two organisations is challenging but I know that we are committed to working well together, using fewer resources for better outcomes.” Martin Donnelly has written to all BRDO and NMRO staff about the decision to combine the two offices into one Regulatory Delivery directorate. Staff will continue to be supported by senior leaders and line managers during the transition.

AESSEAL® IS PLEASED TO ANNOUNCE THE LAUNCH OF THE SHORT CANISTER MIXER SEAL (SCMSTM) The seal has been designed to meet the modern day mixing requirements of faster more efficient mixing from smaller vessels and is suitable for side entry (flooded) or top entry (running in vapour) mounting. The SCMSTM is designed specifically for Mixer, Agitator and Reactor applications and is available in sizes ranging from 30mm to 125mm (1.250” to 5.000”). The dual seal is ideal for both mature and modern mixer designs with its reduced height for applications where space is limited and is available for ATEX applications. The range is dual balanced ensuring that the seal can maintain containment through a range of process fluctuations. The range also incorporates fail safe protection through independent seal face loading using a unique common multi-spring design ensuring production safety. The SCMSTM can accommodate up to 3.5mm of radial T.I.R movement on larger sizes and also has self-adjusting axial movement compensation. Engineered solutions are available for difficult or non-standard applications. For more information contact Aesseal Plc, Rotherham, South Yorkshire. Tel: 01709 369 966 E-mail: marketing@aesseal.com Web: www.aesseal.com

GRUNDFOS MD GETS THE ROYAL SEAL OF APPROVAL At a special ceremony the Queen of Denmark, Margrethe II, presented Peter Reynolds, Managing Director of Grundfos Pumps with an important award in recognition of his achievements.Peter’s 25 years of hard work were acknowledged when he recently was the recipient of two awards - The Diploma of the Danish Export Association and HRH Prince Henrik’s Medal of Honour – which were presented to him at the Danish Embassy in London at a special ceremony. The event was hosted by the Danish ambassador to the UK, Claus Grube and the Danish Queen Margrethe II, presented Peter with his awards. Behind this recognition lies Peter’s long and impressive career with Grundfos that has culminated in his leadership role as Managing Director in the UK, a position that he has now held for ten years. After receiving the awards, Peter said “I feel very proud to receive such an important recognition,” while Group Executive Vice President Poul Due Jensen added his words to underline Peter Reynolds’ importance in shaping Grundfos’ success “in his 25 years, Peter has managed to forge deep and lasting relationships with all customers and partners in our value chain. This has helped consolidate Grundfos’ leading position in the UK market,” he said. The Diploma and Medal are awarded in recognition of an outstanding effort in promoting and marketing Danish products and services abroad. For more information or literature request contact Grundfos Pumps Ltd, Leighton Buzzard, Bedfordshire. Tel: 01525 85000 E-mail: grundfosuk@grundfos.co.uk

SPP Pumps has announced investment into its dewatering division, with the appointment of a new sales manager and a partnership with a new Australian distributor. Colin Baker has been appointed UK and Ireland Sales Manager, and will hold responsibility for maximising opportunities in the market, growing existing relationships and expanding the company’s customer base in the dewatering sector. With nearly 20 years in the pump industry, Colin is excited about the challenges that lie ahead: “When I first met with SPP I was impressed with the scale and set-up of the company - the scope of opportunity is immense and I feel really positive about the future of the dewatering sector.” Colin will be working across the entire dewatering portfolio, promoting SPP’s range of Autoprime pumps … vacuum assisted, self-priming pumps that have become the benchmark for reliable, durable and compliant dewatering applications such as flood protection, ground water control, sewage management and well point dewatering. In addition to the new appointment, SPP Pumps is teaming up with Australian distributor FITT Resources. The partnership will seeSPP’s dewatering range of pumps sold throughout Australia and New Zealand, and an order has already been placed for nearly £200k worth of SPP’s Q Series pumps. FITT Resources specialises in the supply of premium mechanical engineering products, parts and servicing, offering premium pumps across a wide range of industry sectors, including flood protection and water management. Gregg Fowler, Director at FITT Resources, said: “We’re delighted to be working with SPP. Both our companies operate on the same ethos of putting the customer at the heart of everything we do. We respond to customer needs and provide the best solutions.” Duncan Jackson, Business Unit Manager for dewatering at SPP, concludes: “SPP has a versatile range of pumps and box canopies that can provide our customers with the pump solutions they need, when and where it really matters. We have the ability to be versatile and responsive, and that is what enables us to be successful. With Colin Baker on board and FITT Resources already working to sell throughout Australia, I’m feeling confident 2016 will be a great year.” For more information contact SPP Pumps, Reading, Berkshire. Tel: 0118 932 3123 E-mail: enquiries@spppumps.com Web: www.spppumps.com

KSB SUPPLY PUMPS TO THE RENFREW FLOOD PREVENTION SCHEME ON THE RIVER CLYDE

i-ALERT2 EQUIPMENT HEALTH MONITOR “NOW AVAILABLE FOR ANDROID”

KSB and Ferrier Pumps Ltd recently continued their long standing partnership working on a flood prevention scheme for Renfrewshire Council. This involved planning and collaboration on the front end design, pump testing, supply, installation and commissioning of all the pumps and ancillary equipment. The project involved KSB supplying four variable speed submersible pumps from their axial flow Amacan pump range and one variable speed sump pump of type Amarex KRT, to the North Renfrew Flood Prevention Scheme near Glasgow. KSB also supplied the 800mm diameter pump discharge canisters which are currently installed in the Storm Pumping Station situated on the south bank of the River Clyde. The flood prevention scheme will protect more than 300 homes and businesses in North Renfrew and comprises a 3m high embankment and a new underground pumping station at the Mill Burn at Fingal Road. The embankment, which runs westward for 1km from Ferry Road, provides a barrier against direct flooding from the Clyde. The pumping station containing KSB pumps will ensure that tidal surges on the Clyde do not cause the Mill Burn to overflow and flood local properties. The pumping station provides a capacity of 5.5m3/s to provide standard protection against tidal flooding from the River Clyde and fluvial flooding from Mill Burn. The pumping station’s maximum flow rate has been specified to cover a 1 in 200 year flood event. KSB Amacan pumps were chosen for this station as their characteristics ideally suit the transfer of very high flows of water at low heads. KSB’s technically advanced pumping equipment is well-suited for flood control and the Amacan pumps ensure flood-prone areas are reliably drained. KSB Amacan submersible pumps are typically used in land drainage applications and have a compact and slim design, but are extremely powerful. The Amacan’s slim design makes the submersible pump ideal for installation into narrow discharge canisters. Ferrier Pumps Ltd carried out the mechanical installation at the Renfrew project site and found the pumps were easy to install as the Amacan pump’s own weight ensures self-centering seating of the O-ring seals in the discharge canisters, a simple but effective design feature. The Amacan pumps come with bearing temperature monitoring, thermal motor protection and leakage sensor in the motor. They also have a low-vibration hydraulic system and a bellmouth optimised for vortex-free inflow making them an excellent choice for the Renfrew project. Ferrier Pumps also installed in the main sump chamber a KSB Amarex KRT submersible solids-handling centrifugal pump, specifically manufactured in abrasion resistant materials to remove storm water as well as handling a relatively high concentration of solids in the pump station. This variable speed pump is used for sump drain down following cessation of a storm event. KSB have also supplied the pump discharge canisters, which were designed by KSB at their UK Head Office in Leicestershire, and were digitally prototyped and tested using the latest 3D design software. The canisters were manufactured by Powerrun Project Management Ltd of Keighley and each 800mm diameter canister was supplied to site in 3 off individual double flanged sections with a combined weight in excess of 3000 Kgs and an overall assembled length of nearly 10 metres. Before any manufacturing of products or site work began, a report covering the testing and development work was undertaken on a physical hydraulic model of the proposed North Renfrew Ferrier Pumps Ltd, a KSB distributor in Scotland, carried out the mechanical and electrical installation for George Leslie Ltd who was the main contractor for the £3.6m project. The work was commissioned by Renfrewshire Council as part of the overall £10m flood prevention scheme for the town. For more information contact KSB Ltd, Loughborough, Leicestershire. Tel: 01509 231872 | E-mail: sales@ksb.com | Web: www.ksb.com

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

WILO

- TAKING PUMPING TO A HIGHER LEVEL… Wilo and the BPMA share longevity. In congratulating the BPMA on its 75th anniversary this year, this highlights the fact that the BPMA is a comparative youngster as Wilo will celebrate its 144th anniversary this year – heading for its 150th in six years time! Wilo was formed in 1872, as Kupfer-und-Messingwarenfabrik Louis Oplander, originally a copper and brassware manufacturer, and has had an impressive track record since those very early days. Today Wilo – based in Dortmund in Germany - is one of the world’s leading manufacturers of pumps and pump systems for heating, cooling and air-conditioning technology as well as water supply and sewage disposal. The company had a turnover of 1,234.7 billion euros in 2014. With an eye to the future, the company is heavily involved in research and development and is increasingly transitioning from a component to a system supplier. Behind the name are more than 7000 employees in over 60 subsidiaries around the world. Together they turn visionary ideas into intelligent solutions that regularly set new standards in the industry developing innovative, high-quality products that make life easier and more efficient. As well as providing a huge range of products and helping to provide system solutions for customers, Wilo offers leading edge training facilities, accredited CPD information and a first class servicing operation. In the UK, Wilo is based in Burton-on-Trent, with a

team of around 100 in impressive offices that serve as the head office, provide an assembly facility, a sizeable warehouse and an impressive training centre. Wilo UK operates across a number of sectors as pumps are components of so many different business areas. Wilo has been a member of the BPMA since the early eighties and sees its membership as an essential business partnership. The pump market is changing and has changed radically in recent years, in many ways and not just in the achievement of higher levels of efficiency. Perhaps the most important change that has been seen, is the move away from being just a pump manufacturer, simply supplying pumps that consultants and contractors are ordering for a project. The move has been towards the adoption of a proactive approach to supplying total solutions, offering a total response to the need to reduce energy usage, lower energy bills and reduce emissions, whilst seeking innovative new ways of responding to the challenges of modern day building provision and renovation. Every major building relies heavily on pumps of various designs, shapes and sizes to run the heating, air conditioning, chilled water, potable water supply, to distribute harvested rainwater and to remove the sewage and greywater from

the building. Their roles are many and various, but all are vital. Modern pump technology allows these tasks to be undertaken far less expensively in upgrade and renovation projects, simply by replacing elderly existing pumps with modern high efficiency pumps, designed to do their jobs better, quicker, less expensively, in a more environmentally friendly way and more reliably. In new buildings, where you can start from a blank sheet of paper, modern pump technology allows specifiers and consultants to seek the optimum solution for that building without any restrictions on infrastructure, incorporating system solutions that include the latest pump technology from top to bottom, along with the necessary building management system to take advantage of all that new technology offers, within the budgetary restrictions they will inevitably have to work with. The key words when looking at system-based solutions are ‘lifecycle costs’. Modern pumps carry a more expensive capital cost than their elderly relatives. The new technology in the modern pumps comes with a price. But the payback from modern pumps is usually extremely fast in relation to the capital cost, because the energy required to run these new pumps is far less. Over say, a fifteen year lifecycle, huge savings in terms of energy cost can be made, large emission reductions can be shown and with far less energy use, come far lower energy bills and maintenance costs for the building. Find out more at www.wilo.co.uk.

ATLAS COPCO EXTENDS ITS REVOLUTIONARY RANGE OF GHS VSD+ VACUUM PUMPS TO 1900 M³/H Atlas Copco has extended its portfolio of GHS VSD+ vacuum pumps with the launch of a new model offering power of up to 1900 m3/h while retaining the revolutionary level of energy efficiency that has been a hallmark of the range. The new GHS 1300-1900 VSD+ is built upon the success of the GHS 350-900 VSD+, which set a new benchmark for vacuum pumps when it was unveiled in 2015. Incorporating variable speed drive (VSD) technology to keep power closely aligned with fluctuating production demand, the GHS VSD+ range delivers energy savings of up to 50% compared with conventional fixed-speed vacuum pumps. In addition it offers plug-and-play simplicity, advanced control features and lower-than-average noise levels. The GHS 1300–1900 VSD+ is an oil-sealed rotary screw vacuum pump with a range of 1300 to 1900 m3/h and an ultimate pressure of 0.35 mbar(a). However, its footprint is less than 2.3 m3, enabling easy installation without taking up valuable floor space at a production facility. Alongside a clear and detailed front-panel display, SmartLink connectivity is available as an additional option, which provide users with greater insight and control into the machine’s operational performance and thereby maximise uptime. The vacuum pump also boasts Atlas Copco’s Elektronikon for state-of-the-art monitoring, enabling full control to enhance energy savings. Optional water cooled versions are available, with an integrated energy recovery system that could recover up to 100% of the used energy as hot water (90°C), which can be used for process requirements to save on excess fuel usage. The vacuum pump’s market-leading oil retention means that the quality of the exhausted air is optimal, which contributes to employee wellbeing and eradicates oil spills for a cleaner working environment. The GHS 1300–1900 VSD+ is suitable for centralised vacuum systems, glass bottle manufacture and canning, as well as many other applications. The new vacuum pump is also available as a turbo version if fast evacuation times are needed. It enables faster cycle times for higher production and is ideal for meat, cheese and chicken packaging, as well as cooling. For wet applications such as plastics, clay moulding and drying of pipelines, customers can choose the GHS VSD+ as a humid version. You can learn more about the GHS VSD+ oil-sealed rotary screw vacuum pump range by visiting: www.atlascopco. com/vacuum

Magnetic Drive

AXFLOW LAUNCHES RANGE OF ELASTOMER COATED ROTARY LOBE PUMPS AxFlow has extended its range of positive displacement pumps with the introduction of the Boyser LB suite of elastomer coated rotary lobe pumps for flows of between 5m³/hr and 130m³/hr.

For more information contact AxFlow Ltd, Ealing, London. Tel: 020 8579 2111 | E-mail: info@axflow.co.uk | Web: www. axflow.co.uk

Safe, Seal-less, Reliable!

As a UK based manufacturer with over 40 years experience, we are at the forefront of magnetic drive technology. Today we have the largest range of mag drive pumps in the world, covering all industries and applications. We offer products with unparalleled quality, quick lead times and competitive pricing.

WWW.MARCHMAY.CO.UK 11

POWERFUL PERFORMERS Thames water pump application As the BPMA celebrates its 75th anniversary, we take a look at the development of the electric motor, one of the key underpinning technologies of the pump manufacturing industry. Electricity is the driving force of modern life. It powers our factories and illuminates our homes. It fires up our laptops and charges our phones. Without it, our day-to-day existence would be totally unrecognizable. Perhaps surprisingly, it is the humble electric motor that is the biggest single consumer of electricity – with electric motor-driven systems (EMDS) using around 45% of total global consumption1. That statistic reveals a truth: electric motors are the workhorses of the modern industrial world, converting electrical energy into mechanical energy for a wide range of applications including fans, blowers and pumps, machine tools, household appliances and power tools. As such a major consumer of electricity, it is vital that electric motors are as energy efficient as they can possibly be. To fully understand the role that electric motors perform in modern society, it’s useful to trace their development. It’s quite some backstory. As long ago as the 1820s, scientists and inventors were intrigued by the practical applications of the newly discovered phenomena of electricity, magnetism and electromagnetism, and set about developing the first wave of electric machines. The bases of these inventions were the creation of the battery in 1800 by Alessandro Volta, the discovery Werner von Siemens of magnetic field generation by electric currents in 1820 by Hans Christian Oersted and the invention of the electromagnet in 1825 by William Sturgeon. The first device powered by electromagnetic force was created by Peter Barlow in 1822 and, twelve years later, Moritz Herrmann von Jacobi created the first actual rotary electric motor. But despite advances, these machines did not meet the requirements for large-scale production as they lacked operating ease and efficiency. Those limitations began to disappear when, in 1866, the German engineer Werner von Siemens created the first economically viable electric machine: a DC generator. The difference from earlier machines was that the voltage required for magnetism could be obtained from the rotor winding itself, meaning that the machine was self-excitable. In an instant, Siemens created the possibility of supplying electric motors with

Old Motor 12

low-cost energy. After Siemens’s invention, various DC motors began to be manufactured for industry and transport. Nonetheless, they still had problems: they were large, noisy and generated sparks every time the commutator shorted to reverse the direction of the electric current. The search for a cheaper, more efficient and safer motor encouraged research and inventions in the late nineteenth century. That is how AC motors were improved. In 1885, electrical engineer Galileo Ferraris built a biphasic AC motor. The invention’s low yield prevented its commercial production. The same happened with a biphasic motor with a rotor in short circuit, created in 1887 by inventor Nikola Tesla. It was in 1889, that the electrical engineer Michael von DolivoDobrowolsky patented an efficient AC motor. It had three phases and a rotor cage. With 80 watts and an energy return on energy invested of 80%, it was simpler, safer and quieter, and had fewer maintenance problems. From this notable advance, the era of the more efficient electric motor was finally underway. During the early twentieth century, with many manufacturers active in the market, there was no standardisation of motors. This created difficulties when replacing one machine for another, requiring constant adjustments. After several attempts, in 1950, the International Electrotechnical Commission initiated the work of creating separate standards for weight and power, the application of which is linked to the technical requirements of each country’s standards. With effective standards in place, the second half of the twentieth century witnessed an evolution of electric machines. In 1961, WEG Industries was formed in Brazil and achieved notable advances in the design and production of electric motors. WEG’s engineers were at the forefront of weight reduction, experimenting with new materials like plastic, aluminum and new insulators to create different possibilities for the application of these machines. The main revolution, at WEG and other manufacturers, was the use of electronics, both in composition and in manufacture of electric motors. Today, it is possible to construct highly accurate and efficient motors to perform various tasks, especially repetitive or highly complex ones. It is also possible to build large electrical machines for special uses in industries, power plants and agribusiness. The flexibility of the electric motor isn’t in doubt – the challenge lies around improving their efficiency, and reducing their burden on electricity supplies. Take the standard induction motor – it alone uses about 30% of all the electricity generated in the world. Armed with that statistic, it is not hard to realise why better efficiency is crucial for the leading electric motor manufacturers makers in the world. At the heart of these efforts is regulation. In the EU, the Ecodesign directive has been in force since 2011. The 640/2009 regulations mandated that, from June 2011, motors within its scope had to meet at least IE2 efficiency rating, and a more efficient IE3 rating in 2015, unless controlled by a variable speed drive (VSD). With further studies being conducted as part of the revision of the regulations, the requirement for motors to meet IE4 rating is also set to come into force in the foreseeable WEG’s first motor future.

The key to designing a more efficient motor is to understand where the losses occur. When compared to IE3 motors, IE4 designs will need to reduce their losses by between 10 to 24%. At WEG, engineers have investigated numerous techniques to achieve this target – such as reducing the resistance of stator windings, redesigning the shape of rotor bars and short-circuit rings, and using new materials creating motors that already meet anticipated IE4 rating. Development of permanent magnet motor drive systems are now able to offer even further efficiencies. Motors play a key role in improving energy efficiency in fluid / air-flow applications, including pumps, compressors and blowers. Significant advances in the power electronics and control techniques have led to an increasing use of VSDs as a way of increasing energy efficiencies in fluid-flow applications. Permanent magnet and synchronous reluctance motors can deliver IE5 or even higher efficiency levels, with IE6 already being discussed at the moment.

WEG’s IE5 WMagnet Drive System

Ultimately, engineers will ensure that the design of the electric motor will continue to evolve to meet the changing requirements of the world that we live. The electric motor has taken 200-years to reach this stage, and there’s no sign of that journey coming to an end. The electric motor is based on the interaction between electric and magnetic phenomena. In a simplified representation, the motor is composed of coils (the rotor) arranged on top of fixed magnets (the stator). A magnetic field is generated around the coils when electric current flows through it, which interacts with the field of the magnets causing the coils to turn. The coils will not stop turning when a current reversal is applied at a determined frequency. When a shaft is coupled to these coils movement is transferred to the outside of the structure. Several researchers have contributed to the technological advancement of these machines. In addition to Werner Siemens and his DC motor and Nikola Tesla, who invented the two-phase induction motor, two other researchers stand out: Galileo Ferraris, one of the pioneers of AC power systems and the inventor of the induction motor, and Mikhail Dobrovolsky, who developed the three-phase electrical generator and a three-phase electrical motor. 1.http://www.iea.org/publications/freepublications/publication/ee_for_ electricsystems.pdf

PROCESS CONTROL CONTROLLER SAVES SPACE BY PACKING ENHANCED FUNCTIONALITY INTO A SMALLER FOOTPRINT A new programmable DIN-rail mounted controller (PLC) from WAGO has a smaller footprint than its predecessors while providing enhanced functionality for seamless process automation. Available in three variants, the smallest of which measures just 50 mm wide, the PFC100 offers a compact and attractively priced control solution for a wide range of industrial applications. The controller is designed exclusively for e!COCKPIT, WAGO’s new intuitive engineering software suite, greatly simplifying the installation process and enabling

systems to be brought online faster. The controller is based on a Linux® real-time operating system, and its high performance Cortex A8 600MHz processor makes it suitable even for highly complex algorithms and applications. The PFC100 combines the comprehensive computing power and functionality of WAGO’s feature-rich PFC family of controllers with a smaller footprint that can save considerable control panel space. Bringing complex functions into a single device addresses the customer need for multiple advanced control functions and features combined within one device, with a high level of security. PFC100 is a highly specified scalable solution; the compact ECO version (750-8100) is extremely cost effective yet still includes two Ethernet connections, 10MB of memory and a Micro SD slot. Next up, the 7508101 increases the on-board memory to 12MB.. The PFC100 can be linked seamlessly into the e!COCKPIT software platform. Robust cyber security features safeguard the controller from hackers and unauthorised access to data and control functions with packages consisting of SSL/TLS, SSH, VPN, and firewall, as well as integrated password protection and secured communication reducing vulnerability to cyber-attacks. In addition to the processing industry and building automation, typical applications for the PFC100 include standard machinery and equipment control such as packaging, bottling and manufacturing systems, as well as textile, metal and wood processing machines.

For more information contact WAGO Ltd, Rugby, Warks. Tel: 0870 264 0773 Email: info@wago.ltd.uk Web: www.wago.ltd.uk

ABB ZENON EXTENDS AUTOMATION SOLUTIONS FOR THE INTERNET OF THINGS, SERVICES AND PEOPLE ABB has extended its discrete automation offering to deliver more connectivity and application solutions for discrete manufacturing, general machinery and food and beverage machine builders.

The ABB zenon software, developed by the Austrian automation company COPA-DATA, extends communications, machine-to-machine connectivity and application control possibilities for machine builders. This supervisory control and data acquisition (SCADA) software extends ABB’s discrete automation portfolio which includes variable-speed drives, motion control solutions, motors, programmable logic controllers and human machine interface panels. Together, these products enable the development of solutions for the Internet of Things, Services and People (IoTSP), which presents new business models for improving factory and process performance, product quality, production flexibility and energy efficiency. “Innovation and speed are key aspects of our Next Level strategy. The ABB zenon solution complements our discrete automation offering very well, and together we can provide our customers with solutions that help them improve product quality and productivity, save energy, and add flexibility to their processes. This is especially important for our strategic focus on the food and beverage industry,” explains Morten Wierod, Head of ABB’s Drives and Controls business unit.

“The world in which our business and our products were viewed and developed separately from each other became obsolete with the advent of the Industry 4.0 concept (IoTSP). Networking begins not with machines or systems, but primarily with people,” says Thomas Punzenberger, CEO at COPA-DATA. “We can offer our clients real added value only when we are working together to overcome the challenges created by the application scenarios that came out of Industry 4.0.” For more information contact ABB Ltd, Daresbury, Warrington Tel: 01925 741517 | Email: layla.hewitt@gb.abb.com | Web: www.abb.co.uk/energy

Premium goes Prime Introducing the new standard in self-priming pump technology: The Alfa Laval LKH Prime

The Alfa Laval LKH Prime Pump sets a new standard in self-priming pump technology. Based on the market-leading Alfa Laval LKH pump range, it is a versatile, efficient, self-priming pump that uses a combination of air-screw technology and advanced design to meet the most stringent requirements in a range of industries, from food to pharmaceuticals. The superior efficiency of the Alfa Laval LKH Prime results in reduced energy consumption. This, together with the fact that it is based on the market-leading LKH pump range, delivers low cost of ownership and increased uptime. Designed for Cleaning-in-Place (CIP) duties containing entrained air, it can also pump product, potentially reducing the capital investment when designing process systems. Quiet in operation, Alfa Laval LKH Prime is engineered to meet the most stringent standards and hygienic requirements of the food, dairy, beverage, and home & personal care industries. The pump is also available as an UltraPure model, meeting the needs of pharmaceutical customers. For more information or to request a quote please visit Alfa Laval’s official Master Distributor Industrial Trading Solutions

PROCESS INDUSTRY INFORMER May 2016

MARGINAL GAINS Plant and maintenance managers in the food and beverage sector face multiple, potentially conflicting targets. Meeting them calls not for one strategy, but for many tactics. David Oliver, Channel and Platform Development Manager at SKF, explains.

perational leaders in the food and beverage sector have a lot on their plates. Every decision they make can have an impact on numerous different aspects of plant, and corporate performance. Each must be considered in the light of its contribution to a growing, and increasingly demanding, list of

goals and targets. At the top of that list is safety, based around ever tougher compliance requirements, and the recognition that the repercussions of a safety failure go far beyond the direct costs of the incident itself. Research has shown, for example, that after a safety or health recall of a food product, 55 percent of consumers might switch brands at least temporarily, and one in six say they will never purchase the product again. Then there is the need to ensure that all production assets are managed to maximise yield, productivity and profitability. And increasingly, corporate strategies are also being defined by targets for environmental performance and sustainability. Most major food and beverage players have set themselves challenging targets for a range of metrics including water consumption, waste production and greenhouse gas emissions. Optimising production in this complex environment calls for a holistic perspective. Managers must be able to evaluate their choices of technology, processes and operating parameters at the macro level, considering them in terms of their impact on the entire value chain. At the same time, however, the decisions that make a difference to top level targets will largely take place at a micro level, requiring an extremely granular understanding of the details of the products and manufacturing equipment involved. Thinking that way is hard, requiring companies to focus on small details and a philosophy of relentless continuous improvement. But the payoffs can be significant. Like today’s leading athletes, the best food and beverage companies now understand that world-beating performance comes as the result of the accumulation of marginal gains. Let’s look at a few examples of the kinds of changes that contribute to that approach.

ENERGY CONSUMPTION Measures that reduce energy consumption can make a direct contribution to both cost and sustainability targets. And with many food and beverage plants containing hundreds or thousands of items of powered equipment, small improvements to each can accumulate

rapidly into big savings. Installing variable speed drives (VSDs) on the motors used to power pumps, mixers and handling equipment, for example, can reduce their energy consumption by around 30 percent. Fifteen or 20 years ago, VSDs were seen as a luxury. Now, they are widely used and are delivering lower energy bills for large swathes of the manufacturing sector. Companies that have bought VSDs are saving on their electricity bills – and are prepared for ever-tightening legislation, as they are working ahead of the curve on sustainability. Another simple energy saving change is the switch from standard ball bearings to their energy efficient (E2) equivalents. The reason is simple: friction. E2 bearings have been redesigned to reduce friction while maintaining life and cut bearing losses by 30 percent. The way equipment is set up can have as much of an impact on energy consumption as its design. SKF engineers were recently called into one food and beverage plant to look at 12 pumps, for example, which were exhibiting high levels of vibration and rapid wear. The team identified poor shaft alignment as the root cause of the issue. After precision alignment, not only were noise, vibration and reliability improved, but the energy consumption of the pumps was reduced by as much as 20 percent in one case, and by 16 percent on average. The fix saved the company more than 9,000kWh per year in electricity consumption in each pump, and reduced its annual CO2 emissions by 28 tones a year across all 12.

MAINTENANCE & RELIABILITY Equipment maintenance and reliability is another area where best practice can drive significant improvements across multiple performance dimensions. As pumps wear, their efficiency can drop by 10 to 15 percent, for example, and loose drive belts on fans or blowers can increase energy consumption by 20 percent. Leaks in compressed air systems can force compressors to run for longer, driving up energy costs and accelerating wear. Then there’s the impact of unplanned stoppages due to equipment breakdown. Compared with planned maintenance interventions, unexpected stoppages often cost three times as much to fix, and take five times longer. And in the event of an unscheduled stoppage, most plants will leave the vast majority of equipment running while repairs are made. As a result, the energy consumed per unit produced can rise dramatically as plant reliability falls. Smarter, condition-based maintenance approaches can help food and beverage companies to identify equipment problems earlier, allowing them to intervene before performance degrades significantly, or breakdowns occur. As a further benefit, such approaches can also

reduce the amount of unnecessary preventative maintenance required in a plant, reducing spares consumption, saving labour costs and boosting equipment availability. Maintenance teams now have access to a wide range of highly sophisticated condition monitoring tools, from vibration analysis to identify bearing damage or alignment problems to thermal imaging and dynamic electrical testing equipment for motors. Moreover, smart data analysis technologies are making such tools quicker and easier to use, allowing them to be operated by front line staff, rather than specialists. A new generation of online systems can even monitor equipment condition continuously without human intervention, alerting personnel only when potential issues are identified.

LUBRICATION & WASH-DOWN Hygienic wash-downs are a regulatory requirement in any food plant. But washing grease-lubricated bearings can result in water ingress into to the bearing, and the discharge of grease into the production environment. To prevent corrosion or premature wear, it is common for bearings to require re-lubrication after every wash-down. Over time, this cycle of repeated cleaning and re-lubrication can result in significant financial and environmental costs. Beyond the value of the lubricant itself, re-lubrication requires significant labour input and generates contaminated materials – from gloves to cleaning cloths – that will typically go to landfill. Grease contamination also adversely affects the quality of a plant’s wastewater, driving up water treatment or disposal costs. Tackling challenges of this kind also requires changes at a very granular level. High efficiency seals can reduce water ingress into bearings, reducing re-lubrication intervals. Automated lubrication systems can precisely control the quantity and location of lubricants, reducing consumption, minimising contamination risk and saving labour. Perhaps most significantly, a new generation of re-lubricationfree and lubricated for life bearing technologies can allow companies to break the wash-down/re-lubrication cycle for good. The examples above are just a small fraction of the micro-scale improvement opportunities that food and beverage companies can in their quest to meet ever more stringent – and complex – macro-level targets. Indeed, our research suggests that changes at the tactical, operational level can have many times the impact of larger strategic changes, like the choice of basic process technology. The challenge for most food companies, therefore, lies not in finding a one-hit solution for their operational problems, but in building a culture where marginal gains are sought, captured and sustained by everyone in the organisation, from front line operators to senior management.

HEAT TRANSFER & ENERGY LATEST TUNDRA AIR DRYERS OFFER HIGH ENERGY EFFICIENCY Hi-line Industries is unveiling the 2016 model of its best-selling Tundra refrigeration air dryer. The

new models offer an energy-saving controller as standard, thus helping to deliver lower TCO (total cost of ownership) for customers, as well as increased reliability thanks to a redesigned refrigerant system. Further enhancements include design simplifications that have seen Hi-line remove pressure switches on smaller models and adopt more reliable temperature probes for control purposes. The 2016 Tundra range is expected to be even more appealing to potential users throughout industry, including workshop air and machine air in general manufacturing, as well as sectors such as packaging, textile, food, beverage, medical, dairy and automotive, to list but a few. The display of the multi-functional energy-saving controller provides information such as the dryer running dewpoint. Should the dryer go to light duty (i.e. reduced airflow) the refrigerant gas pressure is monitored and adjusted accordingly. The dryer has a built in energy-saving device which will stop the compressor and wait for the refrigerant gas pressure to rise to a pre-set value before restarting. This direct expansion technology not only reduces energy consumption but ensures at least +3°C PDP (pressure dewpoint) is maintained at all times. In contrast, some competitors of Hi-line are importing chilled mass refrigeration dryers that can be as high as +10°C in their thermal cycle, which is not suitable for drying air in northern European countries such as the UK. Tundra air dryers offer a 40-bar pressure range and can be provided with a range of high performance oil and particulate filters to suit dryer inlet and outlet ports. These filters are available in compressed air blue (RAL 5015) to match the dryers. Hi-line Industries currently holds around 700 Tundra air dryers in stock at its Midlands factory ready for next-day delivery. Models ranging from 21 to 1605 cfm capacity are stocked, although larger models up to 10,000 cfm are available to order. The company also stocks 60 Hz dryers for marine and offshore applications. The latest Tundra refrigeration air dryers are sold through a nationwide distribution chain of air houses, compressor sales and service companies. Hi-line has a UK-wide team of service engineers providing industry-leading support to the company’s dryers, as well as other brands.

For more information contact Hi-line Industries Ltd, Tel: 01283 533377 | E-mail: enquiries@hilineindustries.com | Web: www.hilineindustries.com

HBM TECHNOLOGY ENSURES WIND POWER FORGES FULL SPEED AHEAD! As energy markets continue to grow, HBM – a market leader in the field of test and measurement – offers a complete range of professional measurement solutions, designed to increase the efficiency of wind power plants.

When turbines go down due to maintenance issues or equipment failure, the expense of repair crews and crane day rates can send costs per kilowatt hour soaring, not to mention potentially long delays waiting for spare parts, which can further increase costs. Often operating in harsh conditions such as high winds and storms and in remote locations, HBM measurement technology helps to identify mechanical stress on wind turbine components at an early stage, subsequently minimising potential downtime. In addition, professional software solutions from HBM nCode enable engineers to perform fatigue analysis during the design of wind energy facilities for optimal and safe dimensioning of all components. Developed by HBM, nCodeDesignLife™ software contributes to the optimal design of wind power plants from the development phase and determines the probable service life of critical components. During test and production phases, HBM force, strain and torque transducers, together with a large number of electrical and optical strain guages, ensure the quality and subsequent longevity of the components. As recent statistics from National Grid reveal an upsurge in the UKs electricity generated by wind, from 9.5% in 2014 to 11% in 2015, last year was a record year for wind energy generation, with onshore and offshore wind farms supplying their largest ever amounts of clean electricity to UK homes, factories and offices. In line with this growth, HBM offers an exceptionally wide range of wind power test and measurement solutions to ensure wind turbines are working to their maximum performance.

For further information, contact HBM on +44 (0) 20 8515 6000 or via E-mail: info@uk.hbm.co.uk or visit the HBM website at www.hbm.com

PROCESS INDUSTRY INFORMER May 2016

DOING YOUR LEVEL BEST SICK UK’s Industrial Instrumentation specialist, Darren Pratt, looks at the versatility of guided micro-wave technology in successful level measurement in process industries. FLUID DIFFICULTIES

ccuracy in level detection and measurement is highly important in industries where water, oil and other fluids are stored, dispensed into containers of all sizes and/or used in processing and other operations. There are many applications where precise level detection is critical to productivity and ensuring continuity of process for example, keeping a header tank on a bottle filling line at the optimum level by switching on flow from the main tank and warning of supply problems. Alternatively, level detection may be a safety measure to prevent spillage risk of dangerous or valuable fluids. Conversely, avoidance of empty tanks may be essential to stop dry running damage to pumps, machine tools and other equipment or even sediment from a tank being flushed into process lines.

MICROWAVE RADAR TECHNOLOGY In seeking an effective solution to these problems, the development of guided microwave radar technology has led to a number of versatile sensing options. They can achieve high performance, unaffected by density or conductivity. In more advanced sensors the presence of foams or coating deposits can be ignored due to the use of special algorithms built into the level sensor. The consistent accuracy of the technology has seen quick adoption and sensor manufacturers are being asked to come up with ways to expand its uses through the adaptation and configuration of the sensor’s probes for different applications.

A particular problem with some process fluids is their low surface tension and high propensity for foaming. Many additives dissolved in the fluids increase foaming properties and there are also cases, such as in beverage manufacture, where foam enhances the finished product, so it is desirable even though it can create measuring difficulties for some technologies. As a result, standard level technology, such as floats, capacitance, tuning forks and ultrasonics, can struggle when trying to deliver a precise measurement both through the blanketing effect of foam and the difficulty of defining a precise liquid air interface point. Many of these technologies also suffer from filming and coating build-up, or may even not conform to hygiene requirements.

FOAM CONQUERED With the LFP fluid level probe from SICK, for example, accurate measurement in the presence of thick foam is ensured through a patented “foam algorithm” enabling microwave radar probes to see through large amounts of foam and detect the true fluid level. Excellent success rates and significant cost savings have been demonstrated for vessel level measurement and bottle filling applications in liquids such as milk, beer, paints and detergents in the presence of wet, dense foams. On high-speed filling lines, the wastage caused by under or over-filling and line downtime due to false head tank level readings can be significantly reduced.

EXTENDED PROBE LENGTH In response to the needs of end-users, fluid level probes have had practical adaptations to meet specific production challenges. For example, as many level measuring applications have long level ranges either in large tanks or slim deep ones, an extended probe length up to four metres can provide accurate measuring options. Installations with limited headroom above the tank can now be solved using a flexible variant. By substituting a weighted stainless steel rope up to 4m long for the solid probe, to guide the microwave pulse. Installation and handling are very straightforward.

HIGH PROCESS TEMPERATURES Remote amplifier models provide a solution for higher process temperatures, up to 180˚C, or where the separation of the probe and electronics provides easier access to the device for setup and diagnostics. The separation of the probe and amplifier even facilitates autoclaving, a process where the whole tank is removed for deep sterilisation, with the fitted probe provided with a sealed BNC connection.

LOW DIELECTRICS, AGGRESSIVE LIQUIDS & AWKWARD TANKS Guided wave radar fluid level probes can have advantages for example to solve manufacturing challenges. For example: • difficult tank shapes, materials or accessibility • hot fluids that create challenges for the electronic components • fluids with a very low dielectric constant • high foaming or even highly corrosive substances.

A co-ax tube accessory has shown success with applications where the liquids measured have a very low dielectric (e.g. oils and cutting fluids). They are also suitable for use in tanks which are open topped, have non-metallic walls or metal protrusions inside the tank that could disrupt the sensing of the reflected radar pulse. Here, a stainless steel, perforated sleeve over the probe facilitates measurement of the liquid level.

For use where stainless steel would be rapidly corroded or dissolved by chemical and/or galvanic reaction, such as in metal plating or with hot, concentrated acid solutions, titanium wetted parts can be introduced.

CASE STUDY: Versatility Reduces Downtime for Bottle Filling For example, at the Nelson facility of Cott Beverages, the world’s largest retailer brand beverage company, the installation of LFP Inox fluid level probes from SICK UK shows how the versatility of the microwave technology delivered a replacement solution with far-reaching benefits for the whole plant. Ensuring maximum uptime is a key priority on each of the five filling lines for still and carbonated drinks, as well as two aseptic bottling lines housed in a separate plant on a neighbouring site. On a typical multibottle filler, one litre and 500ml carbonated soft drinks like colas are bottled at around 19,000 units per hour, which allows a 40ms fill-time per unit. The syrup is mixed with water, carbonated, and then fed under pressure to the filling bowl, a ringshaped header tank above the filling nozzles. Controlling the level of liquid in the filling bowl is critical to the process as it determines the accuracy of fill. Margins can be squeezed by a run of poor fill. In addition, identifying which conventional level sensor was faulty, replacing it, testing, calibrating and cleaning could take around four hours of downtime, equating to the filling of about 80,000 bottles. Sick LFP Inox hygienic level sensors with IO-Link offered the improvements in performance and data output required. Cott Beverages then worked with SICK technical team to determine the correct specification.

IO-LINK FOR BETTER CONTROL Connection to the three sensors is made via IO-Link via a single gateway integrating all three sensors to the Profibus network. This provides digital access to diagnostic data in each sensor allowing monitoring of the operating status of an individual sensor, and an alarm can be triggered before any failure. In the event of a fault developing with one of the sensors, the alarm and operator instructions on the filler’s HMI control panel facilitate the switching out of the faulty device. An average level of the two remaining sensors is maintained until an assessment can be made during routine maintenance downtime. The SICK LFP microwave sensors also have their own LED and digital readout, so faults can easily be detected either on the HMI or on the filler bowl itself. A two-metre long probe is kept in the back-up spares to fit each application on the plant. In addition, the LFP’s self-teach simplifies set up. The unit can be fitted at the press of a button. Trials showed that the a sensor replacement could be completed during the one hour Clean In Place (CIP) phase between production runs; a quarter of the time it took with the previous level sensing technology.

PROCESS INDUSTRY INFORMER May 2016

PROCESS MEASUREMENT & INSTRUMENTATION ULTRASONIC FLOW METER FOR PROCESS & CONTROL Titan Enterprises announces the Process Atrato - a new low volume, high performance ultrasonic flow meter packaged to address the challenges of the process and control environment.

The compact Process Atrato flow meter combines all the technological advantages of market-leading Atrato ultrasonic technology (high linearity, high sensitivity, wide flow range linearity, no moving parts, fast response time, can be installed anywhere) with a new durable construction. Built from 316 stainless steel and PEEK – the Process Atrato is supplied sealed to the IP65 standard. The combination of durable housing and top performance, in a very reliable flow meter, delivers a new tool for engineers at a reduced cost of ownership compared to existing flow measurement technologies serving the process and control market. Rated for use up to 65°C and 20 Bar the Process Atrato is available in 4 models operating over flow ranges from 2 ml/min to 15 litres per minute, accuracy is ±1% over the whole flow range. Each Process Atrato is calibrated with a pre-set ‘K’ factor so all meters of the same flow range are fully interchangeable simplifying assembly and set-up procedures for OEM manufacturers looking to integrate the flow meter into their process and control set-up. As standard the Process Atrato comes with two frequency outputs (PNP and NPN). Two multicolour LEDs indicate signal strength, power malfunctions and pulse outputs. Electricalconnections are through a standard M12 four pin, sensor connector. Using patented technology that enables it to operate with excellent accuracy over very wide flow ranges, the Atrato range of inline flow meters is a genuine breakthrough in flow meter technology. The advanced Atrato signal processing system permits flow measurement across the whole Reynolds number range allowing both viscous and non-viscous products to be metered anywhere.

For further information on the Process Atrato ultrasonic flow meter visit www.atratoflowmeters.com/atrato-process-ultrasonic-flowmeter-stainless-steel or contact Titan Enterprises on +44 (0)1935-812790 or E-mail: dee@flowmeters.co.uk.

NEW ADDITION TO CORIOLIS FLOW FAMILY OFFERS TRULY SMART FLOW MEASUREMENT ABB’s FCB400 coriolis mass flowmeter includes a new electronics platform that features self-configuration, integrated accuracy verification, builtin valve control and many other smart tools.

The automatic self-configuration function synchronizes the configuration data in the sensor and the transmitter after power has been switched on. The FCB400’s “SensorApplicationMemory” duplicates and stores all data including configuration and calibration settings, measuring point parameters and totalizers in a permanent memory. This ensures safe data synchronization during maintenance, including when the transmitter is replaced. Application-specific software packages enable the FCB400 to be used in an expanded range of installations. In filling processes, the “FillMass” function directly controls the downstream valve via a special digital output. “DensiMass” enables the precise determination of the concentrations of liquid mixtures through high-precision density measurement, as well as the “net mass or volume flow rate”. The FCB400’s “VeriMass” verification function enables it to test whether it is still operating within the specified range. Users can detect possible erosions or deposits inside the sensor without interrupting the measurement or removing the device. Using ABB’s common HMI platform, the FCB400 is easy to set up and operate. The robust design expands usability at ambient temperatures of -40°C to +70°C and desensitizes the device to excessive vibrations. Compact, lightweight and suitable for use in SIL2 applications, the FCB400 is also available in a hygienic design variant for food and beverage applications. For more information contact ABB Measurement & Analytics, Eaton Socon, Cambs. Tel: 01480 213339 | E-mail: david.bowers@gb.abb.com | Web: abb.com/measurement

Markets/Applications u Analytical u (micro) Chemical u Semiconductor u Confectionery u Oil & Gas u Pharmaceutical

Mass Flow Meters/Controllers for Liquids and Gases with

Coriolis sensor

T +44 1223 83 32 22

F +44 1223 83 76 83

PROCESS INDUSTRY INFORMER May 2016

E sales@bronkhorst.co.uk

I www.bronkhorst.co.uk

PROCESS MEASUREMENT & INSTRUMENTATION CONTINUOUS NON-CONTACT LEVEL MEASUREMENT The robust stainless steel construction makes the NR 3000 extremely suitable for all kinds of industrial applications. The unit operates at a high frequency of 78 GHz. This delivers a very small beam angle which eliminates any signal interference at the flange but allows for optimum reflection of the bulk solids material.

The aiming flanges can be adjusted to ensure perfect positioning of the NR 3000. In other words, the angle of the beam can be set to a specific point; for example, at the outlet of the silo. The lens antenna is highly resistant to material deposits and offers a self-clean function for extremely sticky solids using an air flush connection. The plug in display allows programming and diagnostics on-site, making the installation and operation of the unit as easy as child’s play. Aiming flange & Integrated lens cleaner The NivoRadar® offers a flat flange version and also an aiming flange version. Using the adjustable aiming flange, the radar is perfectly aligned since the probe can be fixed to the desired point; for example, at the silo discharge. Due to the default purging air for cleaning the lens antenna, it is ideally placed for use within particularly sticky or caking bulk materials. Even within applications where condensation occurs, the flushing connection provides functionally reliable measurement. The device uses a two-wire technology and is made simple to operate via a local programmer with display and a Quick Start Wizard. The unshielded radar sensor has a completely dustproof design and provides reliable measurement results in high process temperatures up to 200°C.

Efficient Silo Management

The radar sensor can also be easily connected to the silo management system, Nivotec®, for reliable content measurement. Experts in Level Measurement With its head office in Germany for over 35 years and now with an established sales office in the UK, UWT is the leading manufacturer of level measurement technology on the world market. The company is principally focused on the field of bulk solids. The company is certified ISO 9001:2015 and constantly expands its portfolio of product certifications (ATEX, FM, CSA), particularly long service life under the motto of the company “Brilliantly simple level measurement in bulk solids.”

For more information contact UWT UKMLtd, Shrewsbury, Shropshire. Tel: 0845 4810463 E-mail: sales@uwtuk.com Web: www.uwtuk.co.uk

PROCESS INDUSTRY INFORMER May 2016

PROCESS MEASUREMENT & INSTRUMENTATION ALICAT RELEASES GAS SELECT 6.0 FIRMWARE FOR ITS MASS FLOW METERS AND CONTROLLERS New user-selectable engineering units, better control and faster data with new control software.

Alicat Scientific has updated its Gas Select™ firmware for Alicat mass flow meters, mass flow controllers and pressure controllers. Gas Select 6.0 improves user control and data speed, adding features that enable users to make changes to instruments without a factory visit. Gas Select firmware comes standard on all Alicat mass flow meters and controllers, and includes a library of up to 130 preloaded gases, referenced to NIST REFPROP 9. The firmware drives the flexible user interface for controlling instrument operation. A new feature of version 6.0 is user-selectable engineering units. Units of pressure, temperature, volume, standard volume or mass can all be changed in the field. With this capability, flow instruments can be realigned to correlate with other calculations in the process stream, or even repurposed for new applications. Also new with the update is the ability to enter real STP for operating conditions, rather than choosing from a few pre-loaded common standards. New flexibility to filter data line queries down to essential parameters results in faster, more frequent data updates. Setpoint input is now accepted either at the local panel or through the serial port, without first switching the input source. Both sources are active full time. The local panel is also easier to read, with the primary parameter that is displayed centre screen now clearly labelled. The new firmware is compatible with standard Alicat instruments—flow meters, flow controllers and pressure controllers—serial number 80,000 and higher. Gas Select 6.0 is installed on new instruments shipped after March 3rd, 2016. Existing units can be factory upgraded by request during annual recalibration.

To learn more about the Gas Select 6.0 Firmware (www.alicat.com/firmware/) for Alicat mass flow meters and controllers, visit www.alicat.com, or call +1 520 290-6060

PROCESS INDUSTRY INFORMER May 2016

BASIS™ MASS FLOW CONTROLLERS PROVIDE RELIABLE GAS FLOW CONTROL FOR OEM & PROCESS USE Compact units deliver fast, accurate flow rate control

Alicat Scientific has added a new line of mass flow controllers specifically for original equipment manufacture and process integration. BASIS™ is Alicat’s smallest footprint instrument, providing fast, accurate control of gas flow rates in an economical, easy-to-integrate package. BASIS is ideal for use in OEM gas analysers, automated gas mixing on process lines, and anywhere basic mass flow-only control is required. Stocked and ready for quick ship on evaluation orders, all BASIS units are ready to control process flows at full accuracy in just 70 ms. A 100 ms control response enables BASIS to react in real time to upstream fluctuations. NIST-traceable accuracy is +/-(1.5% of the reading + 0.5% full-scale). BASIS is available with the following multi-gas calibrations: Air, Ar, CO2, N2, O2, N2O (selectable over RS-485); He, H2 are also available in single-gas units. Dual communications – RS-485 Serial and 0-Vdc analogue – mean BASIS can be built into a range of end-user products. For process applications, the availability of analogue and digital feedback allows for both PLC and PC control options. To learn more about Alicat’s new BASIS mass flow meters, visit www.alicat.com/basis, or call +1 520 290-6060 E-mail: info@alicat.com

PROCESS MEASUREMENT & INSTRUMENTATION LATEST CURRENT PROBES MEASURE HIGH FREQUENCY MOTOR DRIVE COMMON-MODE CURRENTS Motor installers and design engineers can deal more effectively with high frequency (hf) common-mode currents caused by variable-frequency drives, using the latest noncontact current probes from Power Electronic Measurements (PEM) Ltd.

The new CMC series of current probes, using Rogowski technology, empower engineers to assess the magnitude of the threat posed by hf common-mode currents, that can damage motor bearings and interfere with nearby electrical equipment. The current measurements can help determine suitable corrective action, such as fitting brushes, insulated bearings, or choke coils, and with further measurements assess the effectiveness of the chosen remedy. The screened coils have excellent immunity to voltage disturbances and a low frequency (-3dB) bandwidth that attenuates unwanted 50/60Hz magnetic fields while maximising the SNR of the measurement of the high frequency common mode currents. Available in coil sizes from 300 to 1000mm, and longer if required, making them ideal for use with a wide range of motor shafts. For more information contact: Power Electronic Measurements Ltd, Long Eaton, Notts. Tel: 0115 946 9657 E-mail: info@pemuk.com Web: www.pemuk.com/products/cmc-probe.aspx .

KEEP IT SIMPLE STUPID A major hassle when calibrating a tank sensor to an external controller is filling and emptying the tank. This creates many hours hanging about waiting for the correct levels to be

obtained before calibration can start. There are propriety products on the market which will inject a milliamp signal and some instrument engineers keep such products in their tool bag but not all do and they can be expensive. A simple solution would be to have a software facility in the tank sensor that would give the correct calibrated current output at the press of a button. A neat solution which you will find in the MiniSonda ultrasonic transmitter.

MiniSonda with lid removed

MiniSonda with lid

Then you can add in the fact that one instrument will cover an operating range from 0.5 metres to 8 metres rather than having to stock two or three different products to cover these ranges plus an instrument that is better than IP67 at all times. What else could you ask for? Made in the UK? Of course. For more information contact Hawker Electronics Ltd, Birmingham West Midlands Tel: 0121 453 8911 |Web: www.hawker-electronics.co.uk. |Email: info@hawker-electronics. co.uk

THE BARKSDALE SENSOR FAMILY GENERATION 3000 IS GROWING AGAIN: NOW THE BLS3000 TO MONITOR THE LEVEL IS AVAILABLE The electronic level switch BLS3000 offers a Plus in advantages in relation to traditional level switches. The integrated reed relays enable nearly continuous level measuring as

well as free customized set point adjustment. Due to digital indication and analogue output the feedback of the application is given quickly and reliably. In addition with panel height of 110 mm and diameter of less than 41 mm the required space for a BLS3000 is very low. This means installation even small power packs is easily undertaken. The lengths are available from 250 to 1000 mm. The resolution is at 5 mm. Beside the switch function (max. 2 setpoints) the sensor family can also be used as transmitter with analogue output in 4 … 20 mA or 0… 10 V format. The wide range of process connections (G1/2“ M, G3/4“ M, G1“ M, ½“ NPT M, 3/4“ NPT M, 1“ NPT M, 11/4“ NPT M and M20 x 1,5 mm M) are offered for various applications. The switch target applications are to monitor hydraulic oil or cooling water levels Series BLS is cULus certified as well as the well known pressure switch BPS3000 and temperature switch BTS3000 and covers the protection classes IP65/IP67. The total length of the electronic level switches BLS3000 are available from 250 to 1000 mm. The big 4-digit 14-segment LED display is not only aesthetically pleasing but also a real functional highlight. It ensures a perfect readability independent of the positioning like inversion of the display due to softwarefeatures. Menu and electrical connection refer to VDMA standard 24574-1. Due to rotatable 320° display and electrical connection, the mounting and installation is very easy.

For more information contact Petra Rolfs, Barksdale GmbH, Tel: +49 (0) 60 35 / 9 49-0 E-mail: prolfs@barksdale.de or info@ barksdale.de Web: www.barksdale.de

Featuring protection class IP65/IP67 the new BLS3000 Series electronic level switches are made for

PROCESS INDUSTRY INFORMER May 2016

PROCESS MEASUREMENT & INSTRUMENTATION CORI FILL IS FASTER & MORE ACCURATE THAN WEIGHING SCALES The European market leader in mass flow metering and control, Bronkhorst, is offering a modern alternative to the gravimetric or weighing scale method of dosing additives, fragrances, flavours and colourants. This alternative promises shorter processing times, better product results and improved working atmospheres.

Its latest CORI-FILL® compact fluid dosage assembly, which combines an extremely accurate CORI-FLOW or mini CORI-FLOW flowmeter with a suitable valve or pump, is capable of dosing the exact amount of fluid, whilst multiple instruments can be used for the simultaneous dosing of compounds. CORI-FILL® is suitable for a wide range of batching, blending, dosing, filling and sterilisation applications, at flow rates between 0.4g/hr and 600kg/hr. Aimed at the food & beverage, pharmaceutical, chemical, cosmetics, contact lens and life sciences industries, it has a compact footprint and requires no complex programming of additional hardware. With CORI-FILL® technology, you can dose the precise amount of compound into the collecting vessel, with just a brief reset command to start the next batch. The Coriolis direct mass measurement method eliminates volumetric variation caused by changing temperatures, viscosities and densities of the ingredients. As a result, the CORI-FLOW method is faster, more repeatable and more accurate than weighing scales and product results are better, due to less evaporation of volatile fluids. Moreover, it is possible to dose a number of fluid additives simultaneously, using multiple CORI-FILL instruments, leading to shorter production times, with no intermediate zeroing procedures that are required of weighing scales. The amounts to be dosed can be easily pre-set by digital communications, and the working atmosphere is also improved, as there is no dosing of additive into open storage vessels, of the kind needed for weighing scales. CORI-FILL assemblies are offered with a choice of CORI-FLOW instruments, for flow rates between 50g/hr to 600kg/hr, or the highly compact mini CORI-FLOW series, for capacities from 50 mg/hr up to 300kg/hr. Either instrument type can be combined with a shutoff valve, for short batch sequences down to <2 milliseconds, a proportional valve, for longer dosing times >5 seconds, or a gear pump, for dosing without the need for pressurised vessels. The flowmeter’s on-board PID controller is optimised for controlling the valve or pump, for an instant start to dosing duties. Accuracy is 0.5% or better for mass dosing and 1% for volume. Check out the CORI-FILL technology on the Bronkhorst UK YouTube channel. Thanks to a small footprint, the CORI-FLOW or mini CORI-FLOW instrument is able to be mounted close to the valve or pump, which minimises the internal pipework volume and results in fast response times, down to <0.3 sec, and a reduced risk of gas enclosure in the tubing, potentially causing delay effects. Ready assembled and pre-tested CORI-FILL fluid dosage assemblies are available from Bronkhorst UK, 1 Kings Court , Willie Snaith Road, Newmarket, Suffolk, CB8 7TG tel: 01223 833222 www.bronkhorst.co.uk

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

NEO Monitors introduces a new generation of the safest and most precise instrument to measure NH3 for any type of DeNOx system. NEO Monitors LaserGasTM III ammonia analyzer is designed to operate in hazardous areas to increase efficiency of the DeNOx-processes and minimize emissions. “Meeting strict HSE-regulations is becoming even more business critical. New environmental regulations and the need to decrease emissions of toxic gases is a business critical process that has become an area of concern for corporate management. Our new solution ensures better answers faster, gives more accurate information on critical operational processes and reduce costs,” says Ketil Gorm Paulsen, CEO at NEO Monitors.

The instrument helps the industries achieve better processes control, increase the efficiency of emission reduction and decrease the use of costly consumables such as urea (ammonia). Customers in industries such as oil and gas, power, chemical, petrochemical and steel will benefit from lower operational cost as well as less NOx-emissions. The instrument has been tested in Asia, and 20 units have already been sold, following great feedback and impressive results from pilot installations. The Single path (SP) configuration is a transmitter/receiver solution for cross-duct/stack installation. The measuring principal is based on Tunable Diode Laser Absorption Spectroscopy (TDLAS). “Installation is quick and easy because of the compact and improved design, maintenance costs are low, and the system is factory calibrated, meaning no need for field calibration.” says Paulsen. NEO Monitors is a global leader in laser-based solutions for measuring gases in a wide variety of industries. The company sells through a global distributor network and several of the world’s largest industrial players favor the gas analyzers. The company benefits from the groundbreaking research that takes place at its parent company, the research foundation Norsk Elektro Optikk (NEO). NEO is one of the world’s largest independent R&D organizations in electro optics. For more information contact Ketil Gorm Paulsen, CEO in NEO Monitors Tel: +47 917 77 170 | Email: ketil@n o.no |Web: neomonitors.com

PROCESS INDUSTRY INFORMER May 2016

EFFICIENT STEAM FILTRATION HELPS INDUSTRY REACH MAXIMUM PURITY STANDARDS By Andy Fairlie – Process Market Manager with Porvair Filtration When it comes to the efficient transfer of heat, steam is difficult to beat thanks to its ability to hold a great deal of energy, while remaining clean, reliable and sterile.

n fact, it is considered by many to be the ideal sterile and contaminate-free energy source, with its flexibility meaning it can be used to cook, sterilise, humidify, dry and heat. Steam filtration is increasingly becoming an essential part of any processing plant environment in today’s innovation-driven world. From system cleaning to product processing, steam is a wide, varied, and valued part of the whole system. As a result, the demand for steam filtration continues to rise, especially in critical environments. Steam is sterile in the sense that it contains no viable microorganisms. However, typical steam is not ‘pure’. With companies expected to conform to the most stringent standards of hygiene and contamination control, it is critical that the quality of the steam they use – and the performance of the steam filters installed within the steam production system –consistently produces contaminate-free products. Filtration of steam is essential to avoiding product contamination and unnecessary equipment downtime – and it actually serves to increase system efficiency and protects sterile equipment, removing pipe-scale to prevent fouling of valves or injectors and inhibiting contamination of product. There are several terms used for steam - from ‘culinary steam’ used in food processing, to ‘process steam’ used in process applications as a source of energy for process heating, pressure control and mechanical drives. Process steam does not generally come in contact with the final product whereas culinary steam can, and often does. Culinary steam filters are an essential part of any processing facility. In fact, your steam is only as good as your filter, with effective culinary steam filters helping to protect equipment from costly damage, removing debris and scale from steam lines and systems. Culinary steam is defined by 3A Standard 609-01 as “steam that is free of entrained contaminants, relatively free of water in liquid form and is suitable for use in direct contact with milk or

milk products or product contact surfaces.” In practice this means that the steam filter should be capable of removing 95 per cent of particles 2 microns in size and be manufactured from 300 series stainless steel or higher. By using an effective filter, steam will be free from the contaminants that spoil the final product’s appearance, smell, or taste; lowering downtime and increasing processing efficiency. A typical example of the use of clean steam in product processing is its injection into a vessel to create a sterile environment, whereby components such as ampoules can be processed. In the pharmaceutical and healthcare industries, sterilization is one of the principle uses for steam. This can be for certain products, but more usually for the sterilization of critical equipment. One such application is in the fermentation process which requires a high cleanliness standard of both air for the sparging operation and steam to aid in the sterilization of the vessel and associated pipework. Steam filters in this duty typically require a rating of 1 micron.

FILTERING PROCESS STEAM IS STEAMING AHEAD... Process steam is used in a variety of applications within general process industries; clean, dry steam is critical for plant performance and continuous operation, but where there is no direct contact with the manufactured product. Together with other manufactures Porvair offer a wide range of high quality, industry standard sterilization and processing filters as it looks to meet ever-growing industry demand for higher, more cost-effective performance across applications such as sterile packaging, pharmaceuticals, brewing, dairy farming, food and beverage, and chemical production. For example Porvair’s Sinterflo® stainless steel filter elements are available in high quality 316L sintered metal fibre, metal mesh and sintered metal powder media; all cartridges have a fully welded construction ensuring an excellent resistance to high temperature environments.

Manufactured from randomly laid metal fibres, sinterbonded to form a uniform high porosity filter medium, Sinterflo® F in particular demonstrates a significantly low pressure drop, high permeability and excellent dirt-holding capacity. Pleated sintered metal fibre increases the available filtration area of a filter element, thereby further increasing dirt holding capacity and so minimizing maintenance and maximizing on-stream processing. Cartridge integrity allows for a typical operation in steam from -51°C (-60°F) to 204°C (400°F), seal dependant, and up to 5bar (72psi) differential pressure in normal flow direction. With the feasibility to formulate metal fibres to meet specific application requirements combined with inherent durability, sintered metal fibre filters can be cleaned in situ without interrupting process flow, thereby providing the ultimate in process economics. Steam filters may be regenerated to extend the life and efficiency of the elements. To be specific, filter cleaning using the reverse flow technique may be very effective in fluid streams containing very low contaminants. However, care should be taken not to exceed the reverse pressure in this operation. Other cleaning techniques may be employed for filters that are heavily contaminated or contain aggressive impurities. Ultrasonic cleaning involves the immersion of the filter elements in a non-flammable solvent or water bath. Ultrasonic waves are then used to remove particles embedded within the filter media. Elements which are ultrasonically cleaned may be returned to a near original condition. Continuous innovation in steam filtration products enables manufacturers such as ours,to offer new and better solutions to applications – and the widened range for production processes is pivotal to that ‘strategy. It’s all in the pursuit of the best possible solutions for customers. Honoured last year in the UK with the Queen’s Award for Enterprise in International Trade, Porvair has supplied the process industry with performance-driven filtration equipment for over four decades.

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