Process Industry Informer November 2017 by Process Industry Informer

www.processindustryinformer.com

NOVEMBER 2017 Volume 13 No.6

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

PLASTIC DRUG ADDICTS IT’S TIME TO SOBER UP

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

CONTENTS

FEATURED ARTICLE

PLASTIC FANTASTIC

– CREATING WITH A CLEAN CONSCIENCE By Terry O’Reilly, Manager, NT CADCAM

As a design material, plastic is fantastic. Cheap, durable and light it is the doyen of packaging, the king of all our white goods and the magic ingredient in everything from shampoo to cosmetics. But, as we send more and more plastic to landfill and into our oceans, it is becoming ubiquitous with our environment. Our food chain is now contaminated with it. Plastic particles have been found in a third of fish caught off the British coast (83 per cent in UK-caught scampi), while tiny particles are now present in our sea salt. The latest report by the Ellen MacArthur Foundation says that if we don’t do something soon, by 2050, there will be more plastic in our oceans than fish.

he most common contaminators are microfibers and one-use plastic bottles, of which a staggering one million are bought every minute around the world. With plastics production expected to double in the next 20 years, how can we create a new plastic economy that won’t leave our planet littered with non-biodegradable coffee cups, shampoo bottles and discarded fishing nets? Cyrill Gutsch, a former designer and founder of environmental organisation Parley for The Oceans, says while a massive detox is required, it’s not going to happen overnight. Speaking to online design magazine Dezeen, Gutsch says, “We are drug addicts. We can’t go clean and sober overnight. Recycled plastic is the substitute drug.

Currently only 14 per cent of plastic packaging is recycled. A figure that the Ellen MacArth Foundation says could be raised to 70 per cent with concerted industry effort to achieve a more circular design economy. And the big companies are starting to act. Proctor & Gamble recently announced a limited run of its Head & Shoulders shampoo bottles made from post-consumer recycled (PCR) beach plastic collected from French beaches. IKEA launched its first kitchen range ‘Kungsbacka’ made from recycled PETbottles, while designers Adidas and Stella McCartney used Gutsch’s Parley Ocean Plastic in their trainers. Made using the German sports brand’s existing manufacturing process, the yarns in their shoe uppers are replaced using fibres from recycled waste plastic. Anna Granath, product developer at IKEA, says about 25 halflitre PET-bottles are used to create a plastic foil that coats the reclaimed wood kitchen fronts creating a sustainable kitchen. She says, “What we do at IKEA has a big impact on the environment due to the large quantities we produce, so by using recycled materials, we can create products which are more environmentally-friendly and sustainable. We are looking into new ways to re-use materials such as paper, fibre, foam and plastic so that we can give them a second life in a new product.” Proctor & Gamble’s technical breakthrough came via a partnership with recycling business TerraCycle and waste management firm SUEZ when they were able to turn 2,600 tonnes of PCR into a technically viable material that could be used in shampoo bottles on a larger scale. The company now wants to double the amount of PCR used in its packaging by 2020, announcing that more than half-a- billion bottles in Europe will contain 25 per cent of PCR plastics by 2018. However, one of the biggest issues for designers wanting to use recycled plastics is the challenge in making sure the recycled material has the correct characteristics for mass production. Keith Smith, Technical Director for SOLIDWORKS reseller NT CADCAM, says, “Before an injection moulding tool is made, designers need to know that the recycled plastic material

they want to use is fit for purpose. A CAD software such as SOLIDWORKS has a massive database of different materials, both recycled and virgin plastics, that designers and engineers can test for manufacturing defects. “You need to be able to simulate the flow of recycled plastic in a molten state going into the moulds and be able to see where the shrinkage or sinks are when they cool. Only then, can you design out any faults before going ahead to make an expensive tool. More crucially with a product like SOLIDWORKS Plastics, you can test recycled plastics for material characteristics to check for brittleness once cooled.” One of the biggest issues with waste plastic in our oceans is collecting it before it breaks up into dangerous microplastics. According to The Ocean Cleanup, a Dutch tech company that is developing technologies to extract plastic from our oceans, we need to remove the plastic debris while it is still large. Boyen Slat, who founded the company, says, “Over time, sunshine can make the plastic become very brittle and that’s when it starts to break up into tiny pieces, which are then consumed by marine life.” To collect all these pieces of plastic from 1cm bits up to tens of meters of discarded fishing nets, Slat has designed a floating filtration system suspended in the ocean using SOLIDWORKS 3D CAD4. Speaking at the system launch he said, “The Ocean Cleanup lets the plastic come to us. By using the natural ocean currents to our advantage, we can help the ocean clean itself using a network of floating screens, which will concentrate the plastic so that we can collect and ship it to land for recycling.” Slat says the only way to pave the road towards a plastic free ocean in 2050, is by combining source reduction on land with The Ocean Cleanup, which is set to go live in the North Pacific in 2018 and aims to remove half of the debris over five years. As businesses realise that mainstream technology is there to give them a choice in what recycled plastic materials they can use in design, the better the chance we have in preventing more virgin plastic reaching our oceans.

PROCESS INDUSTRY INFORMER - NOVEMBER 2017

HEALTH & SAFETY NEW FLASH POINT RECOVERY RIG OFFERS “DUAL LEVEL” SAFETY

NEW SLIMLINE SWITCHES FOR FORTRESS INTERLOCK’S amGARDPRO RANGE

A UK thermal fluid system support, maintenance and risk management service provider, has launched a new flash point recovery unit with the ability to guarantee process industry customers an unrivalled degree of safety. Developed using 21 years’ industry experience, Thermal Fluid Solutions (TFS)’ MHTM 2500 Freestanding Portable Thermal Fluid Flash Recovery Unit is the only rig on the market to recover both open and closed cup flash points, the minimum temperatures at which, in the presence of a source of ignition, fluids become flammable. While other units are able to recover closed cup flash points, relating to fluids within closed vessels such as thermal fluid pipes, the MHTM 2500’s ability to also recover open cup flash points significantly reduces the risk of fire or explosion should fluid escape from the system, for example due to leakage. In addition to dual level safety protection, the new unit offers several other benefits. The portable rig can easily be moved by fork lift truck between multiple systems on large sites, and precludes the need for the costly installation of equipment foundations. The recovery process is quickly undertaken while the thermal fluid system is in operation and the process has negligible impact on host system parameters, therefore no down-time is incurred. Fully automated, the MHTM 2500 is able to operate unattended 24/7. Said managing director, Richard Franklin: “A growing number of process industry firms are recognising that regular conditioning of thermal fluid is necessary in order to cost-effectively maintain vital fluid parameters such as minimum flash points, and so too legislative compliance. Our new rig increases our capacity as we work to help these firms manage their risk, as well as offering an unrivalled degree of safety.” For more information contact Thermal Fluid Solutions, Buxton, Derbys. Tel: 01298 815862 | www.thermalfluidsolutions.com.

Fortress Interlocks has brought out two new slimline modules for its amGardpro range of interlock safety gate switches: a slimline solenoid switch body and a slimline option pod body. These new modules allow an even wider range of safety interlock switches to be configured for many industrial applications. The range is supplied in enclosures sealed to IP67, with a 40mm wide body, and has a retention force of 10,000N, making it ideal for ensuring guard doors are held closed until machines and/or processes are in a safe condition. The slimline nature of the modules also means they can be easily fitted to 50mm guarding sections or where space is limited The amGardpro range includes solenoid and non-solenoid safety switches and many additional options, including key control modules, internal and escape release, redundant sensors, lock out/ tag out and push buttons, e-stops and indication lights for enhanced functionality, all assembled in one device. Its robust construction makes the amGardpro ideal for industrial applications when safety, strength and reliability are of paramount importance. The amGardpro replaces all adaptions normally fitted within a guarding system, so additional hardware like door catches, actuators, closing mechanisms, internal release mechanisms, key functions (including authorised access and deadlocks) are no longer needed. All these separate functions can be incorporated into amGardpro configurations, resulting in the most flexible safety gate switch solution available for today’s industrial environment. The range has a unique modular construction which allows easy configuration and provides a total electro-mechanical product for practically any safeguarding application up to EN ISO 13849-1, Category 4, PLe (SIL3). It has also been third party approved by TUV SUD. For more information contact Fortress Interlocks Ltd, Wolverhampton Tel: +44 (0)1902 349000 | Fax: +44 (0)1902 349090 Email: sales@fortressinterlocks.com | Web: www.fortressinterlocks.com

NOVEMBER 2017 - PROCESS INDUSTRY INFORMER

FEATURED ARTICLE

THE FOURTH INDUSTRIAL REVOLUTION

– WE DON’T KNOW WHAT WE DON’T KNOW By Sebastian Amos BSc (Hons) CEng MInstMC | Sector Head – Process Instrumentation & Control | GAMBICA

he following table has been around for many years and reflects four key statements that everyone should recognise. Whilst it may not have been “invented” by Donald Rumsfeld, he brought it to the fore in 2002.

From a brief internet search and summation of the input, the next graphic puts the relevance of these questions into perspective:

Industrial developments and innovation by individuals, academia or manufacturers focus by default on the three smaller of these areas which underlines the issue that there is a high percentage of things we don’t know that we don’t know. We should now discuss why this is important, especially to Industry.

DISCUSSION Adding a little more detail around these quadrants in manufacturing terms will help our understanding of why we are where we are and then consider some ideas about what we can do about it. 1. Know that you know. Manufacturers understand this and it forms the basis of continuous improvements. For example, “we know our product scrappage rates are high and they cost us an additional x% in raw materials per year. We have set KPIs across the business that will focus departments on making changes to reduce this percentage and we know that each % point will recover £y. This will make us more profitable or maintain our competitiveness.” Even more simply, the investment part of the annual budget expects a positive return, thus the issue has been specified, reviewed and processed

long before the money is allocated and reflects investment on process and product. 2. Know that you don’t know. This one is easy to understand. For example, an individual or company understands what they want but do not have a solution. This area is key to innovation, as the problem with a product or a measurement or even a more basic lack of knowledge, is or can be defined and thus ideas can be formed to solve the problem. 3. Don’t know that you know. In this instance, for example, you do not know why there is a yield problem, but there is sufficient data available that, if used correctly, will provide an answer as you know the questions to ask. The idea of brainstorming comes to mind in that it is believed that there is an answer to a problem in the room, but without discussing it, you cannot unearth it. Each of these first three provide questions and answers that can be addressed quickly. For companies, this typically means an urgent response to a problem, or within the annual budget cycle. In addition, you have specified a solution and Engineers are far more relaxed when working to specifications. Those addressing issues of productivity in industrial processes, understand these three segments and the developments they bring. Manufacturers who make products for consumption take advantage of the next generation of equipment that comes onto the market to improve their end products and production facilities. The supporting industries, for example in the control and instrumentation arenas, develop better instrumentation and control products to solve their customers issues, and the universities develop or innovate ideas to feed in to them. Suppliers and manufacturers see these as iterative quick wins. There are many examples of these basic innovations, however, I would argue that these are short term approaches that solve issues with annual business fiscal returns. In other words, companies are attempting to squeeze the last remaining drops of productivity from the existing processes. In the manufacturing circles, it is taken for granted that the basic tools are in continuous improvement cycles for the supporting technologies. CPUs gain performance on a monthly basis allowing software to perform faster. Software operating systems and associated tools from spreadsheets to databases allow businesses to view data in new ways. Communications systems develop to handle higher and higher bandwidths and datacentres provide cloud based distributed storage and processing. Control systems develop to become more effective and enable process vessels or production lines to produce more high-quality products faster and with less wastage. University research focuses on ways to do the detail more effectively. Taking advantage of chemical innovations or data processing of highly complex signal processing algorithms, they provide the science for the next cycle of materials or instrumentation. Whilst all of these are innovative, in many cases, they are basically improvements over what we have already and thus the global manufacturing industry moves on as one. Addressing these keeps the UK process industries up with the pack. The biggest question remains in that “we don’t know what we don’t know” and to take advantage of the 4th Industrial revolution, I would suggest that this has to be an area that we focus on as this would enable manufacturing in the UK to take a real lead.

PROPOSAL So, how do we approach this as an opportunity? The foundations of the 4IR are already in progress. They address the areas where government can take active involvement in education, legislation and taxation. They can support initiatives with grants to universities and industry to enable them to cross the valley of death, the space between a table top idea to a profitable mass-produced product. So, with the help of the Catapult centres and other similar organisations, moving from left to right is being reviewed and supported. Innovation, by definition, a process of improvement or taking an existing process into a new area, occurs reasonably easily, but having that light-bulb moment that provides something very new and seeing if it can be used in future products is rare. One of the most successful recent inventions would be the laser. No one really knew what to do with it. It was not invented in response to a known problem, but now it is key to communications, measurements and welding, to name three. This could be considered a solution to the position that we don’t know what we don’t know. What is missing is innovation from right to left, i.e. from manufacturing back into the laboratories. It is often lacking because it is expensive, risky and time consuming and comes a lowly fourth to the industrial needs of; keeping their customer engaged, increasing market share and increasing profits for shareholders. GAMBICA recently commissioned a short video to be made by a number of 13-15 year olds as part of their studies. Before we could focus on the video and what the message was, we discussed “what is engineering?”. After this, we asked them what, if they were Engineers, they would invent. We had a wide and varied collection of ideas that were by what I perceived as an Engineer of some 40 years, bonkers. At this point you need to take a breath. When you are 13 years old, you tend not to see obstacles and everything is possible. The point here is that these young people were answering the question, we don’t know that we don’t know. We need to look at things with fresh eyes. In the process industries, as with many others, we take on apprentices and graduates and teach them the underlying science to do their jobs and indoctrinate them with the processes and procedures to work in our organisations. What we do not do is let their minds wander.

NOW COME TWO SUGGESTIONS: 1. Companies should run quarterly sessions with all their apprentices and sub 25-year- old employees. The forum would be to allow them to come up with ideas, new processes, “what if we had?” questions that could all be put in the pot. There are no rules, just the ideas from the new generation who have, unlike the majority of the Engineering labour market, grown up with new technologies and the ever-changing world of technology and are now being exposed to manufacturing. 2. For each new project, allow a project team 2 weeks (for example) to come up with a new way of delivering the project. A younger team will be creative and imaginative and there is always the backstop to mitigate risk, return to the same way you did it before. 3. If I had a third, I would add it here. This is for the people reading this to do. If we address the question, we don’t know what we don’t know, we move it to we know what we know, before the competition and then all bets against the UK’s progress are off..

PROCESS INDUSTRY INFORMER - NOVEMBER 2017

ELETRONIC TEST TOOLS COST-SAVING FLUKE 805 FC VIBRATION METER BUNDLE INCLUDES AN EXTERNAL VIBRATION SENSOR FOR ACCESS TO HARD-TO-REACH LOCATIONS

A FREE TELEPHOTO OR WIDE-ANGLE LENS WITH A FLUKE TI300, TI400 OR TI450 THERMAL IMAGER

Until 31st December 2017, Fluke is offering a 16% saving when purchasing a FLUKE-805 FC/805 ES bundle consisting of a Fluke 805 FC Vibration Meter, together with a Fluke 805 ES external vibration sensor. This can be found at www.fluke.co.uk/805. Saving is based on the cost of the items if purchased separately. The 805 ES extends the use of the meter to crowded or hard-to-reach locations. The 805 FC is a portable, multifunction vibration screening tool that provides quantifiable information on the bearings and overall health of motors and other rotating equipment, and can share that data in real time via Fluke Connect™. It is ideal for frontline mechanical troubleshooting teams that need reliable and repeatable measurements of rotating equipment. It measures overall vibration from 10Hz to 1,000Hz and provides a four-level severity assessment for overall vibration and bearing condition. It can also detect peaks in the vibration signal readings of roller bearings and use a proprietary algorithm to interpret severity. For more information contact: Fluke UK Ltd, Northampton, Northants. Tel: 0207 942 0700. Fax: 01603 256 606. E-mail: industrial@uk.fluke.nl | Web site at www.fluke.co.uk

Until 31st December 2017, Fluke is offering thermal imager kits which include a free telephoto lens (FLK-TIxx0 9HZ/T2) or wide-angle lens (FLK-TIxx0 9HZ/W2) with a Fluke Ti300, Ti400 or Ti450 Thermal Imager to extend the focus and the desired viewing angle. These thermal imagers are part of the rugged Fluke Professional Series and compatible with Fluke Connect®, enabling users to share information with others direct from the job site. The offers can be found at www.fluke. co.uk/freelens The Fluke Thermal Imagers included in the offer all 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, and feature Fluke IR-Fusion® technology with AutoBlend™ mode to detect problems faster. For more 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

NOVEMBER 2017 - PROCESS INDUSTRY INFORMER

INSPECTION & VISION SYSTEMS MARTINDALE ELECTRIC PUTS THERMAL IMAGING WITHIN EASY REACH The new IRC thermal imaging cameras from Martindale Electric represent a breakthrough in affordable thermal imaging for troubleshooting of electrical and mechanical installations. The combination of real time thermal imaging with spot infrared temperature measurement, packaged in a rugged pistol design, make it the ideal tool for electricians and maintenance teams needing fast on-site diagnostics. The cameras show hot and cold spots at a glance and accurately measure spot temperatures of hot and hard to reach surfaces. The advanced thermal images, displayed on the 4.5cm colour display, combine colour temperature gradients and component outlines to quickly troubleshoot problems, be it poor electrical connections, phase unbalance or faulty motors and bearings. Both IRC325 and IRC327 include an infrared spot thermometer making it easy to accurately and safely measure the temperature of hot and hard to reach surfaces without contact. For more advanced applications, the IRC327 has an extended temperature range to 650o C and allows simple capture and storage of the image to the SD card for evaluation and reporting. The two models can be used for a wide range of applications from identifying sources of heat loss to reduce energy bills, through to checking the correct functioning of heating and ventilation systems.. For more information, please contact Martindale Electric on Tel: 01923 441717 or visit: Web: www.martindale-electric.co.uk

INFRARED GUIDED MEASUREMENT TECHNOLOGY HELPS ELECTRICAL PROFESSIONALS SPOT PROBLEMS FLIR recently announced that the FLIR DM285 thermal imaging digital multimeter, an industrial inspection, troubleshooting, and diagnostic tool for a wide variety of electrical and electromechanical applications, as well as for heating, ventilation, air conditioning, and refrigeration (HVAC/R) inspection. Electrical professionals and field service professionals can use the DM285 for non-contact thermal imaging to quickly scan for overheating system components, and then use it to test functions to troubleshoot and diagnose the fault. The DM285 is ideal for troubleshooting electrical applications, including overheating panels, fuses, and loose connections. It can be used for diagnosing issues in electro-mechanical equipment such as rotating and reciprocating pumps and compressors, electric motors and drives, and associated monitoring and automation systems. It is also a good choice for HVAC/R applications, as well as repair of printed circuit board components, voltage regulators, power supplies and microprocessors. As FLIR’s most advanced digital multimeter, the 18-function, 160x120 thermal resolution DM285 measures temperatures up to 400°C, stores data for 10 sets of 40k scalar measurements and 100 images, and offers a recall function for data review in the field. It includes a built-in worklight and flexible battery options, including the long-life FLIR TA04 Li-Poly rechargeable battery or standard AA batteries, that ensure operability 24/7. The unit also includes batteries, high-quality silicone test leads, alligator clips, Type-K thermocouple, test lead storage/holder attachment, and a soft carrying case. The DM285 carries a 10-year warranty on both the product and the thermal detector. For additional information visit www.flir.com/IGM-Meters. 14

INDUSTRIAL VISION SYSTEMS LAUNCHES IVS-NCGI CAMERA RANGE

NEW MACHINE VISION CAMERAS REPRESENT A BREAKTHROUGH IN PERFORMANCE AND FLEXIBILITY The next-generation IVS-NCGi range of digital cameras from Industrial Vision Systems (www. industrialvision.co.uk) provides a breakthrough in flexibility, performance and ease of use for machine vision. With heightened resolution options for more precision and faster frame rates, the cameras are designed for integration into modern production processes. Its compact form factor also easily fits into space constrained manufacturing lines and cells. With manufacturers relying on dependable and consistent machine vision throughout the production process, these advanced camera heads provide industrial grade inspection capability with much higher resolutions allowing them to handle the most complex inspection and quality control tasks. Full integration with the IVS software platforms make it one of the most flexible vision systems on the market today. The cameras come ready to be mounted with standard LED lighting options plus a wide range of field-changeable C-mount lenses and industrial autofocus lens options. The IVS-NCGi cameras offer comprehensive and real-time communication between the cameras and factory information systems. IVS vision systems are designed to communicate with all PLCs, master controllers and proprietary factory controls out of the box allowing rapid integration and easy commissioning on the production floor. They offer fast and efficient operation at every stage from image capture to data output. For more information on Industrial Vision Systems cameras please visit: Web: www.industrialvision.co.uk/products/vision-hardware/cameras

MATERIALS HANDLING HANDLING WITH EASE: DEMAG MANULIFT FOR LOADS OF UP TO 500 KG • Extended load capacity range • Single-handed operation Demag Cranes & Components has added a new model to its DCM-Pro Manulift range to accommodate increased load capacities. The new DC 5 Manulift allows users of Demag chain hoists to handle loads weighing up to 500 kg simply and safely. The DC Manulift, used in conjunction with a Demag DC chain hoist, may be used for simple and safe horizontal and vertical movement of loads with minimum operator effort. Loads may be manoeuvred with the operator using just one hand, leaving the other hand free to operate the crane control system. This provides ergonomic advantages over the use of conventional chain hoists, where the operator often needs to use both hands to lift and position loads. It’s control unit is rigidly connected to the load handling attachment, allowing the operator to guide the load with a central handle and, at the same time, lift and lower the load via integrated rocker switches, without having to change the hand position. This arrangement enables loads to be handled quickly, precisely and safely with fluid motions and has been enhanced by the introduction of material handling innovations, such as the latest D-Grip manual force control unit. The DCM-Pro 5 incorporates all of the safety and operational features associated with the established Manulift range. For more information contact Demag Cranes & Components, Banbury, Oxfordshire Tel: 01295 676100 Fax: 01295 271408 Email: bnb-help@demagcranes.com | Web: www.demagcranes.co.uk PROCESS INDUSTRY INFORMER - NOVEMBER 2017

FEATURED ARTICLE

PHOSPHATE MANAGEMENT IN RURAL RIVER CATCHMENTS B r y o n y B o w m a n , Senior Process Engineer at United Utilities, discusses the drive to improve water quality in our rivers and explores an innovative pilot project on the River Petteril in Cumbria which might achieve better phosphate reduction levels than traditional wastewater treatment processes alone.

he Water Framework Directive sets out an ambition to achieve ‘good ecological’ status across all rivers in England and Wales by 2027. A healthy river can provide us with a host of benefits, and clean water is only part of it. The river catchment land itself provides us with flood management, produce from agriculture, biodiversity and scenery to keep us fit in body and mind. Currently only a small number achieve this target with phosphorus concentrations being the predominant reason for a river being of moderate or poor status. The presence of phosphorus can lead to eutrophication and algal blooms which impact on fish and wildlife by depleting oxygen levels within the river. So where does phosphorus come from? It’s found in soaps and detergents, fertilisers as well as human and animal waste. Depending on the river catchment the proportion of phosphorus from each source will vary: in rural catchments the amount of phosphorus from non-water industry sources can be significant. Prior to the current water industry investment period (AMP6) phosphorus permits were driven by the Urban Wastewater Treatment Directive which focusses on large sites in urban environments. Under this directive sites with a population equivalent of less than 10,000 would not have a phosphorus permit. The Water Framework Directive has led to an increased focus on phosphorus in rural catchments and has resulted in an increasing number of small wastewater treatment works with phosphorus permits. Modelling of river water quality can predict permits less than 0.1mg/l total P at very small works in order to achieve ‘good’ status in the watercourse. Is this an 16

achievable standard to meet? Recent industry wide studies into achievable levels of phosphorus removal at wastewater treatment works have set a standard of 0.25mg/l total phosphorus as the lowest technically achievable limit. However, the technologies used to meet this standard have been developed to take advantage of economies of scale and are therefore focused on larger, urbanised wastewater treatment facilities. Once scaled down to small works with a population equivalent of less than 1000 these technologies cease to deliver a cost benefit. So how can we improve river quality in these rural catchments?

THE CONVENTIONAL APPROACH Conventional approaches of removing phosphorus from wastewater have focused on interventions at a wastewater treatment works that have followed either a biological or chemical removal route. These approaches involve major civil engineering and are either energy- or chemicalintensive processes. Biological phosphorus removal is not practically achievable at small rural treatment works leaving chemical treatment as the viable method of removal. Chemical phosphorus removal involves the additional of metal salt coagulants to crude sewage, metal ions form a phosphorus precipitate which is then removed through settlement in primary treatment. The action of coagulant addition consumes alkalinity present in wastewater, which is of particular concern in areas of soft water such as Cumbria.

to a site leads to extra requirements in terms of water supply for safety showers and increased frequency of site team visits. Is this really the best way to tackle the problem, especially in a rural area? Are we over-engineering the solution – using a sledgehammer to crack a nut? Are we building expensive assets and leaving a legacy of big future operational costs for our customers? How can looking at this differently provide greater benefits? United Utilities has created a case study around the River Petteril in Cumbria to understand the issues to be faced in rural catchments and to develop an alternative approach to provide improved river quality. Based on partnership working, it will deliver more effective interventions and reduce the burden of investment costs on customers. The River Petteril begins at Motherby near Penrith and flows north through farmland and rural communities until it joins the River Eden in Carlisle. There are 10 wastewater treatment works along its course, 10 combined sewer overflows and 12 wastewater pumping stations. There are also more than 100 farms, numerous private septic tanks and one motorway service station.

Figure 2: Partnership approach adopted as part of the Integrated Catchments strategy

Figure 1: The River Petteril in Cumbria

The introduction of chemicals to small, rural works also has implications on the number of vehicle movements needed for chemical deliveries; this can also lead to concerns around access routes which may not currently be suitable for frequent deliveries. The addition of chemicals

According to the Environment Agency the majority of phosphorus in the River Petteril is from non- water industry assets. So it became clear that a non-traditional approach was required to achieve tangible benefits in river water quality. We wanted to see how innovative treatment solutions and catchment solutions might provide a better option in the round. To improve our understanding of the River Petteril we have carried out catchment sampling and modelling to determine where effective interventions could be made. We have been trialling innovative treatment methods at one of the wastewater treatment facilities in the Petteril catchment. This involves the use of reactive PROCESS INDUSTRY INFORMER - NOVEMBER 2017

media to provide sustainable phosphorus reduction without chemical dosing or significant levels of energy consumption. The media captures phosphorus in a slow release bioavailable form opening up opportunities to recycle this to land as an alternative to conventional fertiliser. The results have been encouraging and show that the required level of phosphorus reduction can be achieved by this treatment process without the need for chemical addition. Interventions focussed solely at the wastewater treatment works will address these point source discharges, however this has been found to be the source of less than a third of the phosphorus entering the River Petteril. Interventions are also needed that will reduce other sources of phosphorus within the catchment. This is where we have built on best practice and case studies from other parts of our region. Since 2005 we have been leading on a range of catchment-based projects all aimed at keeping livestock out of watercourses, reducing nutrient addition from run-off and helping maintain improvements to the local bathing waters. Through the Petteril project, working with partners like the Environment Agency, the Eden Rivers Trust and Carlisle City Council we’re getting the buy-in to bring all these ideas together into one approach with multiple benefits.

incl. Pumps & Valves FLUIDS

& LIQUIDS HANDLING

EMERSON ANNOUNCES HIGH DENSITY PNEUMATIC VALVE ISLAND, ENABLING REDUCED INSTALLATION COSTS Emerson announces a major update to the ASCO Numatics G3 Series electronic valve island platform, enabling a reduction in installation costs. The valve island has been expanded so that it can control up to 128 solenoid valves on a single valve island assembly. This allows more valves to be controlled from a single node, enabling savings in the number of nodes and the cabling, internal tubing and electrical connections in the cabinet. Customers will benefit when they control a high density of valves or pneumatic equipment in a packaging plant or on a skid. The new functionality enables designers to minimise expensive cabinet space and have fewer nodes dedicated to pneumatic valve islands, said Uwe Claus, Global Vice President Marketing. Now, designers can place more valves in a single cabinet or use a smaller enclosure to house the same number of valves. In addition, installers will only have to set up and configure one node, saving time and labour cost. The expanded valve platforms can support up to 128 11mm solenoid valves and up to 80 18mm and 26mm valves. To increase the valve platforms´ capacity, mid-station blocks were added with valve drivers and auxiliary power connectors. This flexible approach allows customers to pay only for the capacity and functionality required in their design. A wide variety of communication protocols are supported, including Ethernet/IPTM DLR, Profibus® DP, and Valve Sub-bus for distribution. It is highly recommended that customers use the flexible and powerful online Dynamic Product Modelling (DPM) tool when designing pneumatic valve island installations to save time in design and selection. The DPM tool enables the valve islands to be fully configured. It produces a unique specification for that product and enables a CAD drawing to be downloaded. Claus said, Our new G3 Series platform is ideal for use in life science (pharmaceutical and biopharmaceutical), food and beverage, fine chemicals, and water/wastewater applications Claus said. For more information contact Media contact: Chris Parlour Tel: +44 (0) 1695 713678 | E-mail: chris.parlour@emerson.com

CONTROL CAPABILITY DRIVES PUMP SELECTION AT FIDIA FARMACEUTICI · WMFTG has become an established supplier to Fidia Farmaceutici · Fidia leverages close pump control through analogue signal input - Pumpsil Platinum-cured silicone tubing offers fluid sterility

Figure 3: An example of reactive media which has been trialled

And what does this mean for our customers? The original cost of installing and operating traditional phosphate removal technology at all of our assets along the Petteril would have missed the majority of the problem. The cost of the integrated catchment management strategy comes in at a significantly lower cost and will address phosphorus throughout the catchment, there may also be additional benefits by slowing the flow of floodwater and reducing risk to water supply boreholes. This is the start of a three year pilot scheme, but it shows how working in partnership can bring exponential improvements. DEFRA’s current 25 year plan sets out “to be the first generation to leave the environment in a better state than we found it.” Part of its approach, “Pioneer”, brings different agencies together to tackle environmental challenges in a new way, to get the best possible outcomes for the least cost We’re going to be sharing what we learn from the Petteril project with Pioneer, to help shape the UK’s environmental policy for years to come. NOVEMBER 2017 - PROCESS INDUSTRY INFORMER

A leading European manufacturer of health products is benefiting from the control capabilities of peristaltic pumps from Watson-Marlow Fluid Technology Group (WMFTG). The pumps are being used for the precise metering of water-based buffer agents such as hydrogen chloride (HCl) and glycerol, at one of its production facilities on the island of Sicily. Established in 1946, Fidia Farmaceutici SpA is headquartered in Abano Terne near Padua, Italy. The company employs around 1000 people across all of its sites, one of which can be found at Noto near Syracuse, Sicily. The Noto facility produces APIs (active pharmaceutical ingredients) for use in Fidia-branded medical devices, which is where Watson-Marlow pump technology plays a key role. “WMFTG is an established supplier to Fidia and our experience of their products and service has always been positive, which is why we specified their peristaltic pumps again for this latest project,” statesChristian Cuppari, who is responsabile for the production unit in Noto. “In fact, Watson-Marlow is now the predominant pump type here at Noto.” Fidia has 500 and 300 series models, supported by Pumpsil silicone tubing, to pump HCl and glycerol water-based buffer solutions. “For reasons of cost and quality control we required pumps with high control capability, as well as the assurance of fluid sterility with the right type of tubing,” says Dr Cuppari. A pump such as the 520U can be controlled from the keypad or remotely. It features analogue control whereby pump speed can be governed through an analogue signal input in the ranges of 0-10V or 4-20mA. The latter is preferred at Fidia, with the input signal generated by special fermenter control software for biocare applications. With regard to fluid sterility, precision Pumpsil Platinum-cured silicone tubing plays a key role in biotechnology and pharmaceutical manufacturing processes around the world. It is manufactured in WMFTG’s ISO 14644-1 Class 7 clean room and is postcured to improve the finished product. Pumpsil is laser-etched end-to-end with part number, lot number and use-by-date, and has fully documented biocompatibility with a comprehensive validation pack. “We are pumping buffer solutions and acid/alkaline solutions, typically across batch runs that last for around 36 hours,” concludes Dr Cuppari. “This is why we need reliable, close control in our chemical metering, and the pumps from WMFTG are proven in meeting these requirements.” The 520 series pump has since been upgraded to the 530 series model – which features an enhanced operator and control system interface, and a bright colour display. For more information contact Watson-Marlow Fluid Technology Group, Tel: 01326 370370 | E-mail: info@wmfg.co.uk | Web: www.wmftg.com 17

FEATURED ARTICLE

WHAT IS DDMRP

& HOW CAN BUSINESS PLANNERS USE IT?

D e m a n d driven material requirements planning (DDMRP) has been going from strength to strength since its conception in 2011, with adoption from leading companies around the world. Here, Roger Fleury, Managing Director of resource management software specialist Ardent Solutions, Birmingham, explains DDMRP, its fundamental theory and why it’s more than just another industry buzzword.

very business production planner and operations manager understands why effective resource management is a critical component of success. Despite this, even global brands struggle to manage resources in a way that ensures product demand is met consistently. A perfect example of this is Procter & Gamble’s US launch of its Tide pods in 2012. The initial launch date was scheduled for the third quarter of 2011, but the brand postponed the launch until the following year as it needed extra time to increase production to meet customer demands. Commentators astutely identified that this weakened the brand’s market position and gave competitors an opportunity to derail the launch. This is just one example of why traditional approaches to resource planning are often ineffective. Instead of manufacturing product in line with actual consumer demand, many traditional manufacturing philosophies promote the use of forecasts to predict demand. As P& G’s launch shows, these forecasts are often inaccurate. With similar high-profile forecasting errors being an all-too- regular occurrence, why do planners continue to use traditional MRP approaches? In essence, the reason is because MRP methodology became the status quo for manufacturing businesses following its introduction in the 1960s. While customer needs have changed since then, many production planners and supply chain managers remain rooted in the old methods. Unfortunately, this means that there is often a great disparity between actual customer demand and that predicted by forecasting,

which results in wasted stock or underproduction. Both eventualities harm businesses and highlight the fact that forecasting is dangerous for modern production planners, who must overcome the status quo and adopt a pull-based model to stay ahead. Taking a demand-driven approach is simple in principle, but requires a fundamental shift in business culture and mentality to fulfil its potential. While there are five core components of DDMRP, the sixth precursory factor is for operations managers and planners to open their minds to the possibility that the traditional methods are often incompatible with modern markets. Beyond that, the five components of DDMRP are simple. Split into three stages: position, protect and pull, the components are: strategic decoupling, setting buffer levels, dynamically adjusting those buffers, demand-driven planning and collaborative execution of orders. But what do these mean?

POSITION The first and most important step is to strategically set the decoupling points in the supply network. These should be set to dampen variability in supply and demand effectively, which can be determined by considering factors such as the lead times, operation capacity and inventory flexibility at each point of the supply chain. Effectively, production planners should aim to set decoupling points where they provide the most flexibility and compression of lead times. Planners can then use DDMRP software to manage the chain by decoupled segment rather than one overall lead time. For example, imagine the manufacturing of a product takes ten weeks and involves three core phases that can be broken down into subassembly, assembly and customisation. Business planners can align decoupling points accordingly between stocking components, finalising assemblies and delivering product. This can then be managed as a three-week lead time to accumulate raw stock, a further six weeks to create the subassembly and the rudimentary assembly and then a lead time of one week to paint or configure the assembly and deliver a finalised product.

PROTECT To protect the supply chain, a buffer is set at every decoupling point. These buffers will hold inventory, whether it is raw stock or subassemblies, in preparation for the next phase of the supply chain. Yet it’s important to note that this does not mean that excessive volumes of inventory are placed everywhere at the expense of the business. The amount of inventory permitted in a buffer is calculated with a formula that accounts for lead times and the average daily usage (ADU) of stock, ensuring that only a carefully calculated and strategic quantity is held. Each buffer is structured with a traffic-light system; green is the heart of the order generation aspect of the buffer, determining the frequency of order generation and the minimum size of each order; yellow is the heart of the demand coverage in the buffer; and red is

the safety embedded in the buffer position. The system enables business planners to easily identify when action is required and stock needs to be replenished. The optimum range for inventory will be in the primary coverage zone, which is the yellow segment. The dynamic adjustment comes into play in response to the variability of operating parameters or planned future events. As DDMRP software provides frequent updateson ADUs, the buffer levels automatically adjust in response to this. The levels are intentionally flexed or lessened in anticipation of known future events or seasonal changes, allowing for more agile resource management.

PULL The factor that sets DDMRP apart from traditional MRP is that there is a greater and more effective focus on the customer pull. The demand-driven planning component of DDMRP means that orders are only generated by the most relevant demand signals, which is to say qualified sales rather than predicted queries or leads. Demand is only allocated in the DDMRP system once an order is placed. This prevents over and under-stocking, keeping production in the optimal inventory management range and avoiding the unexpected distortion of the supply chain caused by demand oscillations, commonly referred to as the bullwhip effect. This demand is calculated through the daily application of the net flow equation. Simply put, this is the volume of qualified-salesorder-demand subtracted from the cumulative quantity of onhand and open supply. This provides a net flow position that, if in theyellow buffer zone, triggers a supply order. Planners and managers execute these orders through DDMRP software such as DDMRP for Dynamics, which is a remodelled version of traditional Dynamics MRP that can be quickly set up on existing systems to facilitate demand. This provides a clear overview of buffer levels and the status of on-hand stock. The key distinction of this software is that it determines priority based on buffer status rather than due date. For example, if only 20 per cent of on-hand stock is available but the due date is six weeks away, it will be deemed higher priority than an order due in four weeks but with 65 per cent on-hand availability. This allows for better stock management than is achievable with traditional MRP methods. In the same situation, planners using MRP software would simply identify that one order was due two weeks sooner than another. This would subsequently make the order with higher stock availability be considered priority because of its impending due date, ultimately meaning resources are wrongfully allocated and leaving businesses to frantically manage lead times. While still in its infancy, DDMRP is proving an effective means of mobilising businesses for volatile and rapidly changing markets. It’s already benefitted global businesses from British Telecom to Coca Cola, so it’s safe to say that DDMRP is no buzzword — it’s a revolution in resource and stock management.

PROCESS INDUSTRY INFORMER - NOVEMBER 2017

WINTER EDITION 2017

IN THIS ISSUE... BPMA is delighted to announce that its E-Learning Courses are now CPD accreditation - Page 02 KSB Group takes action against Asian brand and trademark infringers – Page 06 Learn about the new Radio Equipment Directive – it could have far reaching implications – Page 03 Consider the true cost of pump equipment and systems? - Page 04 The BPMA’s Pump Industry AwardsNominate now for 2018 - Page 03 Find about the BPMA’s Golf Day for the pump industry. - Page 03 BPMA Membership continues to grow with two new members – Page 05 We acknowledge and celebrate our engineers – Page 05 01

TRAINING FOREWORD Welcome to the Pump Industry News winter edition . This will be my last Pump Industry News as the BPMA president as I will have completed my 2 year term in November and will be handing over the role of President to Duncan Lewis of Xylem Water Solution. I wish him the best for his 2 year term and offer my support to him in what we all envisage will be challenging business times due to the uncertainty of the Brexit negotiations with the European Commission . During my 2 years tenure as President there have been many challenging situations none more so than the major issues we have had with Market Surveillance in the UK, however it was a great privilege to be President at the time the BPMA celebrated its 75 th year. As the festive season is just around the corner and will soon be upon us could I take this opportunity to wish all of you good health and best wishes for a prosperous 2018 .

Regards Peter Reynolds BPMA President

BPMA TRAINING - E-LEARNING INTRODUCTION TO PUMPING TECHNOLOGY - £180.00 PLUS VAT Do you have any new starters or colleagues who are new to pumps, this BPMA e-Learning course could be for you. Providing standardised terminology and a straightforward approach to the various pump types. It is targeted at all employees who need to understand the language of the pump industry. Students will: • Learn why a pump is important • Gain an appreciation of the wide range of pump types and terminology used • Find out how pumps are driven • Gain an overview of pumping issues and Systems • Ofqual has approved the course at LEVEL TWO (QCF) with 2 credits and the course carries CPD Accreditation The Introduction to Pumping Technology course will require up to 20 hours to complete e-Learning Are you Ready to take the Ultimate course in Pumping Technology? Essentials of Pumping Technology - £600.00 plus vat The Essentials of Pumping Technology is aimed at those delegates who through experience and knowledge of the industry feel able to undertake what we believe to be the most comprehensive. Pump Training course available Students will be provided with: - The KNOWLEDGE they will need to complete set tasks in pumping without close supervision. - An UNDERSTANDING of number and physical properties including units and dimensions needed for operating pumps. - The ability to SELECT types of pump for particular applications. - LEARN the theory of rotodynamic pumps, curves, efficiency points and the Affinity Law. - LEARN the theory of ROTARY PD PUMPS, and their similarities and differences versus - rotodynamic pumps. - LEARN the theory of POSITIVE DISPLACEMENT PUMPS, and their specific features. The Essentials of Pumping Technology course will require up to 200 hours to complete Each chapter concludes with a short test and at and the end of the course there is a final assessment. A pass rate of 60% must be achieved in the final assessment in order to gain NOCN certification of 9 credits at Level Four This course covers more ground than that required by the NOCN, hence not all the questions in the final test form part of the NOCN assessment. The BPMA will therefore award their own industry recognised certificate, based on the whole of the Course, which will confer on the successful student an additional benefit to that of the NOCN award. The BPMA award* will be graded as PASS at 60%, CREDIT at 75% and DISTINCTION at 90%. Industry professionals should aim to be awarded the Distinction.

BPMA E-LEARNING COURSES RECEIVE CPD ACCREDITATION Following on from the recent announcement that the BPMA’s ‘Lecture to Student’ training courses are now CPD accredited, the organisation is delighted to announce that both of its E-Learning courses have also achieved CPD status. The independent pump training courses, which the BPMA have been successfully running since the mid 1990’s, have helped equip many hundreds of individuals with the knowledge and skills required to assist pump companies to stay one step ahead of the competition. As part of its ongoing commitment to this important aspect of its service provision, the BPMA has embarked on a process of securing CPD accreditation across its full training programme. Engaging in Continuing Professional Development ensures that both academic and practical qualifications do not become out-dated or obsolete; allowing individuals to continually ‘up skill’ or ‘re-skill’ themselves, regardless of occupation, age or educational level. The two E-Learning courses to achieve this much valued accreditation, both of which are already independently accredited by the National Open College Network (NOCN), cover the following key subjects:• Introduction to Pumping Technology • Essentials of Pumping Technology The final BPMA course to get the CPD treatment will be the ‘Certified Pump System Auditor’ scheme; an industry specific professional qualification developed Press Release by the BPMA. Its objective is to help improve the levels of professionalism in the sector by creating a universally recognised and respected “standard” for individuals assessing the operational performance of a pumping system. Registered Office: Anderson House 523 Eastleigh Road, Eastleigh, Hampshire, SO10 0DW Company Registration Number 07250009 VAT Registration Number 992575370 If you would like more information on any of these courses, including dates, prices and availability go to www.bpma.org.uk or contact s.smith@bpma.org.uk.

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

INDUSTRY NEWS THE NEW RADIO EQUIPMENT DIRECTIVE – IT COULD HAVE FAR REACHING IMPLICATIONS! In this article, Steve Schofield, Director and CEO, British Pump Manufacturers Association (BPMA) offers a quick overview of this contentious legislation. The Radio Equipment Directive supersedes the former R&TTE (Radio & Telecommunications Terminal Equipment) Directive and determines that all and any products that are equipped or combined with a device for transmitting or receiving signals via ‘radio waves’ is in scope of the Directive and so can, and will, be regarded as a RED product. Some would argue that this is an unsatisfactory situation, with most companies taking a pragmatic view and continuing to follow the well-known and fully established procedure in accordance with the R&TTE Directive – the predecessor of RED. In this historical approach, all the equipment that combines to make the machine (and which is now subject to the Radio Equipment Directive) is shipped accordance with the Machinery Directive. Clearly, the introduction of RED will create another layer of documentation and conformity requirement that will have far reaching implications for many equipment manufacturers, as they strive to effectively service the needs of the ‘connected environment’ and the ‘smart factory’. The European Commission has now published the updated list of harmonised standards in the framework of the implementation of the Radio Equipment Directive (RED), which came into effect on 14 July 2017 (C 229/24). Additionally, the Frequently Asked Questions (FAQ) document on RED has been recently updated. It covers key clarifications on the scope and application of RED, as well as the status of publication of harmonised standards, and how manufacturers can ensure compliance with the Directive in the absence of standards. An informal meeting on the Radio Equipment Directive was organised and hosted by the Commission on 3rd October. This meeting focused on the harmonised standards prepared for Articles 3(2) and 3(3) which prescribe the essential requirements of the Directive. More details on RED can be found in the Orgalime Guidance Document which is available from the BPMA, along with the list of FAQ’s. Please contact Steve Schofield at the BPMA s.schofield@bpma.org.uk - to request your copies.

EVENTS 2018 PUMP INDUSTRY AWARDS – CALL FOR NOMINATIONS For the past seventeen years, the BPMA’s Pump Industry Awards Programme has been recognising the best performing companies, products and people for their achievements and positive contributions to this important industry sector. In 2018, the BPMA will again lead the way in championing those who strive for business, professional and engineering excellence. Eight awards are up for grabs at the 2018 event: - Technical Innovation, Products (Sponsored by Process Industry Informer) • Technical Innovation, Projects (Sponsored by Wilo) • Environmental Contribution of the Year (Sponsored by SPP Pumps) • Manufacturer of the Year (Sponsored by Siemens) • Distributor of the Year (Sponsored by WEG) • Supplier of the Year (Sponsored by Tomlinson Hall) • Engineer of the Year (Sponsored by World Pumps) • Lifetime Achievement Award (Sponsored by BPMA) To make a nomination, visit http://pumpindustryawards.com. The prestigious Awards Dinner and Presentation Ceremony will take place on Thursday 22nd March 2018, at the fantastic Heythrop Park Country Resort in Oxfordshire. Dating back to 1710 this quintessential English country estate seamlessly combines elegance with style, and is set in 440 acres of stunning Oxfordshire Countryside. Located just 12 miles from Oxford, its central location ensures easy access from all over the UK. Peter Reynolds, BPMA President, says of the awards, “The competitive nature of the pump industry, and the constant search for greater operational performance Press Release and improved efficiencies across its myriad customer base, requires that all those operating within this important sector be at the top of their game. This awards programme allows the pump industry to come together in recognition of that drive for engineering excellence.” A full complement of Sponsors has once again been secured for this important industry event, with each one contributing to the overall success of the Awards Programme and Presentation Dinner. They include ABB, John Crane, Flowserve SIHI, Process Industry Informer, Siemens, SPP Pumps, Tomlinson Hall, WEG Electric Motors, Wilo UK and World Pumps. As a new category sponsor this year, Richard Harden, Managing Director at Wilo UK, commented, “Having been a regular attendee at the awards dinner over recent years, we have been impressed with the structure and presentation of the event, and of course the opportunity it provides to network with senior figures from across the pump industry. This led us to increase our participation in the last event through sponsorship of the Entertainment, with which we were extremely pleased. As such, and as a further commitment to both the event and he BPMA, we are delighted to be sponsoring the ‘Technical Innovation- Projects’ category in the 2018 awards programme.” Entries are sought for any company, product, application or individual within the pump industry that is worthy of recognition and reward. Nominations and entries are not restricted to BPMA membership, and you can put forward entries for yourself and your own company, or you can nominate others that you know of or work with. The online entry process couldn’t be easier, so if you want to play your part in bringing engineering excellence to the fore, please do visit the PIA website - www.pumpindustryawards.com. The Call for Nominations’ process is now open, with the ‘Online Entry’ Forms being available for completion until 5.00pm on Monday 15th January 2018, providing ample time in which to submit an entry. So if you want industry-wide recognition for a job well done, be it for technical innovation or application know-how, for environmental consideration or distribution and supply, please make a note of this key date.

BPMA GOLF DAY – AN OPPORTUNITY FOR BUSINESS Several years ago the BPMA was approached by a number of member companies asking whether it would be able to organise a dedicated Golf Day for the pump industry. The idea being to create a focused ‘networking’ event to which they could invite their key customers (who also happened to be golf enthusiasts), and enjoy a pleasant day out of the office, in a relaxed, neutral and above all enjoyable environment. The opportunity to mix with other companies and individuals operating with this key sector, to exchange ideas and to make new contacts, was seen to offer a practical and worthwhile business event, and one which dovetailed nicely with some of the core objectives of the sector’s trade association. The BPMA were therefore delighted to be tasked with this activity, regarding it as way of helping members who wouldn’t otherwise have the resources or overall numbers to organise this type of business event themselves. Fast forward and the BPMA Golf Day is now a regular, well-attended annual event; one which members, and their customers, are keen to pencil into diaries. Steve Schofield, Executive Director of the BPMA comments “I am delighted and very often surprised at the attendance this event now enjoys. In a business climate where every penny is precious, and where any expenditure is assessed for optimum benefit, our members still value and support this activity. Having said that, given the opportunity to engage with all manner of business contacts from across the pumps sector, be they suppliers, distributors or end users, it is clear to see that the event provides a wonderful networking environment”. Steve continued, “It’s not just about the golf, but more about having the time to engage and nurture, whilst fostering business relations that might otherwise not exist. The dinner in the evening only adds to the occasion, creating a suitable conclusion to a thoroughly entertaining and productive day”. The BPMA has been fortunate to stage its annual Golf Day at some of the most prestigious Golf Clubs across the UK, and to negotiate some really good prices into the bargain! This year will be no exception with BPMA’s 2018 Golf Day being held on May 24th at the prestigious Wychwood Park, near Crewe in Cheshire. If you would like to find out more, or wish to book a place for your team, please contact Steve Smith on s.smith@bpma.org, who will be pleased to furnish you with all the details.

QUESTION & ANSWER

SOLUTIONS FORUM YOUR PUMPING QUESTIONS ANSWERED “With the increasing focus on both energy use reduction and operational efficiency, how can I determine the true cost of my pump equipment and systems?” When it comes to specifying pumping equipment, many companies, particularly those under increasing pressure to cut costs, could actually be making decisions that will cost them more in the long run. In this article, Steve Schofield, Directorand Chief Executive of the British Pump Manufacturer’s Association (BPMA), explains how lifecycle costing can help to reveal the true cost of a pump. The need to cut costs wherever possible is an increasingly familiar requirement for engineers charged with ensuring the continued smooth operation of plant on a limited budget. When it comes to pumping systems, although choosing the lowest cost option may seem like the best short term solution to achieving cost savings, it will almost always result in additional costs being incurred that could have been avoided by spending a little more time and money during the specification and design stage. According to statistics from the US Department of Energy’s Office of Industrial Technologies, pumping systems can account for between 25 and 50% of the total energy consumed by certain industrial processes. Add to this the need for ongoing service, repairs and maintenance throughout a typical service life of 20 years and pumps quickly begin to represent a substantial area of expense. The expectations of some pump users can be unrealistic when it comes to the cost of pump ownership, in many cases they focus too much on initial outlay, opting for the least cost alternative, which is not always actually the best solution for the application.

So what is the answer? The BPMA and many of its members are keen to emphasise the importance of life cycle costing (LCC) as a vital part of any pump purchasing and ownership strategy. Life cycle costing takes into account many factors, all of which impact on the total cost of owning and operating a pump, which includes much more than just the initial outlay. A pump’s life cycle cost encompasses the total overall costs that accumulate throughout the life of a pump, from installation, energy consumption, operation, maintenance

and down time, even environmental and through to the final decommissioning and disposal of the pump. Lifecycle costing can be useful not only for selecting new equipment but also for justifying the upgrade of existing systems. Throughout the lifetime of a pumping system, it is unlikely that the same operating conditions will continue to prevail. Factors such as the addition of new equipment upstream of the pump or changes in production techniques can all cause variations in pump duty away from the pumps ‘Best Efficiency Point’ (BEP). This is the point where pump capacity and head pressure combine to provide the maximum efficiency performance from the pump. If the pump is incorrectly sized and is operating too far from the BEP, wear and tear can occur which can shorten its operational life. An oversized pump, for example, will not only be inefficient, but will also cost more to maintain because operating too far to the left of its performance curve puts an extra strain on pump bearings and seals. On the other hand, a pump which is undersized for the duty may end up running too quickly, which may potentially ruin the product being pumped and also prematurely wear out parts of the pump. Also its efficiency will be affected, resulting in excessive energy consumption. Although a pump should be sized to an application, achieving this is not always straightforward. Involvement of third parties and the need to meet possible changing future requirements can all affect the sizing of a pump. Over design on parameters is very commonplace. One survey of 4,000 installations showed that water pumps typically operate with a shortfall in efficiency of between 12.5 and 20 per cent because they are incorrectly specified. The situation is worse for pumps that handle more unusual or complex media, such as chemicals or pharmaceuticals. To help with changes in duty and assist with energy reduction many pump manufacturers are now promoting the use of Variable Speed Driven pump systems, frequency drive being the most prominent system used. By using VSD’s you in effect combine electrical and mechanical principles. The addition of the latest controls or ancillary equipment can often help boost efficiency and

enable pumps to meet changes in demand at a fraction of the cost of building a new system from scratch. In some cases, simply upgrading a pumping system can result in energy savings of up to 50%.

THE IMPORTANCE OF GOOD DESIGN Maintenance and energy consumption represent by far the two most significant costs throughout the life of a pump. The answer to minimizing these costs lies in ensuring a well-designed pumping system, where the pump is specified as correctly as possible to the demands of the application. The energy consumption and efficiency of a pump is closely linked to the way that a pumping system is designed and operated. Every pump manufacturer can, or should, supply characteristic curves for their equipment illustrating pump performance under given conditions. These curves demonstrate the inter-relationship between discharge capacity, pump head, power and operating efficiency. The BPMA and its members have been involved in the writing of the following Europump guides to assist users with their selection and operation of pumping equipment: - A guide to system efficiency for rotodynamic systems - A guide to LLC Analysis for pumping systems - A guide to successful applications for variable speed pumping

HOW TO GET IT RIGHT – SOME TOP TIPS FROM THE EXPERTS The following are just some of the key factors that should be considered when specifying a pump, which could help ensure it delivers optimum performance and economy throughout its service life. 1. WHAT SORT OF PUMP DO YOU NEED? There are many different types of pump available, each of which is suited toparticular applications. The two most popular types are Centrifugal pumps and Positive Displacement pumps. Centrifugal pumps are generally suited to fast flowing or low viscosity liquid applications

QUESTION & ANSWER where the pressure is relatively constant. They perform most efficiently and cost effectively when operating at or near their Best Efficiency Point (BEP). Positive Displacement pumps, on the other hand, are particularly ideal for high viscosity applications, as they are better able to maintain a constant rate of flow. It may also be necessary to consider what type of material the pump is manufactured from. Hygienic processes in the pharmaceutical or food and beverage industries, for example, are subject to the strict requirements of the Food and Drug Administration (FDA), which call for equipment to be manufactured from 316L stainless steel. Information on selection and which pump is best suited /used on different applications can be found within the BPMA Buyers Guide, which is available on the BPMA website. 2. IS THERE SUFFICIENT PRESSURE FOR THE PUMP TO WORK EFFECTIVELY? The efficiency and operation of centrifugal pumps in particular can be affected by the Net Positive Suction Head (NPSH) available. Basically, this is the amount of pressure that is required to prevent the liquid being pumped from vaporising inside the pump. If the liquid vaporises, bubbles can be formed which will be carried into the pump. When these bubbles encounter zones of higher pressure in the pump, they will collapse violently, resulting in a phenomenon known as cavitation which can severely damage the pump. When designing a pump system, it is essential to ensure that the available pressure on the pump inlet is greater than the pressure required within the pump to avoid the occurrence of cavitation. 3. IS THE PUMP POSITIONED IN THE CORRECT PLACE? Where a pump is positioned within a pipeline can also greatly affect its performance. As well as determining the amount of pressure available, the positioning of a pump can also affect the quality of the product being pumped. Too much or too little distance in the pipeline before the pump, for example, can lead to friction losses which can affect the flow rate of the substance being pumped, which in turn can affect the efficiency of the pump. The presence of pipe fittings, such as elbow joints, filters or other in-line equipment, can also affect the flow rate of a substance to the pump. 4. DON’T JUST PURCHASE ON COST ALONE When it comes to selecting a pump, cheapest is by no means best. Be particularly careful where reductions in the purchase price have been achieved by cuts in supplier back-up and expertise. Ultimately, the most cost-effective installation will be the one where the supplier can offer good technical back-up, an established track record and a reputation for high-reliability products based on sound research and development. 5. ALWAYS TAKE THE PUMP MANUFACTURERS’ ADVICE! It’s surprising how many customers don’t take advantage of the expertise available from the pump manufacturer when it comes to ways of getting the best performance from their pumps. After all, nobody knows more about how to get the best out a pump than the company that built it. Reader Enquiries to: Steve Smith, Administrator, British Pump Manufacturers Association Ltd Tel : +44 (0)121 601 6691 Email : s.smith@bpma.org.uk Web: www.bpma.org.uk or for further information, please visit: www.bpma.org.uk/ publications

CAREERS TIME TO ACKNOWLEDGE AND CELEBRATE OUR ENGINEERS The prestigious Pump Industry Awards Dinner, which is produced annually by Touchwave Media on behalf of the BPMA, is the ideal opportunity to recognise the exceptional engineering talent that our industry currently enjoys. The skill, innovation, and dogged determination shown by this sector’s engineering staff ensure the delivery of effective and efficient pumping systems, time and again. From pump manufacturers and distributors, through to sector specific end users and system integrators, the depth of technical knowledge and application know- how is really first class. But this high level of engineering excellence doesn’t just happen of course! It takes a great deal of support and encouragement by the employers, and of course hard work, dedication and ongoing training by the individuals themselves. The BPMA is extremely proud of the training programmes that it has been able to offer the pump sector over the years, and remains committed to the ongoing progression of all those opting for an engineering career within the pump sector. This commitment to providing high calibre training modules (all of which are now CPD accredited), along with the constant drive to help pump companies and their systems, also supports and underpins a healthy and robust industry. Additionally, it helps to encourage new engineers into the sector, by demonstrating the opportunity for personal ongoing development and career progression – something which is key to any industry, in helping address whatever skills gap might exist! However, this individual commitment to engineering excellence often goes unnoticed outside of the specific projects or companies with which these individuals are engaged. That is why the ‘Engineer of the Year’ category within the annual Pump Industry Awards programme is crucial to this endeavour. It provides the ideal platform through which to honour their achievements. The online entry process couldn’t be easier, so if you want to play your part in bringing engineering excellence to the fore, please do visit the PIA website -www.pumpindustryawards.com.

KSB GROUP TAKES ACTION AGAINST ASIAN BRAND & TRADEMARK INFRINGERS By Bryan Orchard of Orchard PR When the subjects of counterfeiting and infringing trademarks and patents are discussed, it is a commonly-held view that this happens predominantly in the consumer goods markets where large global organisations go to extreme lengths to protect their brands and corporate identities. The global market in counterfeit goods costs companies many billions in lost revenues and it goes way beyond high profile consumer goods.

Manufacturers of capital goods are also affected damage to Germany’s mechanical engineering sector was with applications ranging from building services, industry and water transport to waste water treatment and power significantly by the illegal activities of enterprises that go estimated to be € 7.1 billion every year (Ref.1). plant processes. The company has a presence on all to great lengths to copy their products and distribute and INTERNET EXPANSION continents with its own sales and marketing organisations, sell them as genuine items. They have no concerns about the potentially dangerous consequences of their illegal Whilst the rapid growth in the internet has brought huge manufacturing facilities and service operations. The success activities. The international pump industry is no stranger to benefits, it has also created opportunities for unscrupulous of the company is based on innovative technology that is counterfeiting and the challenges that many of the leading individuals and organisations to conduct illegal operations the fruit of its own research and development activities in brands face in trying to fight what is termed ‘low-end that can seriously harm legitimate businesses. Within hydraulics, materials development and the automation of the framework of the globalisation and digitalisation of pumps and valves. disruption’. Cynics may say that the global leaders in pump technology business models, large-sized and high-priced investment According to Franz Bosbach, KSB Technology Foresight, a would want to close down any competition in order to goods are now also sold over the Internet. This is leading significant number of Asian manufacturers are using the maintain their profit margins, and there may be an element to a sharp increase in brand and trademark infringements good reputation of the long-established manufacturer KSB to market their products. “Under protected KSB brand of truth in this. However, the use of counterfeit pumps regarding offers made on online platforms. Over the last few years, the German based pump and names, they offer pumps and valves as well as spare parts across all areas of fluid handling puts the end-users at the valve manufacturer KSB has been closely monitoring this for sale on international trading platforms,” comments risk of damaging their production equipment, producing situation. The KSB Group is among the world’s leading Bosbach. “In particular, the names of well-known products sub-standard products that do not comply with international suppliers of pumps, valves and related services, such as Etanorm, Omega and BOA, regulations, contributing to environmental are frequently used. But the pollution and putting employees and the umbrella brand ‘KSB’ is also public at risk. Those end-users that often misused to maliciously knowingly purchase counterfeit deceive the targeted buyers.” pumps and components are equally Not content to sit back and let complicit in this pernicious trade. this situation continue, KSB is Many German industrial being proactive in tackling enterprises are complaining both the manufacturers and about soaring problems with the on-line shops selling the counterfeit products from China. counterfeit products. To put The VDMA (Verbund Deutscher a stop to these activities that Maschinen- und Anlagenbau) are harmful to its business, Mechanical Engineering Industry KSB has now established Association represents more than a task force to combat 3,200 mostly medium-sized these illicit activities. companies in the capital goods In cooperation with industry, making it the largest Italian project partner industry association in Europe. Convey, KSB is reporting In its 2016 Product Piracy Study, these infringements to 70 per cent of its participating the platform operators companies indicated that they and instructing them to take were victims of product or brand The KSB Etanorm pump series is an international best seller, but has been the subject of counterfeiting. down the offending offers. If piracy. Its findings indicated that the

necessary, legal action is also brought against the brand and trademark infringers. It is proving to be highly successful for in its first year, starting in July 2016, the KSB Group identified 420 marketers on eight different online platforms who had been illegally misusing its product names. Between April and August 2017 it uncovered 4,000 illegal offers and had them removed from the associated trading platforms. “This is a great success for KSB since KSB stands for reliability, quality and know-how, especially in Asia. Our policy is to continue identifying counterfeits on Chinese trading platforms in order to defend KSB’s brand and trademark rights more vigorously,” continues Bosbach.

GLOBAL CHALLENGE

Clearly counterfeiting is a serious global problem for all pump manufacturers, but it is also a problem for would-be pump buyers. Many of the counterfeiters use sophisticated techniques to replicate the OEM’s website and this makes it very difficult to check product authenticity. Buying pumps that claim to be from the OEM (Original Equipment Manufacturer) and then fail because they are counterfeits, can do major harm to the user’s business, not to mention the OEM’s reputation. Counterfeiters will go to great lengths to replicate the true product employing reverse engineering techniques. This low end disruption is problem that is of major concern not only to KSB but many other global brands. “KSB has many brands that are several years old and are well-established and are regarded as a premium product,” says Bosbach. “We are constantly upgrading these brands to meet our customer’s requirement and to offer improved operation, but this adds costs to the purchase prices and endusers are not always willing to pay more. We are aware of one Chinese manufacturer that has built up a considerable customer base selling a copy of one of our established brands. The quality is not the same as the KSB product, but some customers are willing to accept the risk because it is cheaper than the true KSB pump. By taking down these manufacturers before they get too big we protect our brands, quality and sales reputation.”

CONVOY COOPERATION

Franz Bosbach says that KSB is highly active in tracking down counterfeiters and getting them closed down. “The problem is that it can take a long time to take them down. For a single company like us, it is difficult to get a platform to take down a counterfeiter’s site so it was for that reason we teamed up with Convey,” he reports. “They have established connections with all the major platforms and this gives them considerable influence.” Italian-based Convey is an internet brand protection agency and hunts down fakes. The internet is probably the cornerstone of the counterfeit industry, and Convey has a dedicated team of engineers to develop new products to detect counterfeiters and multi-lingual experts in international property rights. Once a counterfeiter has been tracked down, Convey take the appropriate action to defend its clients’ brands. Whilst China leads the world in the manufacture and sales of counterfeit products, the irony is that some Chinese manufacturers are turning to the resources of companies like Convey to protect their own products. “Throughout the world there are a great many platforms which make it easy to set up an online shop,” says Michele Provera, Vice-President IPR Protection Convey SRL. “In the pumps and valves industries there are the manufacturers

who make counterfeit products and traders who sell counterfeit products. Many of these traders sell any number of pump and valve brands and not all customers are endusers. Thus the counterfeit sales chain is complex. The internet provides counterfeiters with a world-wide market and anonymity. Then there are spare parts, where the number of units purchased can run into thousands.” Michele Provera continues: “In our first year of working with KSB we concentrated on manufacturers selling in China and South East Asia as they are the starting of point in the trade. It is very difficult to shut down the manufacturers, but we can take steps to reduce and shutdown their sales over the internet. We have sophisticated technologies called ‘crawlers’ designed in-house that can analyse hundreds of thousands of web pages on the internet each day. We are able to detect all the shops selling KSB products and we can see the products that they are selling, the prices, suppliers and where they have come from.” KSB recognises that counterfeiting has been a problem for a long time, but identifying rogue sellers has been difficult and taking them down took a long time and involved considerable resources. With the expansion of the internet and growth in counterfeiters setting up websites, the incidents of counterfeiting have a higher visibility so it is possible to take them down more effectively. However, as soon as KSB takes a site down which has been selling counterfeit products, the site re-emerges often selling competitors’ products. Convey has been checking twenty online trading platforms and eight social media channels for KSB to root out counterfeits. In future, patent and design rights are to be added to the monitoring of brand and trademark rights. It is also possible that the number of trading platforms to be checked will be increased and that the project will be further expanded globally. “KSB has a great many registered trademarks and patent rights so we can see if the products being offered are registered,” says Provera. “If they are not then we can instigate enforcement procedures to take the offending websites down. The seller receives a warning and if they fail to respond we alert their service provider to the violation of intellectual property rights via their network. This involves issuing Take Down notices to the website hosting providers informing them of infringements, for they are legally obliged to cease transmission in such instances. If they do not take action, then they become liable to prosecution by KSB. This approach is very effective. Most sellers remove their offers after the first warning.”

KSB goes to great lengths to protect its brands and reputation around the world and has set up a task force to combat and shut down illicit activities. Many websites operate a penalty points system, so when a first notice of infringement is issued they will be served a penalty point. If they ignore this, a second penalty is issued

and again if this is ignored then the site is shut down with immediate effect. Within the pumps and valves industry, it is highly probable that the trader is selling any number of manufacturers’ brands, so by shutting down the website the trader can loses its entire portfolio of products. This approach is more effective than instigating legal procedures which are expensive, complicated and take a long time. In the meantime, the seller can move their trade elsewhere or continue under a new name. Convey makes sure an offer is taken off the internet within days and that the seller is removed from the market place.

THE CHINA CONNECTION

In China, arresting the people behind the counterfeits is one of the central elements of the work with KSB. It is not enough to merely delete a counterfeiter’s offer. The goal must be to shut down this shop on the respective trading platform and ensure through constant checks that the trader does not open a new shop. This requires close cooperation between the parties involved. Due to the excellent contacts between Convey and the platform provider Alibaba and their IP complaint systems, these infringements of law can be quickly eliminated. This is also in Alibaba’s interest since the company does not wish to find these infringements of law in the wider Chinese eshopping marketplace either. According to Michele Provera those responsible at Alibaba want to ensure that Western companies have secure access and are able to examine the associated legal bases. Convey takes care of that for KSB as its team includes law enforcement specialists who are qualified in trademark and patent law and speak Mandarin Chinese fluently. In close cooperation with its subsidiary in Shanghai and local lawyers, KSB takes legal action against serious violations of law.

SUMMARY

The pump industry is probably one of the most exposed to counterfeiting and it is huge and is worth many billions of dollars. For KSB, and for a great many other companies, the major problem is what happens when a company buys what it believes to be a genuine product and it turns out to be a fake. The failure of a pump or valve can have very serious consequences, so should such a situation arise then the user will usually take issue with the manufacturer. Problems can also arise when a counterfeit component is fitted as a replacement in a genuine KSB pump and then causes damage to the pump. Investigating claims for compensation can be complex and costly and the onus is on the manufacturer to prove that the product is a counterfeit. Where litigation is enforced, courts may well acknowledge that the product is a counterfeit. However, they will argue that it is not sufficient to prove that that it is a counterfeit, but to demonstrate that the manufacture has taken action against the counterfeiter. If it can be shown that efforts were not undertaken then the manufacturer can be charged with negligence. What KSB is doing by working with Convey is to show that it is taking all possible steps to close eliminate counterfeiters internationally and protect its patents and trademarks.

Ref 1. VDMA Product Working Group on Product and KnowHow Protection. www.protect-ing.de

GOLDEN PUMP PROMOTION HMD KONTRO CELEBRATES SEVENTY YEARS OF SEALLESS PUMPS WITH SPECIAL GOLD PUMPS It is 70 years since the very first magnetic drive pump was invented in Eastbourne, UK, by HMD Kontro, or Hydraulic &amp; Mechanical Developments, as it was known then. To celebrate, as a no-cost option, HMD Kontro is offering its sealless pump range finished in a special gold paint, the colour originally used as standard in the early years of production. Having pioneered the magnetic drive pump, HMD Kontro has continued to develop the technology and now offers an extensive range of products to satisfy pumping needs across multiple industries. The magnetic drive pumps pioneered by HMD Kontro offer the ultimate solution to environmental concerns, seal system complexities, recurring mechanical seal problems and health & safety issues whilst minimising spare parts inventory and maximising plant uptime. Recent advances in sealless technology by HMD Kontro have further expanded and enhanced the capability of magnetic drive pumps, including ZeroLoss containment shells for reduced energy consumption and power saving plus the VapourView gas in liquid detector to prevent dry running. In addition, the company is now able to offer secondary containment options and sealless pumps in a vertical format to reduce the footprint for where space is at a premium. For further information about HMD Kontro Sealless Pumps and to enquire about or order a special edition golden pump, please see Web: www.hmdkontro.com Tel: +44 1323 452000 or Email: info@hmdpumps.com.

IP69K RATING FOR LABTECTA® OP

October 2017 Rotherham, UK: AESSEAL ® is pleased to announce a recent update to it’s popular maintenance free bearing protector, the LabTecta ® OP. Now with an IP69K rating offered as standard, the LabTecta ® OP can be used in areas where high pressure equipment washing is common. An IP69K rating now enables maintenance teams to safely wash down equipment using high pressure water jets up to 100 bar and at temperatures up to 80° C. LabTecta ® OP continues to bring the same benefits to users and is still the most cost effective alternative to lip seals, eliminating all issues associated by their use. Designed specifically to protect bearings and bearing oil from contamination, this innovative device will essentially eliminate up to 52% of all bearing failures. This type of protection prevents water and dust ingress and with its non-contacting design will stop shaft damage. It can even be fitted to a shaft previously damaged by lip seal use. For more information contact AESSEAL Plc, Rotherham, South Yorkshire. Tel: 01709 369 966 | E-mail: marketing@aesseal.com | Web: www.aesseal.com

CARTRIDGE MECHANICAL SEALS FROM FLOWSERVE INCREASE RELIABILITY AND REDUCE COST OF OWNERSHIP Designed to meet the dimensional standard ISO 21049, to fit ISO 3069 seal chambers, means that the ICS2 cartridge mechanical seal can be used to replace inferior seals that are installed into hundreds of differing pump & m i x e r models. Already the first choice for many world leaders, the ISC2 Series of mechanical seals provide exceptional reliability and standardisation over the widest variety of applications and equipment. Improve operational efficiency throughout your facility Based on an extensive global review of equipment requirements, performance expectations, service conditions and best practices; ISC2 seals are arguably the most capable general purpose cartridge seals available. Manufacturing plants and industrial processes that standardise with ISC2 seals can immediately benefit from less inventory, greater flexibility, rapid availability and repairs, less downtime and longer seal

life. Protect your employees, protect your environment ISC2 seals do more to provide a safe work environment and protect the natural environment than other standard cartridge seals. Single seals have capable throttle bushings to protect against leaks. Pressurized double seals provide zero process emissions. The outboard seal of the Flowserve ICS2 double seals can handle full operating conditions if the inboard seal were to fail. All seal faces are dual balanced for normal and reverse pressure operation. ISC2 seals work hard to eliminate the possible causes of failure &amp; leakage: Robust seal face drive mechanisms, highly efficiency barrier (re)circulation, and high quality materials all contribute to the improved seal life associated with this seal. Moreover, with multiple operating conditions, and frequent starts/stops, this seal offers resilience. Thermal management, and fluid presence, technology can also be employed in which to further protect against dry running. Capable of sustaining years of uninterrupted, long-term operation, the ISC2 seals could be the standard to suit all of your needs - across your whole operation. Shaun Hampson, Managing Director, Flowserve SIHI commented, “The ICS2 cartridge seal is the operator’s choice when pump or mixer failure isn’t an acceptable, nor imaginable, option.” For more information contact Flowserve-Manchester QRC, Trafford Park, Manchester Tel: +44(0)161 9287631 Email: ProcessUK@Flowserve.com Web: www.Flowserve.com

GRUNDFOS SIMPLIFIES PUMP REPLACEMENT

The Grundfos Product Center (GPC) is well-established as the ‘go to’ pump selection tool of choice for an increasing number of industry professionals. This could be because much thought and consideration went into its design to deliver a pump selection tool that would make choosing the right pump solution as straightforward as possible. This ease of selection is also true when a replacement pump is required. Simply log onto the Product Center and select the REPLACEMENT option on the home page. From here enter the name of the old pump into the Quick Search field or alternatively, you can enter the pump name and other data into the Classic Search field. The Product Center will then display the top three replacement pump choices and you can filter your selection by choosing either the pump with the lowest purchase price, or the pump with the lowest energy consumption or the pump with the lowest total lifecycle costs. Additional requirements, such as fluid type, lifecycle costs and evaluation criteria provide additional filtering options and will ensure that finding the best pump replacement choice is there waiting for you, whenever you need it. Check it out for yourself at www.grundfos.co.uk

A MAGNAIFICENT PERFORMANCE

When Grundfos introduced the MAGNA3 range five years ago, they hoped that consultants and contractors would embrace this flexible range of intelligent, high-efficiency circulators. Today, having just past the 1,000,000-pump produced milestone, the MAGNA3 is an established firm favourite for a wide range of projects that involve heating, cooling, ground source heat pump systems and domestic hot water applications. In fact, any solution that can benefit from an intelligent high efficiency circulator. Available in single and twin head options that cover a wide range of duties, specifying the MAGNA3 is straightforward, as the range offers a maximum head of 18m and flow of 70m3/h (140 m3/h for twin head models), and supports 6 to 16 bar system pressure. All of which means the MAGNA3 will be a perfect fit regardless of the project. To find out more about these pumps as well as the rest of the commercial range from Grundfos visit www.grundfos.co.uk/ magna3 - you’ve now got a million more reason to do so.

WEIR MINERALS LAUNCHES 2ND GENERATION WARMAN® WGR® PUMP In line with Weir Minerals’ commitment to continually reduce total cost of ownership of its equipment, the company is launching the 2nd generation of the Warman® WGR® pump. Weir Minerals unveiled the 2nd generation of the WGR® slurry pump at an official launch day in October at its plant in Yateley, Hampshire, United Kingdom. The 2nd generation WGR® pump boasts several innovative features including fully replaceable liners designed using Computational Fluid Dynamics (CFD) simulation that provide a significantly improved performance over the first generation WGR® pump. The liners and impeller are manufactured from premium Linatex® rubber and housed within robust casing halves. Enhancements to the casing design simplify maintenance and minimise downtime. Other new features include the introduction of an expeller gland seal for optimum performance, as well the option of having a low flow packed gland and the unique D gland seal. The rugged design of the WGR® pump makes it ideal for use in the production of sand and aggregates, as well as other applications within mineral processing, coal preparation and power sectors and general industrial applications. Available in seven different sizes, from 35mm to 250mm, the Warman® WGR® pump includes: •Wear components that are optimised using the latest technology; •Impeller and volute liners designed to reduce turbulence and deliver longer wear life; •High capacity bearings to withstand high loads;

•Large diameter expeller seal to protect against high inlet pressures; •Replaceable premium Linatex® rubber liners; •Simplified wet end design with fewer parts for ease of maintenance; •Lifting points added to aid safe handling of heavy castings; •Axial impeller adjustment to maintain the gap to the throatbush, reducing recirculation wear. Harvinder Bhabra, Weir Minerals Europe’s Senior Product Manager for Pumps, said: “We have used the very latest technology to produce a pump solution that will be a leader in its class. Slurry pumps are central to modern extraction processes so must be reliable and cost-effective. Our 2nd generation Warman® WGR® pump combines exceptional performance, reduced downtime with added safety features and a lower cost of operation.”

WEG REDUCES COSTS FOR WORLD’S LARGEST PRODUCER OF ORANGE JUICE CONCENTRATE Electric motors and drives supplied by global power and automation provider, WEG, are delivering improved performance at production plants for Citrosuco, the world’s largest producer of orange juice concentrate. Citrosuco production relies on four processing plants, three of them situated in the state of São Paulo, Brazil, and one in Florida, USA. In addition, the company operates twenty-nine farms, three storage operations, five shipping port terminals and six commercial offices. Citrosuco’s installed production capacity is equivalent to more than 40% of the annual volume of orange juice produced and exported by Brazil. Since 2015, Citrosuco has been using the WEG Cooling Tower Direct Drive System in its production plant, which features permanent magnet motors to ensure high performance levels with high torque, even at low speeds. This system replaces conventional ventilation systems in cooling towers – consisting of motors, transmission shafts and gearbox assemblies – reducing mechanical losses and resulting in improved reliability and higher operational efficiency. The WEG Cooling Tower Direct Drive System solution operates with the CFW11 frequency inverter drive, where speed is modulated according to application demand, thus providing energy savings and reducing water consumption. WEG’s advanced CFW11 system drive (covering power levels from 1.1 to 63 kW) is ideal for use with both

permanent magnet motors and induction motors. The drive offers many innovations that deliver specific benefits to customers such as Citrosuco. For instance, Vectrue Technology® allows WEG inverters to combine V/F, sensorless vector, VVW and vector (with encoder) control techniques – all in one product. This capability not only helps to increase productivity, but offers efficiency ratings greater than 97%. Further CFW11 innovations include Optimal Braking®, a special braking method in vector control mode that provides an effective alternative to using braking resistors, and Optimal Flux®, which eliminates the need for independent ventilation or motor oversizing in applications with constant torque loads at low speeds, saving both space and cost. Implemented in Citrosuco’s plant situated in the municipality of Matão, São Paulo, the WEG Cooling Tower Direct Drive System solution with the CFW11 frequency inverter drive has delivered a significant reduction in maintenance costs, by making the system more reliable and efficient. Additionally, corrective maintenance in the system has been virtually eliminated, by transitioning to a preventive maintenance approach. Wanderley Garcia Cabrera, Reliability Engineer at Citrosuco’s Matão operating plant explains, “Before upgrading to the WEG solution, the cooling towers used to offer low reliability, requiring constant interventions on the transmission and gearing systems, resulting in high maintenance costs. After installing the WEG solution, corrective interventions were virtually eliminated, significantly increasing the uptime availability of the equipment and substantially reducing the costs of corrective maintenance. We now only have to carry out routine lubrication every ten thousand hours of use, as recommended by WEG.” For more information on WEG’s energy efficient drive solutions visit www.weg.net/uk.

ITT GOULDS PUMPS – INNOVATORS FOR OVER 160 YEARS INTRODUCES i-ALERT2 The i-ALERT Equipment Health Monitor is a Bluetooth Smart-enabled machine health Monitor that allows customers to identify potential equipment problems before they become costly failures. ITT’s ALERT2 tracks vibration, temperature and run-time hours and wirelessly syncs the date with smartphone or tablet through the i-ALERT2 mobile app. This condition monitor combines the latest in Bluetooth low-energy and sensor technologies commonly used in the newest consumer health and fitness trackers and smart watches. It is the first condition monitor to successfully integrate these technologies into an industrial package in a small footprint for [2.24 in. (L) by 1.54 in. (W) by 1.40 in. (H] which is half the size of a credit card. It is engineered and rated for use in a wide range of industrial environments. It is chemical resistant, rated for extreme temperatures (40 to 183 F) and is rated to operate in environments with explosive gases, dust and fibres. With 24/7 monitoring, a wireless range of up to 100 ft and the abitlity to scan multiple i-ALERT2 devices at once with a mobile device, customers will be able to quickly and safely inspect multiple pieces of equipment and be alerted of potential problems before they become critical failures. Through mobile app, customers can now view real-time and historical data, diagnostic information and machines records. This provides them with the data necessary to make informed decisions. Customers can now spend less time collecting data and more time saving problems. The i-ALERT2 is fitted as standard to Goulds ANSI and ISO process pumps and comes with a 5 year warranty. For more information contact: Tel: 01297 639100 www.gouldspumps.com|www.ittproservices.com

PUMP GENIUS

Pumping Control Software WEG’s Pump Genius process control software is designed to reduce pumping system operation and maintenance costs whilst increasing process accuracy and protection. Working with the CFW11 variable speed drive the software provides multiple pump control and protection as well as system monitoring, flow and pressure management for up to six pumps. For more information visit www.weg.net 11

PUMP INDUSTRY AWARDS 2018

The Pump Industry Awards are back! The Pump industry awards have grown into one of the leading industrial awards programmes, celebrating the achievements of pump businesses, large and small. if you or your company have something to shout about, these awards provide the perfect platform to get noticed. We believe the best way to celebrate excellence is by bringing people together at live events, so the annual gala presentation dinner caps off the awards programme in style. As always there will be excellent networking opportunities, great food and superb entertainment. It’s your chance to celebrate with colleagues, connect with peers and be part of the pump industry’s biggest and best celebration; put the 22nd March 2018 in your diary now. Peter Reynolds, Managing Director of Grundfos Pumps, and BPMA President, says of the Pump Industry Awards, “The competitive nature of the pump industry, and the constant search for greater operational performance and improved efficiencies across its myriad customer base, requires all those operating within this important sector to be at the top of their game. This awards programme allows the pump industry to come together in recognition of that drive for engineering excellence”.

The 2018 Call for Nominations will open on the 14th September, so be sure to visit the Pump Industry Awards website to review the award categories and decide which ones you will be entering!

www.pumpindustryawards.com

EVENT calENdar NomiNaTioNs oPEN

NomiNaTioNs closE

judgiNg sEssioN

fiNalisTs aNNouNcEd

wiNNErs aNNouNcEd

September

January

January 2018

February 2018

March

2018 ParTNErs

Organised by

on behalf of

www.pumpindustryawards.com

GRACO’S INNOVATIONS IN SAFETY FOR CHEMICAL TRANSFER Chemical transfer applications demand maximum performance and superior chemical containment. ChemSafe pumps feature 100% PTFE and UHMWPE fluid paths and are chemically safe. You can use these pumps with a variety of materials, plus they deliver unmatched chemical compatibility with challenging corrosive acids and destructive slurries. The precision-machined body features a tie-bolt design that ensures reliable sealing surfaces free of leaking. Two steps forward, one step back. That’s what it feels like to run an operation with a leaky pump. Leaky pumps inevitably lead to unscheduled downtime and increased maintenance needs. This stalls productivity and costs the average company hundreds of thousands of dollars per hour of downtime. Now add hazardous chemicals into the equation. Aggressive acids and slurries can cause pumps to leak much faster, and they create an unsafe work environment. While these chemicals are necessary for the production of pharmaceuticals, printing inks, steel production, ceramic finishing, and more, they are also a huge liability. Selecting and maintaining the proper equipment to control hazardous materials is crucial to the long-term success of a business, but it isn’t easy. With so many different pump designs on the market, end-users are having a tough time distinguishing between the pumps that will cost them and the pumps that will save them.

AODD CHEMICAL PUMPS

Air-Operated Double Diaphragm Chemical Pumps (AODD) offer many benefits to manufacturers who require the use of hazardous materials. While most other pump designs rely on mechanical seals for chemical containment, mechanical seals are known to be prone to chemical erosion and leaking. AODD chemical pump designs eliminate the need for mechanical seals by using bolts to secure the pump together and create an effective seal. In addition, the AODD pump’s diaphragms move in gentle cycles to minimize turbulence and protect the liquid from shearing. In many instances, these chemicals can be as fragile as they are hazardous, and any mild turbulence can alter their chemical properties, wasting the

material and costing money. Lastly, because AODD pumps are powered by compressed air rather than electric motors, they can dry run and deadhead without the risk of burning, seizing, or harming internal components. The problem with AODD chemical pumps is that their designs can vary in quality and effectiveness, which means that end-users must select their pump carefully. The crucial factors of the AODD chemical pump selection process are chemical containment capabilities, corrosion resistance, and icing prevention.

LEAKY AODD CHEMICAL PUMPS

Safety is the primary concern when moving dangerous chemicals. Chemicals must be properly contained in order to fulfill their intended purpose without harming employees. This requires a pump with a leak-free design. Unfortunately, even some of the best AODD pumps struggle with leaks over the course of the pump’s lifespan. Although leaking may seem natural or unavoidable, costs of employee injury and wasted materials are too great to ignore. A few design features stand above the rest to address certain factors that lead to leaking. In the case of plastic AODD pumps, leaking is often a result of cold flow and creep, which are caused by high temperatures, amount of time under load, and level of torqueing stress. While metal pumps are rarely damaged by loads at low temperatures, plastic pumps can be damaged by continuous loads at fluctuating temperatures, which is termed, “cold flow.” As temperature increases, the effects of cold flow on a plastic AODD pump escalate. Cold flow causes deformation of the plastic pump over time, causing its components to release against compression points and begin to leak. Creep refers to the total deformation of the pump beyond the immediate strain of loading and can cause significant leakage. PTFE is one pump material that is most susceptible to leaking caused by cold flow because PTFE tries to escape the load as it gets warmer. PTFE is one of the most chemically compatible materials for resisting corrosion, which would make it a desirable pump material if not for its susceptibility to cold flow. The material, UHMWPE, is second to PTFE in terms of chemical compatibility, but it is similarly susceptible to cold flow leaking, although at a lower rate. In addition, the violent forces of operation and continuous loading can eventually loosen the AODD chemical pump’s bolts and create leak paths. End-users are recommended to re-torque bolts regularly. Some AODD pump designs require even further leak prevention steps, such as the use of reinforcing metallic plates in attempt to evenly distribute the load from the housing bolts. While these quick fixes may work in the short term, constant checkups and reinforcements are far from ideal when controlling hazardous fluids in a fast-paced work environment.

SOLUTION TO CREEP AND COLD FLOW

A proven solution for leak prevention is a machined body reinforced with a dual force, tie-bolt design. Overall, machined housing components are an essential feature to provide a precision fit that will distribute the load evenly and greatly reduce leaking. With this design, components made with PTFE and UHMWPE, which are highly NOVEMBER 2017 - PROCESS INDUSTRY INFORMER

susceptible to creep and cold flow, are held securely by tie-bolts that are resistant to the effects of cold flow and violent forces. This allows the pump design to make use of these chemically compatible materials without allowing leakage due to cold flow.

CORROSION RESISTANCE

Pumps that have exposed metal or wet parts composed of metal are highly vulnerable to corrosion. Therefore, AODD chemical pumps designed with metal free exteriors will be more durable in corrosive environments. Similarly, interior corrosion can be prevented using PTFE and UHMWPE fluid paths to ensure chemical compatibility. This means that the entire fluid path—from entering the inlet, passing the first check ball, leaving the fluid chamber through the second ball, and finally exiting the outlet of the pump—is either PTFE or UHMWPE, so there is no need to worry about incompatible chemicals eating away the pump’s interior.

AIR MOTOR ICING STALLS PRODUCTION

Because AODD pumps are operated by compressed air, they are subject to rapid changes in temperature. The air is very hot when it’s compressed and cools rapidly as it expands. Air motors operate compressed air at about 20 to 180 psi (1.4 to 12.4 bar) and exhaust air at atmospheric pressure, approximately 14.7 psi (1.0 bar). This is an extremely high percentage of pressure decrease occurring in a short time span. Since the exhaust air will be below freezing temperatures when it exits, moisture in the air freezes and crystallizes inside the air valves. This buildup of ice can cause the air valves to stall, creating unplanned downtime and increased maintenance needs. One possible feature of an AODD pump for icing resistant air systems includes parallel pilot shifting valves. This stall-free design reduces icing and maintenance needs while keeping production moving.

SUMMARY

Several visual clues can indicate whether it is time to replace an old or deteriorated pump with current technology. These include a corroded pump exterior, leaks around the manifolds, worn internal fluid bowls, and discoloration on the floor caused by severe leakage. Premature deterioration can be prevented by carefully selecting the best quality pump for operational needs. A dual force, tie-bolt design and precision machined components offer a leak-free precision fit for effective chemical containment and safe operations. Wherever harmful chemicals are present, business owners must be mindful of the proper safety precautions and continue to educate themselves on current trends for chemical handling.

FEATURED ARTICLE

MAINTAINING UPTIME According to a 2017 survey conducted by Oneserve in partnership with British manufacturers, downtime costs Britain’s manufacturers more than £180 billion every year. This is an extraordinary figure, but additional unexpected costs hit businesses in high volume low margin sectors hardest. Here, James Davey, service manager at industrial systems integrator, Boulting Technology explains how to choose the best maintenance plan for your manufacturing plant.

igh volume, low margin manufacturing is a challenging business model that typically applies to fast moving consumer goods (FMCG) or food and beverage manufacturers, particularly the makers of private label or generic products. These sectors rely on maximising production volumes and minimising overheads. If volumes are below forecast or overheads are above, the manufacturer risks slipping margins or even running at a loss. Worse still, some retailers may impose fines on suppliers who fail to deliver on time. There are tough decisions for manufacturers to make about how much cost and effort should be assigned to maintain a plant at a level where breakdowns will be sporadic enough to ensure volume targets are met. In the low margin high volume world, money spent on preventative maintenance may be seen as wasted, as there is no immediate benefit from the outlay. Even long-term benefits are difficult to attribute to earlier spend, since the benefit is typically a reduction in breakdowns, which can be difficult to monitor with no baseline.

CORRECTIVE MAINTENANCE As an alternative to preventative maintenance, plant operators

might opt for corrective or reactive maintenance, which means waiting for something to fail, then trying to fix it as quickly as possible. The downside of this method is that the maintenance team could be faced with the difficult and time-consuming task of getting production running again. With thousands of possible failure scenarios, there is a risk that the information, spare parts, tools or knowledge may not be on hand to enable the machine to be fixed quickly. In most cases, manufacturers use a combination of preventative and reactive maintenance. However, reactive maintenance will always take priority, meaning that preventative maintenance may not take place when a plant is experiencing regular breakdowns. This can lead to the situation becoming even worse.

PREVENTION At its most basic, preventative maintenance consists of activities performed on a regular basis to lessen the likelihood of equipment failing. During these activities parts will often be replaced based upon statistics such as average lifespan and known likelihood of failure, rather than their actual wear. Regular preventative maintenance does increase asset lifespan and reliability, but it can also be costly in terms of parts and scheduled downtime. Without maximising wear of parts there is no guarantee that the valuable funds could not be better spent in a different part of the plant.

PREDICTIVE MAINTENANCE Another option is predictive maintenance, a specific form of preventative maintenance. In predictive maintenance, a maintenance regime is determined by the actual condition of equipment, rather than relying on expected statistics, such as average lifespan of parts. By using sensors to monitor equipment, predictive maintenance can accurately predict failure before it occurs. For example, if a sensor detects a motor is running at a higher temperature than usual, lubrication and cooling systems, such as fans, can be checked and changed, even if a replacement wasn’t yet scheduled. Likewise, if the operational conditions are more favourable, maintenance intervention can be delayed in order to maximise the lifetime of parts. Using the concepts of Industry 4.0 and the Industrial Internet of Things (IIoT), when connected to the plant networks, data produced by sensors can be transmitted to a centralised location or the cloud, where it can be stored and analysed to highlight trends, reducing

the chance of future breakdowns.

RISK BASED MAINTENANCE Manufacturers looking to benefit from predictive maintenance can also carry out risk based maintenance. For many businesses operating under high volume low margin parameters, risk based maintenance can be the best compromise as it allows for significant reduction in breakdown costs, without the need for the high upfront costs associated with predictive maintenance. Risk based maintenance integrates analysis, measurements and periodic tests, in addition to using predictive lifecycle statistics. During risk based maintenance, a plant is expertly assessed, taking into account each of these parameters, before an appropriate maintenance programme is decided on. This includes decisions such as what maintenance tasks are urgent or crucial, based on the risk it poses of causing downtime. A risk based strategy also allows for maintenance to be carefully scheduled, which could mean part of the plant can continue to operate while planned downtime is carried out in another area. Information used to plan risk-based maintenance must be taken in context with the environment, operation and process condition of the equipment in the system. For example, the same motor will last longer when used intermittently in an automotive parts production plant than when used continuously and subjected to washdowns in a food processing plant. All equipment that is deemed to be high risk by displaying abnormal values when undergoing periodic tests, or equipment that is likely to become obsolete, will be replaced or refurbished during risk based maintenance. This can extend equipment life span and guarantee high levels of reliability, safety and efficiency, without the expense of condition based predictive maintenance. Risk management assessments are easy to carry out and can allow plant managers to spot problems before they occur and put solutions in place. Boulting Technology’s no obligation online control system risk management tool considers factors such as obsolete parts, equipment lifecycle and efficiency to produce a traffic light system and make recommendations on how plant managers can reduce the risk of their system breaking down. Regardless of the type of maintenance being carried out, there are a few considerations to be aware of throughout a product’s lifespan and planned for accordingly. These include planning for obsolescence, even when the product is new, and ensuring each addition to the manufacturing line does not compromise the cyber security of the plant. It also helps ensure that new vulnerabilities are not opened up as a result of a lack of maintenance.

PROCESS INDUSTRY INFORMER - NOVEMBER 2017

OBSOLESCENCE MANAGEMENT Businesses may be taken by surprise when they realise that the part they need to restore the system has become obsolete and is no longer available. This can result in long wait times and increased costs associated with using parts sourced from a legacy parts supplier, or adapting the system to use parts that remain available, which may require redesigns and often demands requalification to ensure the equipment complies with the latest regulations and safety standards. Obsolescence can also rear its head when the item in question is no longer suitable for current demands, for example a programmable logic controller (PLC) that can no longer communicate with other plant devices, leading to bottlenecks and limitations on performance and efficiency. Despite many components, such as PLC’s, having a predicted lifespan of around 20years, the risk of them becoming obsolete should be a constant consideration when upgrading systems or performing maintenance to avoid being caught out. Having a comprehensive obsolescence plan, such as that produced from a risk based maintenance strategy, allows plant managers to assess the entire system and easily take obsolescence into account when making decisions.

CYBER SECURITY In 2010, the infamous Stuxnet worm was discovered. Stuxnet, which affected supervisory control and data acquisition (SCADA) systems and PLCs, was the first to target control systems. It made many plant managers aware of the risk of attack on their systems. In the past 20 years, systems that have been traditionally isolated are now connected using the plant network and often utilise cloud storage. The benefits of the IIoT are huge, allowing for the production and storage of data such as trends and alerts, which can be fed back into maintenance regimes. However, this method of connectivity can also result in system insecurities and vulnerabilities. Cyber security itself relies on continuous updates to ensure software is up to date and any bugs introduced are patched out immediately. In addition to a plan that ensures patches are regularly checked for and updated. Other measures, such as two-step authentication and managing and updating of control lists, also help with keeping the plant’s control systems as secure as possible. Following a threat assessment model, defence mechanisms, such as firewalls, should also be integrated into the plant where necessary. Through continuous assessments and regular anti-viral updates, vulnerabilities can be addressed and benefits realised for IIoT.

REACHING OUT When cyber security, obsolescence management and analysis of risk are all taken into account, it can be easy to see why preventative maintenance is shied away from by high volume low margin manufacturers, despite the immense savings associated. As these companies’ business models mean overheads must be reduced, employing an experienced team to analyse the plant and create a risk based maintenance plan or carry out any reactive maintenance if a part breaks, may not be an option. In these cases, forging close links with an external maintenance team may be the best option. A regular fee is much easier to manage than additional employees and the experience held by these specialist engineers can be invaluable. The Boulting Technology service team offer a unique, cost effective risk management service using dedicated engineers and UK wide coverage, including its new risk based approach, management strategy and cyber security assessments. Expert knowledge and experience in these sectors provide the safety net that clients within high volume low margin industries quite rightly want. Boulting Technology’s holistic approach and 24/7 support capability works with clients and their maintenance teams to ensure that faults, breakdowns and unplanned downtime are rarities. If a call does happen, the collaborative maintenance team, which includes both Boulting Technology and the client, ensures the plant can be up and running as soon as possible. Together, a comprehensive risk based maintenance plan, which takes into consideration cyber security and obsolescence management, can be the perfect way to reduce downtime. The myth that structured maintenance plans are costly or not worthwhile has been thoroughly debunked by the staggering £180 billion annual cost of downtime.

NOVEMBER 2017 - PROCESS INDUSTRY INFORMER

incl. Pumps & Valves FLUIDS

& LIQUIDS HANDLING

AMARINTH DELIVERS API 610 VS4 PUMPS TO METITO FOR ADCO AL DABB’IYA FACILITIES, UA Amarinth, a leading company specialising in the design, application and manufacture of centrifugal pumps and associated equipment to the Oil & Gas, petrochemical, chemical, industrial and power markets, has successfully delivered an order of API 610 VS4 pumps to Metito for installation in a waste water treatment plant at the ADCO Al Dabb’iya Facilities Development Phase III project, Abu Dhabi. Amarinth secured its first order of pumps from Metito, a leading provider of intelligent water management solutions, earlier this year. The API 610 VS4 vertical pumps will be installed in an effluent treatment package at the ADCO Al Dabb’iya Facilities Development Phase III project, which is located 40 kilometres south-west of Abu Dhabi. Like the many other pumps that Amarinth has supplied to ADCO process application projects, this waste water treatment package required high specification pumps. The API 610 VS4 deoiler pumps must operate reliably at low NPSH for the plant to successfully separate the oil from the waste water. The pumps were manufactured in super duplex stainless steel to withstand the corrosive fluid. Amarinth drew on its extensive knowledge of ADCO specifications and requirements to deliver a cost-effective design in under 20 weeks for this waste water application. Oliver Brigginshaw, Managing Director of Amarinth, commented: “We have provided pumping solutions to many ADCO projects for various EPCs and package providers and we are delighted to have successfully fulfilled this first order from Metito, a leader in water management solutions, which further extends and strengthens our offering across both process applications and water treatment into the oil and gas industry.”

ALBION INTRODUCES NEW GAS SOLENOID LINE Albion, a leading UK valve supplier to the building services and industrial sectors has introduced a new line of gas solenoid valves to their product portfolio. The new range is certified to EN 161 standard and complies with PED 97/23/EC. Due to the ever changing and often complicated legislation determining what products are required in gas applications, the job of specifying the correct equipment can be extremely difficult. However, Albion distributors can now be assured that their product is fit for purpose, and that their customers will benefit from a reliable and trustworthy automated gas control system across a host of applications. In most gas applications solenoid valves are the first line of safety. Their functions range from managing the mains gas supply to a building, enabling instant shut off if required, to controlling gas flow and isolating specific areas of a building, for example in an apartment block they can create individual closed circuit areas for each unit. In industry, gas solenoids are a vital cog in the smooth running of factories and in the industrial process. The solenoid’s simple on/off mechanic is one of the most widely used in operations in any factory. Albion’s solenoid range features a <1 second activation time and up to 20 activations per minute, making them an ideal solution for all types of factory line. The new range of valves are available with either flanged or screwed fittings in sizes from (½’2”) screwed and (2 ½ - 4”) flanged and can withstand temperatures from -20°C to +60°C, with 360 mbar maximum pressure. Les Littlewood, Sales Director at Albion Valves UK Ltd commented: “Solenoids have always been a best seller. Due to the huge success and increasing popularity of the solenoid range, it made total commercial sense to be able to offer a gas certified option. Distributors should contact our customer service team to discuss the best options for them.” For further information call 01226 729900 or visit www.albionvalvesuk.com

NEW ALL-IN-ONE CONTROL VALVE REMOVES NEED FOR COSTLY BY-PASS With an innovative built-in design, IVL Flow Control’s new C-Valve offers leading-edge advanced pressure management - and eliminates the need for a costly and time-consuming by-pass in water supply networks. Operating from zero flow and a maximum weight of just 19Kg for the largest 150mm cartridge, handling of the C-Valve is a one-person operation, requiring no lifting equipment. As well as being easy to install (no excavation required) and very easy to maintain, the C-Valve significantly reduces the health and safety issues caused by working in a confined space. Benefitting from an intelligent manifold construction, this new IVL Flow Control C-Valve can be tailored to suit even the largest pipe diameters. And because each valve cartridge is situated within the manifold, it can be individually isolated for ease of maintenance, without causing interruption to customer supply - which could then lead to damaging SIM (Service Incentive Mechanism) Points or OPA (Overall Performance Assessment) Points. For further information contact: Email: craigstanners@ivlflowcontrol.co.uk Web: www.ivlflowcontrol.co.uk Tel: 01384 458411 33

AIR MOTORS

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves

NEWS FROM GAST

TAKE YOUR PICK WITH THE GRUNDFOS PRODUCT CENTER The Grundfos Product Center is an online selection tool that will help you to size and specify pumps for any need. Launched 2 years ago it has continued the tradition of offering a range of people who need to specify pumps with a leading-edge pump selection tool. Today the Grundfos Product Center is fast, intuitive and designed to help let you find the answers you need. You can start your pump search in a number of ways such as searching for a pump you already have, sizing a new pump, finding a replacement pump or a pump for moving particular liquids. Once you have found the pump you want, you will find pump-specific documentation, CAD and BIM drawings, spare parts and service kits, as well as instructional videos. Simply visit www.grundfos.co.uk and click on the Product Center link. While you are there sign up as a registered Grundfos Product Center user, as this will give you access to recent searches, products and give you the ability to save items for future reference, including entire projects.

Gast introduces new, proprietary vane material that provides reliable performance with or without lubrication GAST’s LubeFree option for its AM series air motors uses a proprietary vane material that provides versatility, allowing users to oil or not oil the motor. LubeFree has expanded GAST’s range of 2AM, 4AM and 6AM Series and affords operators the flexibility to modify their maintenance schedules or save money by eliminating oil, lubricator components and system maintenance. As Gast’s European Business Manager, Andrew Lidington explains, pneumatic motors operating with in-line lubricators have the benefit of extended life, they improve efficiency and act as a protectorant of surface finishes against dirty or humid inlet air. However, ensuring that motors are regularly oiled can be costly, cumbersome and, in some applications, not even an acceptable option. “With the LubeFree option, GAST now has a simple and effective solution. In fact, independent tests have shown more than 10,000 hours of operation in completely oil-less applications and, when lubricated regularly or even occasionally, the motor’s life can be extended by up to 110%!” For further information contact: Gast Group Limited, Redditch, Worcestershire. Tel: +44 (0) 1527 504040, Fax: +44 (0) 1527 525262 Email: gastgroup.uk@idexcorp.com Web: www.gastmfg.com | www.jun-air.com

A CUT ABOVE THE REST For reliable 24/7 solids pumping pick a pump with a proven pedigree, a VAUGHAN CHOPPER PUMP. Vaughan has built a reputation as the market leader in the design and manufacture of chopper pumps for the most challenging solids pumping applications. Vaughan Chopper Pumps are not to be confused with other types of chopper, cutter or grinder pumps. Take a closer look…

Vaughan’s unique cartridge style mechanical seal handles the toughest slurries, outperforming standard single-spring seals by reducing problems associated with wrapping or abrasion.

An optional disitegrator tool agitates and breaks up large solids to prevent suction blockage. The tool is removable for stringy solids.

Stray solids are trapped in the mechanical seal area are shredded and removed by the impeller vanes turning against the upper cutter.

Solids are chopped by the cupped and sharpened impeller blades turning across the cutter bar, creating a smooth “slicing” effect. The conditioned slurry is easily pumped through the pump and piping system without plugging.

The nut cuts stringy materials that can tend to wrap at the pump inlet.

Rag, fat, hair, wet well, dry well, submersible or self-priming…from inlet to outfall think long-term, not short-term and invest in a Vaughan Chopper Pump.

Performance guaranteed…a cut above the rest. Tel: 01487 830123 - sales@pumpmix.co.uk

www.pumpmix.co.uk

ENCLOSURES HYLEC-APL LAUNCHES NEW DEDSS SERIES LOCKABLE IP66 IK10 STAINLESS STEEL ENCLOSURES FOR CHALLENGING ENVIRONMENTS Time-saving “everything supplied” kit; suits corrosive and hygienic environments; six sizes available. Hylec-APL, the specialist supplier and manufacturer of electrical and electronic components and enclosures, announces its new DEDSS Stainless Steel Series of lockable, solid door enclosures specially designed to provide high-quality, secure, cost-effective protection for specialist and demanding electronic and electrical installations. The DEDSS Enclosure Series is IP66 rated and protects contents against water and dust, as well as being able to withstand impact to IK10 specifications and extremes of temperature ranging between – 20degC and +55degC. Suitable applications for DEDSS enclosures include corrosive environments, such as the chemical and petrochemical industries, and environments where strict hygiene is required, for example, the agro food sector. The rugged DEDSS enclosures range is manufactured from grade 304 stainless steel and supplied as a complete kit. This comprehensive range encompasses six different sizes, ranging from 300mm high x 200mm wide x 150mm deep to 500mm high x 500mm wide x 200mm deep, so offering a wide choice capable of accommodating most installations. Many accessories that fit the DEDSS range are available from Hylec: cable glands, Kwik-Fix cable glands, venting elements, contactors/thermal overloads, filter fans and other fans. For more details please visit: www.hylec-apl.com/Enclosures-and-Junction-Boxes.html

AB17-1037

PROCESS INDUSTRY INFORMER - NOVEMBER 2017

WELDING

FEATURED ARTICLE

NEW ESAB RENEGADE™ SERIES OF MMA/TIG INVERTERS OFFERS MORE POWER IN A HIGHLY PORTABLE PACKAGE ESAB Welding and Cutting Products has launched its Renegade™ Series inverters for advanced DC TIG and MMA/Stick welding. Combining power with low weight and location flexibility, the Renegade Series has three models: Renegade ES 300i for MMA and Live TIG, Renegade ET 300i for MMA and TIG with high frequency (HF) or Lift TIG arc starts and Renegade ET 300iP, which adds controls for pulsed TIG welding. Portability and Power Renegade ES 300i weighs only 15.5 kg and Renegade ET models weigh 17 kg. All models measure just 460 mm by 200 mm by 320 mm, giving them the smallest footprint among their competitors and simplifying trolley maneuvers when configured as a water-cooled system. With Renegade’s unique handle design offering built-in storage and security for the welding cables, operators can quickly pack up and go by wrapping the cables around the handles and locking them in with a dedicated shoulder strap. “Renegade is a next-generation work shop and field welding machine combined into one, offering more power and a design that’s easier to move around any jobsite,” says Martin Freibergs, Business Product Manager Industrial/Light Industrial Product Systems, ESAB. “When Renegade can’t be located next to the work piece, its strong output enables the use of long welding cables and longer work leads.” For more information, visit www.esab.com.

CALIBRATION DIGITAL SENSORS SIMPLIFY CALIBRATION & MAINTENANCE When it comes to the maintenance of critical water chemistry equipment, analogue transmitters, sensors and analysers have been on the market for years. New, digital-based technology simplifies and reduces the overall frequency of analytical sensor calibration and maintenance. Intelligent Sensor Management (ISM®) is a process analytics platform that uses on-board microprocessors to provide worry-free measurement points and maximum confidence in your processes. ISM sensors can be calibrated in any convenient location, under controlled conditions. They can then be stored until they’re required. Once connected to an ISM transmitter, the instrument automatically recognises the sensor type and its calibrated data, configuring itself without any operator involvement. Real-time predictive diagnostic tools give you advance warning of when servicing and maintenance are required, critically before sensor failure or loss of accuracy occurs. METTLER TOLEDO Thornton’s ISM UniCond® sensors eliminate the need for different models of conductivity sensor, measuring ultrapure water with higher accuracy than analogue sensors. The same sensor can measure up to the range of seawater, meaning it can be used throughout a makeup water treatment system, as well as for all cycle chemistry monitoring points. Switching from polarographic or amperometric membrane-based sensors to Thornton’s Optical Dissolved Oxygen (ODO) sensor can significantly reduce maintenance time, labour and costs. For more information contact Mettler-Toledo UK, Leicester Tel: 0116 234 5095 | Email enquire.mtuk@mt.com Web: www.mt.com/uk-power-diagnostics-guide

NOVEMBER 2017 - PROCESS INDUSTRY INFORMER

THE EVOLUTION OF

ROBOTICS:

MEET YOUR NEW COLLEAGUE Volker Spanier, Head of Robotics Solutions for Epson Europe

Robots have transformed the workplace and will take industries to new levels in the coming years as technology, workplace practices and industry processes become increasingly innovative. To date, robots have notably taken their place in largescale production, but advances in robotics technology are presenting sizeable productivity and profitability opportunities for a wealth of industries where more small-scale, lean and agile operations are required.

s the market share of robots is expected to surge over the coming years, the market is turning to trusted, market-leading brands such as Epson for support. Even though there is some way to go until robots become the norm, innovative robotics technology is supporting the move towards a more nimble and sophisticated robotic workforce every day. In fact, the number of industrial robots deployed worldwide is expected to increase to around 2.6 million units by 2019. That is about one million units more than in what was previously considered record-breaking back in 2015. Furthermore, next to the rise in the number of industrial robots, advanced cobots (‘collaborative robots’) are expected to increase too. While they only accounted for 5% of global robot sales in 2015, Barclays Equity Research estimates that this $120 million market could jump to $3.1 billion by 2020 and $12 billion by 2025. That would mean 150,000 cobots sold in 2020 and 700,000 in 2025. This is all happening because robotics are opening doors to more opportunities for local production (reshoring) and the development of more tailored products for consumers (personalisation). In addition, as increased cooperation with humans, including physical cooperation, becomes apparent, novel business models and deployment strategies are entering other industries including services in healthcare and hospitality. As these demands grow, and innovation evolves, smaller, smarter and more nimble robots are becoming the clear contenders to match the fast-paced and dynamic requests of consumers around the world, as well as the growing sense of sustainability.

THE INCREASING MARCH OF TECHNOLOGY To support this, market leaders are advancing access to these technologies. The price of robots is coming down as more entry-

level robots become available for purchase directly from websites. As such, the possibilities of offering a modular approach to robotic solutions are becoming more apparent as are robot systems that can be sold at a low cost and adapted by the end user. The capacity of robots to adapt to different products or needs is improving at breakneck speed too. While they may still be ten or so years away from the dexterity needed to pick strawberries as well as a human can, developments in sensing technology such as Epson’s Force Sensor, are already enabling robots to automatically modulate the force they apply to objects. This is rapidly expanding their capabilities and allowing the automation of complex tasks that formerly required human sensory perception. In fact, certain robots can now work at speed with incredible precision, picking up and sorting elements that are neither aligned nor identically positioned. In practice, the advent of all of this can be seen in the reshoring activities of two well-known European apparel manufacturers – Adidas and Mango. Adidas has recently set up a speed-factory near Ansbach, allowing the production of a shoe in five hours from start to finish. Mango’s decision to reshore some parts of production is mainly for the same reasons. Thanks to the benefits brought by new technologies like robots, 3D printers and body scanners, they hope to be able to develop new collections every two weeks instead of three. For both companies, although large-scale production remains elsewhere, robotics technology is allowing them to react faster to market changes by shortening the value chain and moving production closer to the end-user.

THE CONCERNS FOR JOBS New robots such as the Dual Arm, currently in the final stages of development, from Epson aim to go one step further and eliminate the need for detailed programming by allowing the robot to create its own preferred trajectories and actions based on specific objectives. This ease of programming reduces the need for a specialised skill set to manage the robot, and allows for one machine to be relocated and reused within a factory for multiple tasks. The growth of robotics in Europe continues to pose questions for the labour market. Robots may not yet be able to pick strawberries or thread laces but they are learning fast, understandably for some this is seen as a potentially worrying development as robots are able to take on roles previously occupied by humans. Others point to a different scenario however; yes, robots will take over some jobs, but as with previous industrial revolutions in the past, new ones will likely also be created. In a few years, we will all look back and relate to robots going through the same process as the smart phone: remember the size of the first mobile phones that have now transformed into our essential, go-to mini-machines smaller than our back pocket? Robots will continue to get smaller, smarter and more sensitive – and it is nothing to be concerned about. In fact, it is more a case of being prepared for a future where our jobs are more stimulating and creative, where we have access to more personalised solutions and greater access to goods. As robots become more nimble, we humans must too.

BEARINGS BOWMAN INTRODUCES PEEK-LINED BEARINGS Leading manufacturer and distributor of bearings and sintered components, Bowman International, has introduced a range of high temperature, self-lubricated PEEK-lined steel or bronze backed wrapped bearings. Bowman’s new W/MP® range is designed to combine the durability and anti-corrosive properties of Polyether Ether Ketone (PEEK), with the production and cost reduction benefits of conventional wrapped steel bearings. It delivers optimised performance in applications operating at up to 250OC, alongside low torque properties and impressive corrosion resistance. As a high-performance polymer, the cost of producing and machining PEEK from solid bars or tubes often prohibits its use in the manufacturing of many component parts. By using it to line steel or bronze components, rather than making solid PEEK products, Bowman can now offer a cost-effective range of bearing solutions suitable for particularly harsh environments. Manufactured to order in accordance with ISO 3547 dimensions and tolerances, in both Metric and Imperial sizes, the W/MP™ range includes cylindrical and thrust bearings, with the option of PTFE and fillers included. Plates and bespoke parts can also be supplied. Paul Mitchell, Managing Director for Bowman International, comments: “We strive to solve the componentry, plant performance and maintenance issues faced by our customers through a process of material innovation, product development and cost-efficient manufacturing and distribution techniques. Our new high temperature, self-lubricated PEEK-lined bearings are a problem-solving product designed specifically with harsh applications in mind. PEEK is well known for its exceptional thermoplastic properties, and by combining its performance benefits with more economically viable materials and production methods, we can offer a win-win solution to our customers.” For more information on Bowman’s PEEK-lined bearings visit www.bowman.co.uk or call Tel: 01235 462 500.

ANALYSERS NEW VERSION FLUKE 438-II POWER QUALITY AND MOTOR ANALYSER CAN ALSO BE USED FOR INVERTER DRIVEN MOTORS Analyses electrical and mechanical performance on operational motors to extend system lifespan, without mechanical sensors The new version Fluke® 438-II Power Quality and Motor Analyser also supports measurements for inverter driven motors. The Fluke 438-II simplifies the process of motor performance diagnosis by providing analysis data for both the electrical and mechanical characteristics of the motor while it is in operation. It uses innovative algorithms to analyse not only three-phase power quality but also mechanical power, torque, efficiency and speed, to determine system performance and detect overloaded conditions, eliminating the need for potentially costly or inaccessible motor load sensors. To find out more, and how to obtain a free firmware upgrade for an existing 438-II, visit www.fluke.co.uk/438 Using proprietary algorithms, the Fluke 438-II measures the three-phase current and voltage waveforms and compares them against rated specifications to calculate motor mechanical performance. The analysis is presented in simple readouts, making it easy to gauge the operating performance and determine if adjustments are needed before failures cause an operational shut down. The Fluke 438-II analyser also provides measurements to determine a motor’s efficiency (i.e. the conversion of electrical energy to mechanical torque) and mechanical power under operating load conditions. These measures allow maintenance engineers to determine the motor’s in-service operating power compared to its rated power to determine if the motor is operating in overloaded condition or, conversely, if it is oversized for the application when energy may be wasted and operating cost increased. The 438-II is part of the Fluke 430 Series II of three-phase power quality and energy analysers that provide frontline troubleshooting and long-term trending to keep equipment running smoothly. For more information about all Fluke products, contact Fluke UK Ltd, Northampton. Tel: 0207 942 0700. Fax: 01603 256 606. E-mail: industrial@uk.fluke.nl | Web: www.fluke.co.uk.

VIBRATION SENSORS NEW INDUSTRIAL ACCELEROMETERS FROM HANSFORD SENSORS ARE SMALLER, LIGHTER AND OFFER HIGHER PERFORMANCE

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

Pick the perfect pump – from Pump Engineering

AB13-613

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

Hansford Sensors, the leading UK manufacturer of industrial accelerometers, has launched the latest versions of its proven HS-100 and HS-150 Series vibration sensors. The new sensors are over 10% smaller and lighter than existing versions, and offer even greater frequency response, with a significant improvement in resonant frequency. The new family of HS-100 and HS-150 accelerometers is designed for use throughout industry, typically on drives and rotating shafts such as those found in pumps, fans, motors, gearboxes and compressors. In common with all vibration devices from Hansford Sensors, the new versions are designed and manufactured in the UK, to offer a robust, reliable and extremely accurate solution when used with condition monitoring, predictive maintenance and plant management systems. The improvements in size, weight and performance have been achieved through a combination of modified engineering techniques during manufacture and adoption of recent enhancements in component technology For more information on the extensive range of Hansford Sensors products, please visit www.hansfordsensors.com. PROCESS INDUSTRY INFORMER - NOVEMBER 2017

FEATURED ARTICLE

IDENTIFYING THE CAUSES OF

BEARING DAMAGE Bearings don’t often fail – but when they do, a close visual inspection of the damage can reveal details of machine operating conditions, and sugges possible remedies, as Phil Burge, Marketing and Communications Manager at SKF explains.

hile bearing failure is a common fear in industry, it only happens in a tiny proportion of cases. A staggering 90% of bearings outlast the machine in which they are installed. Only an estimated 0.5% actually fail in service. The main reasons are fatigue and poor lubrication, though contamination and poor installation can also play a part. The remaining 9.5% of bearings are replaced in service prior to failure, for safety reasons. When failures do occur, it’s critical to understand what went wrong. If a bearing continues to fail in service there is likely to be an underlying cause. Careful analysis of the damaged bearing can reveal crucial details about the underlying cause of failure, in order to correct it in future. Using the methodology detailed in the international standard ISO 15243:2004 – which categorises six main damage/failure modes, broken into 14 sub-categories – it is possible to pinpoint the cause of failure, and change machine conditions accordingly in order to overcome the problem.

INSPECTION STANDARD The standard relies on a visible inspection of rolling element contact and other functional surfaces – such as raceways – which will suggest the mechanisms involved in each type of damage or failure. The main causes of bearing damage can be linked to six main damage/failure modes: - fatigue; - wear; - corrosion; - electrical erosion; - plastic deformation; and, - fracture/cracking Further investigation will help to determine which sub-mode was responsible for the failure, which will ultimately reveal the likely cause – and its solution. While damage can be divided into six modes, the ways in which this comes about can be varied. For instance, ineffective seals allow contamination to enter the bearing. These contaminant

NOVEMBER 2017 - PROCESS INDUSTRY INFORMER

particles can then be over-rolled by the rolling elements, creating indentations in the raceways. Hard particles can cause indentations with sharp edges. Once the area around the indentation is subjected to cyclic stress from the rolling elements, surface fatigue can set in – causing metal to break away from the raceway, in a process called spalling. Once spalling has begun, the damage will worsen until the bearing eventually fails.

SPALLING SURFACES Fatigue failure might be seen in the form of sub-surface microcracking – which is usually as a result of long-term abnormal loading – or as spalling of raceway surfaces, which can indicate lubrication problems. Here, fatigue is the prime failure mode, subdivided into sub-surface or surface manifestations of fatigue – either of which will identify the underlying cause of failure. Damage to cages and raceways is usually caused by contaminants that have entered the bearing, either by way of the lubricant or as a result of poor or inadequate sealing against adverse operating environments. Inadequate lubrication can also cause ‘adhesive’ wear: material transfers from one mating surface to another as a result of heightened friction between them. This is sometimes accompanied by tempering or re-hardening of the surfaces, producing localised stress concentrations and potential spalling of the contact areas. Bearing damage can be light or severe, and close inspection can identify the cause of the problem. The key is to look for ‘patterns’ – especially path patterns – on the raceway. Some patterns are normal, but others can be indicative of a problem. Different types of bearings will exhibit different ‘problem’ patterns. However, a knowledgeable engineer can identify a failure mode by inspecting the surface damage. For instance, in a radial bearing working under normal conditions, the wear pattern will be restricted to the centre of the raceways and will be evenly distributed. If an axial load is applied to the bearing, the wear pattern becomes eccentric, or off-centre. As problems become more complex, so do the surface wear patterns.

PROBABLE CAUSE In a failure mode, a variety of causes can lead to the same effect. However, identifying the most likely causes – or combination of causes – is the aim of an investigative process called root cause analysis (RCA). RCA works on the theory that every failure stems from at least one of three basic causes: physical or technical; organisational failures related to systems, procedures and decision-making processes; and human errors of omission or commission. After a bearing has failed, RCA must first identify one or more of the three basic causes that initiated the problem. The root cause is then defined by matching the failure mode and its sub-modes with the operational conditions from the time of failure – based on detailed visual inspections of the bearing surfaces and subsurfaces. The investigating engineer must then develop and apply

a solution, and monitor its effectiveness. Identifying the root cause of the failure is not easy – as it is often hidden among a host of ‘secondary effects’. Examining a bearing that has run for some time will reveal a number of changes: dull or even shiny areas on raceways and rolling elements; discoloured inner and outer ring seats; evidence of cage wear; and fretting corrosion on the inner ring bore or outer ring external surface. By carefully analysing the evidence – in the form of damage ‘patterns’ on the surface – an experienced engineer can track down the root cause. It is not always a straightforward diagnosis. When searching for an answer, investigating engineers need all the relevant data – which may involve reviewing equipment maintenance history, and the actions taken in response to similar failures in the past. Understanding the maintenance procedures in place at the time of a failure – and the precise conditions that led to it – is also a crucial part of solving the puzzle.

ELECTRICAL PROBLEM In one case, a variable speed electrical motor – used in the reel section of a tissue paper machine in a paper mill – was experiencing bearing failure after only 1-2 months. There was severe damage to the cylindrical roller bearing (but none to the ball bearing). The machine was stopped due to high vibration levels. There was heavy, irregular wear on the raceway of the inner ring. Some flats were observed, and it was dull grey in colour. The outer ring had a similar appearance, and also included marks similar to those caused by vibration. The initial diagnoses suggested two possible causes: excessive vibration; or current passing through the bearings – though the customer insisted the bearings were insulated. The bearing was cut open and inspected microscopically, which revealed micro-craters on the raceway surface. These were caused by current leakage. This then led to vibration, which created a telltale ‘washboarding’ pattern. Because current leakage was identified as the underlying problem, the customer inspected the electrical system, which showed that a grounding (earth) cable had been disconnected from the motor during repairs, and not reconnected. Once this was fixed, the problems did not return. While inspecting the bearing and identifying its failure modes is essential, the ultimate aim of RCA is to prolong service life. In the above example, a fault in the electrical system was corrected. In other cases, the long-term solution may require other actions, such as overhauling maintenance procedures, introducing automated lubrication or installing a condition monitoring system. In fact, successful diagnosis of the problem is really only the beginning of the solution. Once the underlying cause has been identified, it is vital to introduce some kind of monitoring system in order to ensure that problems are not repeated – because replacing a bearing ahead of time is preferable to replacing it after a shutdown.

PROCESS MEASUREMENT & INSTRUMENTATION ROTRONIC PROCESS PRESSURE TRANSMITTER BF227 Continuously developing the product range to meet customer’s needs Rotronic launched the BF2 series of measurement transmitters. In addition to the established BF220 process pressure transmitter the BF227 is now available with RS-485 communication The process pressure transmitter BF220 is ideal for measurement of absolute pressure in applications with fast temperature changes and in compressed air, HVAC and pneumatic systems. It measures the pressure of neutral gases and nitrogen in piping and closed containers. The pressure of the medium being measured acts on a pressure cell, which converts the pressure into an electronic signal. The new process pressure transmitter is an ideal complement to the low dew point probe HC2LDP and ATEX version Hc2-LDP-EX. Benefits of the new process pressure transmitter with RS-485 interface (BF227) •Compact and robust construction •Measurement range: 0…10 bar •Piezo resistive steel sensor •Zero and range adjustable with internal potentiometer •Digital RS-485 communication communication with independent networks •IP protection IP63/IP65 •Accuracy at 20 °C ±2 K: ±0,25 % FS max •Long-term stability: ±0,2 % full scale/year For more information contact ROTRONIC, Crawley, West Sussex. Tel: 01293 571 000 E-mail: instruments@rotronic.co.uk Web: www.rotronic.com

FUNDAMENTAL PRINCIPLES FOR FLOW RATE MEASUREMENT EXPLAINED IN COMPREHENSIVE ABB HANDBOOK ABB has released an updated version of its comprehensive industrial flow handbook. Titled “Industrial flow measurement: Basics and practice”, it explains the key methods and factors to consider when measuring industrial flow rate and associated applications. Available at http://bit.ly/ABBflowguide, the handbook covers a wide range of topics, including how to identify the correct measurement technique and the best flowmeter to use for specific fluids. Other important topics covered include calibration; communications options, including HART and Fieldbus; fluid mechanics concepts and an overview outlining the suitability of different flowmeters and materials for measuring corrosive fluid flows. The guide also includes a handy reference section containing a list of standards and a synopsis of keywords for operating conditions and measuring point requirements. For more information visit www.abb.com/flow, email enquiries.mp.uk@gb.abb.com, or call 0870 600 6122 ref. “Industrial and utility flow”.

HP PNEUMATIC ACTUATOR RANGE REMAINS BEST BUY The UK’s leading independent provider of valve automation products, Actuated Solutions, has hailed the HP Pneumatic actuator range a ‘best buy’ for the general process market, thanks to its high specification, SIL rating and relatively low cost. Designed for use with quarter-turn valves, the HP pneumatic series has a wide torque range, meaning they can match the operational characteristics of devices requiring precise and reliable 90º rotary motion. Actuated Solutions believes the HP pneumatic range offers customers the best value on the market, as managing director, Paul Slaughter, comments: “No other comparably-priced pneumatic range offers a SIL rating or the same degree of specification. When it comes to an actuator range that will remain fully operational under the most severe conditions, these relatively low-cost, high-quality models provide a remarkably reliable and cost-effective means of valve operation, ensuring a longer service life and lower overhead costs.” For more information, visit www.actuated-solutions.co.uk

MONITORING COOLANT FLOW TO INDUSTRIAL AND MEDICAL LASERS

Used in thousands of industrial and medical laser installations, the Titan Enterprises 800 Series turbine flowmeter is a trusted monitoring device that ensures accurate and repeatable long-term operation. There are many applications of industrial and medical lasers. Whether used for cutting, welding, micro-machining, cosmetic or eye surgery - lasers generate a significant amount of heat. To ensure stable long-term laser performance, this heat needs to be quickly and effectively dissipated. Water circulated through a chiller or heat transfer system is a popular cooling method for lasers. To ensure consistent laser cooling accurate and repeatable water flow measurement is required. Titan Enterprises has supplied variants of its 800 Series turbine flowmeter to several leading industrial and medical laser system integrators for this application. Titan Enterprises 800 Series flowmeter offers an excellent balance of measurement accuracy, long term resistance to coolant fluids, high reliability and ease of maintenance. Operating over 6 flow ranges from 0.05 to 15 litres per minute, the 800 Series turbine flowmeter combines high performance and competitive pricing. Using totally non-metallic wetted components makes the 800 Series turbine flowmeter is an ideal choice for the metering of laser coolant flow. For further information on the 800 Series turbine flowmeter please visit Web: www.flowmeters.co.uk/pd_800series.htm or contact Titan Enterprises on

Tel: +44-1935-812790 | Email: sales@flowmeters.co.uk. 38

PROCESS INDUSTRY INFORMER - NOVEMBER 2017

PROCESS MEASUREMENT & INSTRUMENTATION SENSOPRO COMPLETE CONDUCTIVITY MONITORING SYSTEM Toroidal conductivity sensor paired with Modbus-equipped transmitter for reliable conductivity and concentration monitoring in a single package To meet conductivity control needs in online water quality and process applications, Sensorex has introduced the Sensorex SensoPro Toroidal Conductivity Monitoring System. The system combines a Sensorex TCS3020 probe, capable of reliable conductivity measurements in even the harshest of environments, with the company’s new EX2000RS transmitter, featuring Modbus communication for robust system integration. Monitoring with SensoPro can prevent scaling and corrosion, reduce excessive water usage, and optimise processes in a range of applications including cooling tower water control, wastewater treatment, brine analysis, desalination, chemical processing, and other harsh or high conductivity environments. The TCS3020 probe used in the SensoPro system measures conductivity using toroidal sensing technology, which is more stable and reliable compared to traditional contacting conductivity sensors. Toroidal conductivity sensors do not cause polarisation, do not become fouled, and rarely require maintenance. This design, along with the TCS3020’s rugged Norylbody, reduces maintenance and increases reliability, resulting in more cost-effective operation over time than contacting sensors. The Modbus-equipped EX2000RS toroidal conductivity transmitter completes the SensoPro system. The unit includes one analogue output and can monitor conductivity, percent concentration, total dissolved solids (TDS), and salinity. Sensorex’s SensoPro Toroidal Conductivity Monitoring System is backed by a one-year limited warranty. This system as a whole features a conductivity measuring range of 0.0 µS/cm-2000 mS/ cm, percent concentration measurements for NaCl, HCI, HNO3, NaOH, H2SO4, H3PO4, and automatic or manual temperature control. The result is a reliable conductivity and concentration monitoring system, in one simple package. To learn more, or to purchase the Sensorex SensoPro Toroidal Conductivity Monitoring System, visit Web: www.sensorex.com, E-mail info@sensorex.com or phone +1 714-895-4344 NOVEMBER 2017 - PROCESS INDUSTRY INFORMER

PROCESS MEASUREMENT

& INSTRUMENTATION

MULTI-FUNCTION FLOW & TEMPERATURE SENSORS IMPROVE EFFICIENCY Precise flow and temperature measurement is essential in many applications and the recently expanded range of FLEXFLOW process sensors available from BAUMER LTD provides some highly efficient and flexible solutions. FlexFlow sensors are based on the calorimetric measurement principle which enables the monitoring of both flow and velocity in addition to media temperature in a single instrument. The combination of 2 measuring functions in a single sensor reduces the number of measuring points required in closed systems and therefore minimises installation costs, service and storage. FlexFlow sensors incorporate features such as; an IO-Link and depending on settings and connections, either 2 switching outputs, or one switching and one analog output (4 / 20mA, 0 / 10V). Also, thanks to their symmetrical, centred design, the sensors can be optimally installed in the process, independent of their installation position and orientation to ensure precise and safe measurements. The range includes the PF20H and PF20S options which are suitable for hygienic and industrial applications. The IO-Link enables users to simultaneously configure several sensors and this simplifies and saves time and FlexFlow sensors are designed to enable diagnostic data polling and process evaluation at all times which helps to maximise system uptime and improve efficiency. All the sensors in the FlexFlow range are temperature resistant to 150ºC and CIP (Clean-inPlace) and SIP (Steam-in-Place) capable. For more information contact Baumer Ltd, Swindon, Wilts. Tel: +44 1793 783839 Email: sales.uk@baumer.com Web: www.baumer.com

PROCESS CONTROL WHEN THE GOING GETS TOUGH BAUMER SENSORS MEET THE CHALLENGE

Reliable sensing, measuring stability and accuracy, along with the speed and change of direction of rotation in heavy duty machinery presents tough challenges and it’s where the BAUMER MAGRES range of magnetic absolute encoders excel. Heavy duty industrial applications like utility vehicles, cranes, wind energy plants, steel and metal processing require accurate, efficient and reliable components and Magres absolute encoders are ideal for these situations. The MAGRES EAM580 and EAM360 are the latest addition to the extensive range of absolute encoders available from Baumer Ltd. They combine outstanding reliability with precision, even in the harshest conditions and comply with EN13849 requirements. Their maximum angular accuracy of ±0.15º ensures absolute reliability and precise positioning for optimum process control for applications which previously required optical encoders. Thanks to their compact size Magres encoders fit into the tightest spots while the modular design means that the ultra-compact 36mm option utilises the same large ball bearings as the 58mm version which helps to ensure a consistent and robust performance. Another feature is the bearing less encoder kit where the magnet motor is installed separately as an individual component which means without bearings, the encoder operation is virtually wearfree. Installation is also simplified as the multi-turn variants feature a 2mm wide air gap. For more information contact Baumer Ltd, Swindon, Wilts. Tel: +44 1793 783839 E-mail: sales.uk@baumer.com Web: https://goo.gl/4Lh8Ur

PROCESS INDUSTRY INFORMER - NOVEMBER 2017

MAINTENANCE CLOG RESISTANT TANK CLEANING MEANS LESS DOWNTIME The Problem In certain tank cleaning applications in the food and beverage industry a common problem can be clogged tank cleaning heads. The result is unwanted process downtime and increased maintenance costs. Clogging is usually caused by particles within the recycled cleaning fluid blocking the small holes in traditional spray balls and even more seriously, these can clog the bearings or gears on rotary devices. As a consequence, pre-determined cleaning patterns fail, cycles are incomplete resulting in missed areas. Often a secondary manual cleaning operation is then required to complete the cleaning process. The solution The HYDROCLAW™ is a new design of tank cleaning head which has been introduced by THE SPRAY NOZZLE PEOPLE offering the important benefit of being clog resistant. Traditional cleaning heads typically have multiple small orifices which form a 360º cleaning pattern. However, the new Hydroclaw impacts a jet of water on a claw like plate which shatters the fluid into a 360o pattern. As there is only a single orifice for the cleaning fluid to pass through the overall free passage is dramatically increased (between 3 to 5 times higher) allowing for high particle content liquid (for particles over 7.6mm in diameter) to be used as the cleaning media. The shape of the ‘claw’ is designed to ensure that the fluid shatters into a genuine 360º pattern effectively covering the whole tank. Initially developed for wine producers, the HydroClaw has applications for the wider brewing and distilling industry as well as for other non-food tank cleaning systems where clogging is a problem. Features The HydroClaw is made from FDA compliant 316L stainless steel so is ideal for food grade and aseptic clean-in-place (CIP) applications. In addition to its innovative design it has no moving parts and is selfdraining, self-flushing and is laser welded for optimum durability. It provides with low pressure / high flow to enable quick cleaning of tank walls and helps to reduce water consumption compared to a static spray ball. The HydroClaw is designed to fit through a 76mm opening and is available with a variety of connection types such as 1“female NPT or G threads, 1½” or DN40 tube clip-on. For more information contact The Spray Nozzle People, Lewes, East Sussex Tel: +44 (0) 1273 400 092 E-mail: Ivan@spray-nozzle.co.uk. Web: www.spray-nozzle.co.uk NOVEMBER 2017 - PROCESS INDUSTRY INFORMER

WEIGHING STOP STATIC BEFORE IT STOPS YOU

Worry-free Weighing

Download a free anti-static white paper & receive a free anti-static kit with purchase of an XPE balance Did you know that the accumulation of electrostatic charges can skew your weighing results? You can also eliminate static permanently with our Anti-Static Kit, free with 13 Ways to Eliminate Electrostatic purchase of any XPE balance until December 31st 2017. Forces That Disrupt Weighing If you work in a lab, you have likely encountered this disappointing scenario: When weighing a dose of powder into a polymer vessel, your balance will not stabilize. The most likely culprit is electrostatic charges, also known as static. Fortunately, static can be stopped by a range of simple low-to-no cost solutions before it has a chance to harm your analytical results. In “13 Ways to Eliminate the Electrostatic Forces That Disrupt Weighing,” you will learn: If you work in a lab, you’ve been there: You’re weighing a dose of powder into a polymer vessel – and, much to your dismay, your balance will not stabilize. The most likely culprit for this disappointing outcome? Electrostatic charges – also known as static.

Dry powders are very susceptible to static and difficult to weigh.

- what causes electrostatic charges - how these charges affect samples and weighing vessels - how you can avoid creating static charges, and - Solutions that eliminate existing charges. Solutions range from allowing new vessels to “air” for several hours before use so any built-up ions dissipate to simple balance attachments that ensure ions are discharged before a vessel is placed on the weighing pan. These solutions eliminate static and ensure the kind of accurate, repeatable results that eliminate rework, waste, and even consumer risk. In addition to the free white paper, we are pleased to offer a built-in Anti-Static Kit valued at $2,000USD with every XPE Analytical balance purchased until December 31st 2017. XPE Analytical balances use static elimination technology coupled with an improved SmartGrid weighing pan to give you trustable, highly repeatable results. Download here: https://goo.gl/Wt2jnr For more information contact METTLER TOLEDO GmbH Laboratory Weighing, 8606 Greifensee, Switzerland TEL : +41 44 944 22 11 | E-Mail: branko.radovinovic@mt.com|Web : www.mt.com

NEW WHITE PAPER EXPLAINS CALIBRATION AND HOW IT CAN IMPROVE WEIGHING ACCURACY Calibration is a small detail that can make a big difference in ongoing balance or scale accuracy. A new METTLER TOLEDO white paper discusses why this essential test for balances and scales is important whether or not the industry is regulated. Despite the importance of calibration, many people don’t understand what it is and why it is necessary. “Calibration: What Is It?” answers this important question to help improve weighing accuracy and provide better quality to customers. This new installment in METTLER TOLEDO’s “Small Details, Big Difference” series covers three topics essential to calibration: •Why calibration is necessary, •The difference between calibration and adjustment, and •Tolerances and why they are critical. “Calibration” and “adjustment” are often used interchangeably. However, adjustment should never occur in the absence of calibration. Only after an instrument’s current performance is clearly understood through professional calibration should any type of adjustment be attempted. In short, calibration keeps weighing from becoming guesswork. To learn more about how calibration can improve weighing accuracy and process or product quality, download “Calibration: What Is It?”today from here: https://goo.gl/hKzZvD

Your Right Connection For Hygienic Process Systems Valves

Fittings

Hose

Engineered Products

Fabrication

Tel: +44 (0)1772 323529 Email: sales@dixoneurope.co.uk www.dixoneurope.co.uk 42

PROCESS INDUSTRY INFORMER - NOVEMBER 2017

FEATURED ARTICLE

INDUSTRY 4.0

IS DISRUPTING THE SUPPLY CHAIN

FOR GOOD

The impact of industry 4.0 and smart use of data is reducing disruption in the supply chain says LLamasoft’s Michael Wallraven

The impact of Industry 4.0 could easily be identified as a threat and a disruptor to the traditional supply chain. The truth is that, when deployed correctly, this dynamic combination is the antidote to supply chain disruption.

n 2016, global supply chains were impacted by a series of unfortunate natural disasters including earthquakes and typhoons that ravaged nations throughout Asia. In 2015, analysis by insurance firm Allianz Global Corporate and Specialty found that between 2010 and 2014, the top five causes of business interruption loss globally were fires and explosions, storms, machinery breakdowns, faulty equipment or materials, and workforce strikes. Current events that are continually unfolding must also be considered, such as the economic nationalism propelled by the election of Donald Trump and the UK’s impending exit from the European Union. However, there are less dramatic situations that can cause supply chain disruption on a more frequent basis – small acts than have a large impact, such as human error causing delays on the production line. This creates an obvious knock-on effect that directly impacts the rest of the supply chain. It is clear that the supply chain is vulnerable to disruption. The traditional supply chain ecosystem is built around a rigid process that does not provide supply chain organisations with the flexibility to adjust to disruptions that will impact the bottom line, or the opportunity to predict or prepare for those disruptions. The traditional process is typically governed by inaccurate analysis of the market that dictates supply chain operations in order to meet the predicted sales. A digitised reinvention of the supply chain will replace this inaccurate, siloed process with a flexible and agile NOVEMBER 2017 - PROCESS INDUSTRY INFORMER

solution that utilises data to severely diminish the impact of disruption.

INDUSTRY OF THINGS The moniker Industry 4.0 represents the fourth industrial revolution which in turn refers to the rise of data exchange and automation in manufacturing technologies. ‘Internet of Things’ (IoT) is a similar term that supports the same notion of the world becoming more connected and is widely used to describe connected devices used in both industrial and domestic environments. In theory, connected devices, whether in a factory or in the home, bring all of these environments together to create one interconnected ecosystem. Take Amazon Dash, for example. The e-commerce giant’s Wi-Fi- enabled device can be placed anywhere in the home and reorders a specific product with the press of a button. The user could place the button in a kitchen cupboard, enabling them to replenish their supply of a specific product. Even smartphones providing access to online shopping platforms have enabled consumers to directly impact the supply chain from their own homes. The domestic benefits of connected devices are clear, but there is now an opportunity for the supply chain itself to benefit too. The ‘smart factory’ utilises automated machinery connected via the internet to facilitate more efficient and flexible production processes that can quickly adapt to production changes and demands. The Siemens AG plant in Amberg, Germany, is 75 percent automated while German truck builder MAN is building IoT technology into its vehicles, enabling haulage operators to access live feeds of raw data on the vehicle’s performance and track their journeys. For supply chain organisations, these developments provide them with the opportunity to pull their supply chain operations forward into the future. In comparison to the interconnected and automated technologies going into these factories, as well as the technologies that are making homes and shops smarter in the way that they are supplied with products, the traditional supply chain is exposed as outdated and inefficient. With the right flow of data, a digitised supply chain can help organisations thrive.

DISSEMINATING THE DATA From the shop floor to the factory floor, each connected device provides important data that can be fed into the digitised supply chain. To be of true value, this data must be tracked and visualised. Visibility is a key area of focus in leveraging data in the evolution of Industry 4.0, and it’s equally as important in the supply chain. Once the data is feeding into the supply chain and clearly visualised, the organisation can begin to think about disruptions before they occur. This can be achieved by manipulating the data in three key areas; supply chain design, event simulation and decision support. These three areas make up the functionalities of the solution that can be provided by digitised supply chain software. Designing the overall supply chain requires the visualisation of any route within the supply chain network, beginning with partners such as suppliers and service providers. Following the overall design of the supply chain within the software, the potential scenarios and ‘what if’ questions can be entered. As the software runs these scenarios, the outcomes will be generated and from here, organisations can explore the actions that can be taken to avoid total disruption should any of the potential events unfold. From this point, the supply chain becomes a flexible and reactive system that ensures disruptions have minimal impact. However, this all depends on the quality of the data that is fed into the digitised supply chain. Organisations will rely on the data to answer the tough questions, therefore flow of data must be carefully managed and stored to provide the most accurate responses. As the availability of data increases from all directions, including the factory, the warehouse and the shop floor, the data that is relevant to each organisation and its own supply chain must be filtered out. Without effective filtration of the data, the digital supply chain will become overwhelmed and the clear resolutions to disruption will not be achievable. When the flow of data is suitably managed through the adoption of intelligent supply chain software, organisations will benefit from a farreaching view across all potential scenarios, enabling them to recognise and react to supply chain disruption before it has the chance to make an impact. 43

FEATURED ARTICLE

LIFTING THE LID ON LIFE CYCLE COSTS OF

COMPRESSORS At present, zerohour data which is CAGI* verified is commonly used to calculate the life cycle cost (LCC) of an air compressor. However, these figures assume that a compressor’s efficiency remains constant regardless of how long it has been used. In reality, a compressor’s Specific Energy – a measurement of its energy usage changes over time. Andy Jones, managing director at Mattei, explains how this significantly impacts on the decision-making process when comparing different options and assessing whether to invest in a piece of equipment.

he Government’s recent ‘Clean Growth Strategy’ set out its proposals for decarbonising the UK’s economy in the future whilst growing the country’s national income. Recognising that 25 % of carbon emissions is generated by business and industry, the Government has promised to develop a package of measures to support businesses to improve their energy productivity, by at least 20% by 2030, and to work with seven of the most energy intensive industrial sectors on joint energy efficiency plans. So how do compressors factor into this? According to a 2016 paper on the energy saving potential of existing air compressors, the electrical consumption of the industrial sector constitutes over 50 per cent of global usage, and up to 20 per cent of this can be attributed to air compression and delivery to final uses. 1 It is therefore safe to say that this is an area where energy efficiency is critical, and that compressors are a key part of lowering the overall usage of energy in industry. This is not lost on policy makers, and legislation is likely to come into play in the near future which removes inefficient compressors from the market. However, it is at this point, where compressor efficiency is evaluated, that problems begin to arise and questions must be asked about how we analyse lifetime performance. A whitepaper launched by Mattei this year, Air Compressors – The real economic and environmental impact of using the current industry standard Life Cycle Cost analysis – has revealed the serious inaccuracies in how compressor efficiency is currently assessed, especially in respect to the difference between vane and screw technologies. The core issue centres around the accuracy of the Life Cycle Cost (LCC) calculation. At present, this considers three factors – capital equipment expenditure (CAPEX), ordinary maintenance costs and

energetic consumption costs. Generally based on independently verified CAGI datasheets, this information is combined to produce an LCC for a compressor. But, as addressed in Mattei’s whitepaper, this calculation assumes that air compressor Specific Energy stays constant over time. Specific Energy is generally based on the number of kW required to compress 1 m³/min of air. This is then multiplied by the Free Air Delivery (FAD), operating hours, and local cost of electricity, to produce the complete running cost of the compressor. However, as referenced earlier, this can only form part of an accurate LCC if we believe that this level o f Specific Energy will not change over time – and this is not correct for vane or screw compressors.

VANE COMPRESSORS Conversely, the efficiency of a rotary vane compressor actually improves over an initial running-in period.

SCREW COMPRESSORS In the case of screw compressors, efficiency deteriorates from the beginning of operation. This is essentially due to wear related to the fundamental design of this technology.

Screw compressor illustration birdseye view

It is an accepted fact that roller bearings and thrust bearings are subject to wear, and that the rate of this is contingent on speed and load. To counter this, screw compressor manufacturers advise the substitution of all major rolling and thrust elements after a certain number of operational hours – often between 40,000 and 50,000. This wear results in a degradation of performance over time, especially as the unit approaches the point where parts need to be replaced. Although there is a surprising lack of research around this topic, there are small studies available from energy audit companies which illustrate the phenomenon. For example, one such audit, which tested 27 refrigeration screw compressors varying in age up to ten years, found that the average deterioration level was 30 per cent, with the worst compressor performing at 55 per cent degradation level. This clearly has major implications for the LCC of a screw unit. As the standard calculation uses the zero-hour data provided by the manufacturer’s CAGI verified datasheet, it paints a very misleading picture, as it doesn’t take into account inevitable wear, and how this relates to the Specific Energy level of the unit over time. This poses a real problem, as it means that those looking to purchase a compressor, or policymakers building energy related regulations, are using an incorrect LCC, which is far removed from the real costs and efficiency of these units over their lifespan.

The design of rotary vane compressors means that there are no roller and thrust bearings to experience wear within the unit, which means that the technical datasheet remains accurate throughout the life of the compressor, regardless of running hours. This also means that there is no need for part substitution, so rotary vane manufacturers like Mattei can offer extended warranties without a cap on operational hours. Beyond this, from the moment a rotary vane compressor is turned on, to around the 1,000- hour mark, the blades undergo a polishing process. This results in less friction, and consequently, better operation and reduced energy requirement. Tests conducted by Mattei in 2016 found that after 1,000 hours of operation, the two Mattei units analysed (Maxima 75 Xtreme, Maxima 55) both presented remarkable improvements in Specific Energy levels, with an enhancement of up to 5 per cent. Given that the Specific Energy level of a screw compressor will degenerate from the beginning of operation, whilst a rotary vane will improve, it is clear that the zero-hour Specific Energy of these units should not be used as part of an authoritative LCC. This is no small matter – a 75kW screw compressor which sustains a degradation in performance of 10 per cent over ten years can cost an owner 12 per cent more, including part replacement costs, than a 75kW vane compressor which has an identical zero-hour performance, amounting to an additional cost of almost £150,000 for the user of the screw compressor. In overlooking the changes in efficiency over time, buyers cannot see the true cost of owning and running an air compressor over its lifespan. Not only are investment decisions being made based on misleading information; the effectiveness of any potential legislation to improve the efficiencies of industrial air compression may also be compromised. That’s why it’s time to use variable Specific Energy information which reflects a compressor’s energy performance more accurately, and improve how the LCC of compressors is calculated to benefit both industry and the environment. 1.https://www.edie.net/news/11/Engineering-sector- -energy- efficiency-must- playcentral- role-in- Industrial-Strategy/ * Compressed Air and Gas Institute, based in North America. This body only provides information for 60Hz air compressor models, but as there is no independently verified 50Hz data published in the same format these are often referred to as a guide

PROCESS INDUSTRY INFORMER - NOVEMBER 2017

HEAT TRANSFER & ENERGY

AIR COMPRESSORS

AFP1: HANDY MULTI-PARAMETER MEASURING INSTRUMENT FOR HVAC APPLICATIONS

WHITEPAPER: COOLING SYSTEM DESIGN USING ECO-FRIENDLY REFRIGERANTS

BOGE INTRODUCES SUSTAINABLE LUBRICATION PACKAGING

The new AFP1 multi-parameter measuring instrument measures air velocity, humidity and temperature and is ideal for spot measurements in HVAC systems. Thanks to easy operation via a smart phone, it is possible not only to take random measurements, but also to record, export and display data as wanted. With the extendable telescopic rod, the measuring head can be brought to the desired measuring point in or on the ventilation shaft easily. The AFP1 sensor is operated via Bluetooth communication with the ROTRONIC smart phone app, which can be obtained free-of-charge from the App Store (iOS) or Play Store (Android). The app offers functions to display, log and send the required measured values by e-mail. It is also possible, among others, to define parameter-specific settings and options for the measurement. Features: •Measures air velocity, humidity and temperature •Small vane anemometer for in-tube measurements •Smart phone connection via Bluetooth® •Easy data logging via iOS or Android app •Direct volume flow calculation •Numeric or graphic display •Simple data export for evaluation on a PC For more information contact ROTRONIC, Crawley, West Sussex. Tel: 01293 571 000 E-mail: instruments@rotronic.co.uk Web: www.rotronic.com

Sensata Technologies, one of the world’s leading suppliers of sensing, electrical protection, control and power management solutions, has published a new white paper to help manufacturers of HVAC and cooling systems design next generation solutions that can take advantage of ‘green’ refrigerants that do not adversely impact the environment. This means replacing refrigerants that can damage the atmosphere and deplete the ozone layer with natural refrigerants that do not negatively impact the environment. According to author William Bentley, engineering manager, Industrial Solutions at Sensata Technologies, this includes new hydrocarbon refrigerants such as R290, R600a, R32, as well as CO2 and Ammonia: “Given the changes in refrigerants being used around the world, it is clear that natural refrigerants are important to the future landscape of the HVAC industry. “However, these emerging refrigerants come with a variety of challenges such as extreme high pressures, extreme corrosiveness, and flammability.” Titled ‘How to Solve the Challenges of Using Natural Refrigerants in Cooling System Design’, the new Sensata white paper provides an overview of various methods used to mitigate these technical challenges as well as a look at the some of the HVAC and refrigeration hardware and safety technologies required to handle these new refrigerants, especially pressure switches and pressure sensors. “Component manufacturers must meet the design challenges posed by these non-synthetic refrigerants to optimise safety and efficiency,” William continues. “A critical part of this evolution is the knowledge of what kinds of hardware and systems must be specified for the safe implementation of these new and more technically challenging materials.” The new Sensata white paper is available as a free download at www2.sensata.com/natural-refrigerants.

NOVEMBER 2017 - PROCESS INDUSTRY INFORMER

BOGE has become the first compressor manufacturer to offer lubricant in environmentally-friendly packaging, thanks to the launch of its ‘Lube Cube’, an ecological alternative to traditional plastic containers. Lube Cubes are stackable (and therefore easy to store and transport) and simple to use (‘anti-glug’ taps dispense the lubricant when required, and eliminate spills and waste). They are also almost entirely recyclable and therefore dramatically reduce environmental impact and disposal costs, and increase sustainability. The Lube Cube’s ‘bag in a box’ concept comprises a robust 100% recyclable corrugated cardboard outer to provide protection during transportation and use, and a 98% recyclable inner. This means they boast greater sustainability and have a significantly lower carbon footprint than other packaging. Once empty, the boxes can be simply flattened and recycled. It costs around £3 to dispose of a 20 litre plastic drum compared with just 6p for a Lube Cube. For more information contact BOGE Compressors Ltd, Tel: +44 14 84-719921 E-mail: uk@boge.com | Web: www.boge.co.uk

VIEWPOINT ARTICLE

SMART MANUFACTURING: WHAT YOU NEED TO KNOW BEFORE IT’S HERE

by Megan Ray Nichols, editor of Schooled By Science S m a r t manufacturing might sound like the newest i n d u s t r y buzzword, but it has the potential to shape the entire manufacturing industry in the next decade or so. Countries across the globe are making plans to adopt smart manufacturing as a way to strengthen their own hold on the industry. Let’s take a look at smart manufacturing and what you need to know before it becomes mainstream. WHAT IS SMART MANUFACTURING? At its core, smart manufacturing is the use of Internet of Things (IoT) devices in manufacturing, but there is much more to it than that. The concept of smart manufacturing is made up of 4 main pillars: Smart Factory: Mixing data and physical production to eliminate things like downtime and product defects. Industry 4.0: A perfect merging of computers and automation, with the potential for computers equipped with learning algorithms that could eventually learn to correct their own mistakes. Digital Manufacturing: Using 3-D rendering to directly assist in the creation and manufacturing of new products. IoT/IIoT (Industrial Internet of Things): Relying on internal and external networks with a net of interconnected machines. Also known as smart devices, IIoT refers to the specific types of IoT devices that are used in the manufacturing industry. Smart manufacturing is essentially the first step toward utilizing this technology to make your factory, shop or 46

business more efficient and effective. What do you need to know before this practice becomes an integral part of the manufacturing industry?

YOU DON’T NEED TO REPLACE YOUR EXISTING EQUIPMENT We all know how expensive it can be to replace an existing piece of equipment, especially if that hardware is new and hasn’t yet paid for itself. Thankfully, the minds behind smart manufacturing have considered this fact. You don’t need to buy new IoT-enabled equipment to benefit from it. You can retrofit your equipment to make it IoT compatible without replacing the entire unit. This effectively makes the transition to smart manufacturing much simpler and doesn’t involve emptying your company’s coffer to keep up with the changing face of the industry.

IT MAKES THE WORKPLACE SAFER Workplace injuries in the manufacturing industry are on the decline, but injuries still occur throughout the year. The introduction of IoT and smart manufacturing can, in essence, take employees out of the line of fire by using robotics and networked hardware to complete the most dangerous and injury-prone jobs on the factory floor. And don’t worry — this isn’t a case of replacing workers with robots. Instead, it’s a way to keep your employees safe while they’re on the job. Completing the job is important, but so is keeping your employees injury-free.

HOW CAN I ADOPT SMART MANUFACTURING TECHNIQUES? After you understand smart manufacturing and how it can benefit your business, you can start incorporating it into your own little corner of the industry. Here are a few tips: Collect. One of the biggest things you’re going to need as you start transitioning into smart manufacturing is data. If

you don’t already collect and store all of your data, start now. Once you collect a good base of information, you can start applying predictive analytics, which is taking the mass of data you’ve collected and applying predictive algorithms to it. You can find trends, predict industry changes and better determine what parts of your manufacturing process would benefit from the introduction of smart manufacturing. Work from the top down. No matter what part of the manufacturing industry you work in, smart manufacturing will require an investment and quite possibly a massive overhaul of your techniques. Any switch to smart manufacturing starts at the top of the company and trickles its way down. You wouldn’t want to start installing IoT retrofits that take your company in the opposite direction from where you’re trying to go. Don’t be afraid to start small. It might be tempting to jump in with both feet and start retrofitting everything you can, but enormous changes like that will hobble your production while you’re trying to adapt. Instead, start small and make sure the change is fully incorporated into your standard operating procedures before taking the next step. Stop being afraid of change. Companies around the globe have already started adopting IoT-based techniques, much to their benefit. One report found that between 2013 and 2014, companies that started adopting IoT saw an average of a 28.5% increase in revenue. Where would your company be if you made more than a quarter more than you did the year before? Smart manufacturing is the newest innovation, following in the great tradition that started with the invention of the steam engine and the beginning of the industrial revolution. These new innovations will make the manufacturing industry more effective, more efficient and more productive than ever before. PROCESS INDUSTRY INFORMER - NOVEMBER 2017