Process Industry Informer September 2016 by Process Industry Informer

www.processindustryinformer.com

SEPT 2016 Volume 12 No.5

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

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

CONTENTS. 4-5 News & Events 5-7 Applications 7 Welding 12 Network & Communications 12 Solids Handling & Processing 14 UV Systems 15-20 Process Measurement & Instrumentation 35-39 Fluids & Liquids Handling (incl. Pumps & Valves) 41 Water & Wastewater 41 Enclosures 42 Weighing 46-47 Health & Safety 49-50 PPMA releases

CHANGE MANAGEMENT: MAKE THE CHANGE

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

21 BPMA News

TAKING THE TEMPERATURE OF THE PROCESS

MEETING THE INDUSTRIAL HEATING CHALLENGE

Printed By Bishops Printers Ltd Advertisement & Editorial Offices Process Industry Informer, Passfield Business Centre, Lynchborough Road, Passfield, Liphook, Hants, GU30 7SB Tel: 01428 751188 Fax: 01428 751199 Email: info@piimag.com Web: www.piimag.com Subscriptions UK £25 | EIRE £35 Overseas prices on application © Process Industry Informer

GLOBAL EVENT FOR PROCESS & ENVIRONMENTAL

LOGISTICS IN THE DIGITAL AGE:

NON-NEGOTIABLE: THE IMPORTANCE OF RELIABILITY IN VALVE

RUPTURE DISC RATIONALISATION

THE IDEAL PUMP FOR FOOD & COSMETICS APPLICATIONS

THE FUTURE OF UK MANUFACTURING DEBATE HEATS UP

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

whatsoever and however arising, whether due to inaccuracy, error, omission or any other cause, and whether on the part of the publishers of Process Industry Informer, or their servants or agents, or any other person. Although it is the intention of the publishers in general to run copy as supplied by advertisers, advertorial item headings, which are not charged for, will be selected by the Editor, and other minor changes may be made, at the Editor’s discretion, for the sake of clarity, to avoid offence, for legal reasons or to ensure conformity to house style. Copy supplied over length will be cut to the amount paid for. Units and abbreviations will be standardised in accordance with house style. No part of this publication may be reproduced or transmitted by any means without the prior written consent of the publishers.

NEWS & EVENTS ALICAT SCIENTIFIC ESTABLISHES EUROPEAN OFFICE UK location to provide engineering support, product service and user training.

Mass flow device manufacturer, Alicat Scientific, has established a new regional office in Cambridge, United Kingdom. The new location gives customers across Europe local sales and service for Alicat’s line of pressure controllers,mass flow controllers, meters, and accessories. The new office will be headed up by European Territory Manager, Andy Mangell. Mangell joined Alicat earlier this year, with a strong background in the European market and mass flow technology. Now that he has established a strong foundation in the region for application engineering support, calibration services, and end-user training, he is tasked with growing the localised support team and service capabilities. “Alicat prides itself on the speed and accuracy of its instrument response time,” says Mangell. “However, within the discerning marketplaces where we operate, this is simply not enough. Providing the very best localised support is absolutely paramount to our devotion to speed. With this new location, we can ensure immediate engineering support, a quotation within hours, delivery within seven to nine days and service turnaround in under four days. This commitment to the European market is on-going, as we add yet more staff and capability at the Cambridge facility.” Alicat is headquartered in Tucson, Arizona. In addition to the newly established Alicat Europe, the company has regional service and support centres in India and China. Alicat Europe is located at 2 College Park, Coldhams Lane, Cambridge, CB1 3HD. To learn more about Alicat’s mass flow meters, visit www.alicat. com, call +1 520 290-6060 or via email at europe@alicat.com.

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

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

HBM training explains the tips and tricks to optimise your data acquisition challenges.

Following on from a successful series of training, HBM – a market leader in the field of test and measurement – has announced the date for its next ‘HBM on Tour’ training day, which will take place on Wednesday 19th October 2016. ‘Tip and Tricks to optimise your Data Acquisition challenges’ is a comprehensive one day training course, which has been designed to offer both practical and theoretical solutions to users from all fields who would like to optimise their data acquisition hardware and software. Presented by a wealth of presenters from the prestigious HBM Academy, the course will begin by explaining component evaluation and life prediction using HBM nCode analysis software. Looking at how well participants know their data, the course will also offer valuable advice on how to keep track of valuable data in terms of analysis and traceability using nCode Automation. Established in 1982, nCode software from HBM is the leading brand for engineering data analysis solutions with special concentration in fatigue and durability. Suitable for applications across a broad range of industries, nCode software helps customers to understand product performance, accelerate product development and improve design. Located at the Silverstone Wing in Northants, which sits in the heart of Silverstone’s world-famous Grand Prix circuit, this memorable venue combines the glamour and heritage of the home of British motor racing, with stunning designs. And what’s more, participants are invited to join a free Silverstone Racetrack Tour at the end of the seminar! Free to attend; with lunch and morning and afternoon refreshments included, spaces are available on a first come, first served basis. To register for further information on these training courses and to reserve your place on the Silverstone tour, contact HBM on +44 (0) 20 8515 6000 or via email: info@uk.hbm.co.uk or visit the HBM website at www.hbm.com/en/menu/seminars/ seminar-calendar/

HBM ON TOUR! HBM workshop explains fundamentals of strain gauge installation at Silverstone. As part of its highly acclaimed HBM on Tour series of workshops and training courses, HBM – a market leader in the field of test and measurement – has announced the date for its latest ‘Installation of Strain Gauges’ training course, which takes place on 18th October 2016. Taking place between 9am to 5pm this comprehensive one day training course will explain the fundamentals of strain gauge measurement, ranging from gauge selection, through to analysis and evaluation of acquired data. Providing both practical and theoretical advice on the principles and application of classical and fiber optic strain gauges and how to correctly measure the strain, the course will also look at the different adhesives and covering agents which can be used in installation. Located at the prestigious Silverstone Wing in Northants, which sits in the heart of Silverstone’s world-famous Grand Prix circuit, this memorable venue combines the glamour and heritage of the home of British motor racing, with stunning designs. And what’s more, participants are invited to join a free Silverstone Racetrack Tour at the end of the seminar! Suitable for all users from all technical fields who would like to install and apply their own classical and optical strain gauges, no prior knowledge is required to participate although a basic knowledge of measurement technology would be useful. Free to attend; with lunch and morning and afternoon refreshments included, spaces are available on a first come, first served basis. Please reserve your spot by booking at www.hbm.com/en/3157/webinars . The HBM Academy trainers have a wealth of knowledge in all aspects of strain gauge measurement and analysis of measurement data and have been successfully training engineers worldwide for many years. HBM has been a leader in strain gauges for over 60 years. Its extensive range allows for an exceptionally wide range of differing strain measurement applications, from experimental stress analysis, durability testing through to transducer manufacturing. Additionally, HBM provides all the necessary accessories and components for the installation of strain gauges, for maximum convenience. HBM also supports its customers with training and contract installation to ensure optimum operational usage. To register for further information on these training courses, contact HBM on +44 (0) 20 8515 6000 or via email: info@uk.hbm.co.uk or visit the HBM website at www.hbm.com/en/menu/seminars/ seminar-calendar/

PROCESS INDUSTRY INFORMER September 2016

NEWS & EVENTS ARC ENERGY RESOURCES ANNOUNCES ACQUISITION OF CLG ENGINEERING Gloucestershirebased Arc Energy Resources has acquired precision m a c h i n i n g company CLG Engineering.

Commenting, group managing director Andrew Robinson, says: “This is a fantastic opportunity, with CLG Engineering’s precision machining capability perfectly complementing our cladding and fabrication offering. I have great plans for future growth, and am looking forward to supporting our clients on new and larger projects.” The acquisition means that Arc Energy Resources’ 80 employees are supplemented by CLG Engineering’s 14, to create a stronger team with a wider mix of skills. Both companies are supported by teams of experienced project managers, inspectors and welding engineers, with access to a wide range of auxiliary processes in-house, including heat treatment, NDT and CMM inspection. Arc Energy provides corrosion-resistant weld overlay cladding services to a variety of clients in the oil and gas, defence, power generation, petrochemical, water and nuclear sectors. CLG Engineering provides CNC milling/turning and assembly services to oil and gas, automotive and rail industries. For further information contact: Arc Energy Resources, Eastington, Glos. Tel: +44 (0)1453 823523 E-mail: sales@arcenergy.co.uk | Web: www.arcenergy.co.uk

JWE ANNOUNCES KEY MANAGEMENT CHANGES THAT BUILD ON SUCCESS The business success that is reported by process line specialists, Jacquet Weston Engineering Ltd. (JWE), is now being reflected in major developments to its management structure.

The company, which has seen a 250% turnover increase since 2011 and has consistently exceeded its sales targets for a number of years, is announcing four key appointments. It demonstrates its willingness to optimise its service both by bringing in new personnel and developing the skills of its current staff. A key appointment sees Chris Romer join the company to take on the new role of Quality and Health & Safety Manager. Seen as a development of JWE’s existing operational structure, his involvement will include overseeing standards and new requirements relating to regulations. The appointment of Steve Harper to the position of Works Manager reflects JWE’s belief in enabling personnel to develop their role within the company. Three years’ ‘hands-on’ shop-floor involvement now sees Steve in a position to enhance the link between manufacturing and management. The company’s design capability has also been enhanced by the appointment of Phil Waters to Design Engineering Manager. The move, which strengthens the established design role, reflects JWE’s advanced design capabilities – such as animation and the latest Finite Element Analysis that focuses, particularly, on stress and loading factors. JWE’s belief in providing career development opportunities is also clearly demonstrated by the fourth personnel appointment being announced – Briony Jordan now becomes Finance Manager. Her commitment to the department has been underpinned by consistent training achievements and her skills in this field are now applicable to every part of JWE’s operation. “We have effectively restructured and reshaped an important tier of management,” says Nick Weston, JWE’s Managing Director, “both to enhance our internal procedures and also, importantly, to develop our services to customers. With both new appointments and promotions from within the organisation we are not only utilising our established skills but adding a new dimension to our capability.” For more information contact Jacquet Weston Engineering Ltd, Hungerford, Berkshire. Tel: 01488 674400 E-mail: info@jweltd.com Web: www.jwtltd.com

APPLICATIONS FIRM AVOIDS £50,000 ELECTRICAL SUPPLY UPGRADE USING ABB DRIVE A £50,000 upgrade to a company’s electrical supply is avoided by installing an ABB drive to reduce the current drawn by a new wood chipping machine.

The installed production machinery at garden and architectural stonework specialist, Haddonstone, was collectively drawing 200 A, and at the limit of the company’s electrical supply. Installing the wood chipping machine, known as a hogger, would add 70 A to the load, exceeding the available supply capacity. Improving the supply to account for the higher power demand would have required the company to install a new transformer costing £23,000. “We would also need to contribute to the connection of the transformer to the external utility supply. It could have ended up costing us anything up to £50,000,” says Haddonstone’s production director Tony Mason. ABB authorised value provider Inverter Drives Systems recommended installing a 45 kW ABB general purpose drive to control the speed of the hogger’s motor. The drive’s improved power factor and peak torque limit function allows the hogger to be run at a slower speed meaning it now only draws around 45 A. This has enabled Haddonstone to run its production machinery – and the hogger - from its existing power supply without the need to upgrade the electrical supply. Running the hogger at a slower speed has also made the operation more efficient. For more information contact ABB Ltd, Tel: 01925 741517 E-mail: layla.hewitt@gb.abb.com Web: www.abb.co.uk/energy

PROCESS INDUSTRY INFORMER September 2016

BOGE COMPRESSOR CLEANS UP FOSSILS AT MULTIMILLION POUND JURASSIC MUSEUM BOGE Compressors has supplied one of its highquality, fully featured compressed air stations for an unusual application at a multi-million-pound museum on Dorset’s Jurassic coast.

The celebrated Etches Collection of around 2,200 fossils will be housed in a purpose-built £4.7 million building in Kimmeridge, which will feature an area demonstrating fossil cleaning and preparation. Visitors can watch the process of air abrading the matrix off of the specimens, which will be completed using BOGE’s C5DR compressed air station. Its small footprint will allow it to be installed easily in the fossil museum workshop, right where it is needed. David Whetlor, director of Poole-based BOGE Platinum Partner Wessex Compressors, explained: “Because the compressor will be on show and sometimes operating during demonstrations, it is important that it looks good and is whisper quiet. The BOGE product is both these things.” For more information contact BOGE Compressors Ltd, Brighouse, West Yorkshire Tel: 01484 719921 E-mail: m.heeley@boge.com | Web: www.boge.co.uk

APPLICATIONS ECLIPSE GUIDED WAVE RADAR CYCLONE LEVEL APPLICATION In addition to their battle to gain the favour of consumers, attaining operational efficiencies has always been essential for brewers. Beer and yeast separation and recovery is one aspect of the brewing process where brewers using separators with cyclones can realize greater efficiencies.

Yeast, the microorganism responsible for fermentation, also greatly influences a beers flavour and character. In the latter stages of beer production, brewers separate the spent yeast from fermented beer through the use of separators. The fermented beer is processed downstream and the spent yeast is processed for resale. Spent yeast is marketed as baker s yeast, as bedding for growing mushrooms, and as an ingredient in ethanol fuel. Since spent yeast is very high in protein and B vitamins, it has traditionally been given to livestock as a valuable feeding supplement. Separators have been essential equipment in beer brewing for decades. They ensure economical operation, a higher quality of beer, and efficient reclamation of beer and spent yeast. Over a period of time, however, a working separator starts to lose its efficiency due to yeast packing, and the bowl of the separator must be discharged of packed yeast. The bowl discharge of the separator is called a “shoot”. The objective of controlling the shoots is to clean the separator bowl of caked yeast and also minimize the amount of beer that is lost when the separator bowl is open. When the separator bowl shoots, it discharges the beer and yeast mixture into the top of the cyclone, tangentially to the sidewall. The yeast/beer slurry decelerates and collects in the bottom of the cyclone. The spent yeast is then pumped out of the bottom of the cyclone by means of a positive displacement or peristaltic pump and enters a yeast decanter or yeast thermalizer. Any beer that is discharged with the shoot is lost. The cyclone also acts as a surge vessel between the separator bowl and the spent yeast storage, located below the pump. When the bowl shoots, additional beer will be discharged with the yeast into the cyclone. Our customer, a major U.S. brewer, had controlled the level in 64 cyclones throughout its breweries by using a competitor s point level capacitance probe. The probe measures high level only and indicates when the cyclone is full of yeast/beer slurry. This was not enough information for the brewer! Magnetrol worked with one of the company’s breweries to prove that continuous level measurements could be made in a cyclone. The Eclipse rod is bent to measure down the sidewall, down the cone at the bottom of the cyclone, and into the discharge piping below the cyclone. By measuring level down to the outlet, the brewer can determine when there is slurry in the bottom of the cyclone and initiating pumping into the spent yeast cyclone. When the level is low, the pump will be stopped. This operation controls the discharge of the cyclone during separator shoots. The brewer was aware that during normal separation of yeast (clarification of the beer), the separator bowl was to remain closed – not discharging slurry into the cyclone. However, the bowl of a separator is sealed by a elastomeric gasket. That gasket is prone to leakage, allowing good beer to be discharged at a low rate into the cyclone. This brewer monitors the cyclone level between shoots of the separator. If the separator bowl seal is leaking, the level in the cyclone will slowly increase. Therefore, by monitoring the level between shoots, the “health” of the separator bowl seal is monitored. Naturally, if beer is wasted by a damaged separator bowl seal, the brewery is sending good beer to waste! If a leak is identified, the separator is scheduled to have the bowl seal replaced. Following that test, it was determined by the brewer that the payback for continuous level measurements using Eclipse GWR would be less than three months a payback calculated by limiting the amount of beer lost in the separation process. Magnetrol now has 64 Eclipse transmitters installed to provide continuous cyclone measurement throughout the company’s breweries. If this brewer can save one tenth of one percent of the beer by utilizing Eclipse GWR, this translates into saving tens of thousands of gallons of beer per year–and that s a whole lot of beer! For more information contact Magnetrol International, Zele, Belgium. Tel: +32 (0) 15245 1111 E-Mail: marketing.magnetrol.be or go to www.magnetrol.com

HIGH-SPEC CHOPPER PUMPS MEET THE CHALLENGE OF HANDLING CONCENTRATED LABORATORY WASTE Solids pumping specialists P&M Pumps have recently secured another significant order for 12 VAUGHAN Vertical Pedestal pumps destined for one of the largest pharmaceutical companies, at their Biomedical Campus site in Cambridge.

These twelve pumps will be vertical pedestal, high-specification Vaughan STPE3P6 models in all 316 stainless steel and CD4 (Duplex Stainless Steel) construction, driven by 7.5Kw motors. This is another example of the effective pumping solutions that P&M Pumps are providing for a wide range of ‘challenging’ process applications in the UK. The installation is part of a completely new pumping system for the campus handling both its foul or domestic waste water and research laboratory waste which is to include corrosive substances and will be extracted then suitably disposed of later in the process. The system features storage and feed tanks which are situated underground and made from HCR (Highly Chemical Resistant) GRP600 grade plastic. The stainless steel material is required due to the concentration of laboratory waste material that will be entering the pumping system. The pumps will be variable speed drive (VSD) which will enable them to handle the varying volumes of liquid within the waste system. Through their experiences at numerous UK waste water treatment and manufacturing sites, P&M Pumps continue to demonstrate that Vaughan Chopper Pumps are an extremely flexible and effective option on the most challenging waste pumping applications. Further information on Vaughan Chopper Pumps is available from; Matt Harvey, P&M Pumps, Sawtry, Huntingdon, UK. Tel: 01487 830123. E-mail matt@pumpmix.co.uk Web: www.pumpmix.co.uk

NETHERLOCKS BRINGS LATEST VALVE POSITION INDICATION TECHNOLOGY TO ASIAN MARKET Valve safety specialist to display Valve Position Indicator at Tank Storage Asia

Netherlocks’ recently-launched Valve Position Indicator (VPI) is now being introduced to the Asian tank storage market. After positive responses from visitors to Tank Storage Germany, StocExpo Antwerp and the ILTA conference in Houston, the VPI will be introduced to the Asian market at Tank Storage Asia in Singapore. The VPI offers a highly reliable way to detect open and closed positions of manual multi-turn valves. Whereas for quarter-turn valves there is a wide range of switch box solutions readily available, getting a reliable signal from multi-turn valves has traditionally proved difficult. End users and valve companies have usually decided to make their own indicators, which were often unreliable and impractical. Although cheap in material costs, these solutions often proved expensive in the long run, due to high installation and maintenance costs and the risk of incorrect signals. The VPI offers the tank storage industry reliable real-time information about the position of manual valves in the field between tanks and loading arms. The product delivers accurate valve configuration information to the control room, allowing operators to verify that all valves are correctly positioned before loading begins. The VPI ensures that wrong (off) loading operations, product spills and product contamination are avoided. Tank Storage Asia takes place on 27-28 September at the Marina Bay Sands, Singapore. Visitors will find Netherlocks on stand B33. For more information contact Netherlocks Safety Systems BV, Tel: +31 (0)172 427 851E-mail: rbarendregt@netherlocks.com Web: www.netherlocks.com

PROCESS INDUSTRY INFORMER September 2016

APPLICATIONS AXION’S LABORATORY-BASED PROCESS DEVELOPMENT PROVES ‘IDEAS CAN WORK’ Axion Consulting’s expertise in laboratory-based process development and optimisation work can help turn clients’ recycling concepts into commercial reality, contributing to the recovery of valuable resources within the Circular Economy.

A great example of this is the collaborative RECOVER R&D project with fuel cell components manufacturer Johnson Matthey Fuel Cells Ltd and nonwoven materials manufacturer Technical Fibre Products. The project was cofunded by the UK’s innovation agency, Innovate UK. Axion’s specialist team developed a financially-viable process to separate and recover the high-value platinum and polymer materials from fuel cell membrane electrode assemblies (MEAs) that has moved the closed-looped recycling of these components further forward. The polymeric membrane conducts protons but is impermeable to electrons; this facilitates the electrolytic reactions of the fuel cell, allowing the creation of electrical current. “We’ve demonstrated a viable process that we developed ourselves from just an idea,” explains Sam Haig, Axion’s Senior Engineer. “Having proven the pilot-scale process, for which a patent has been applied, we are very confident that it can be scaled up to potential industrial scale very easily.” The ‘process journey’ involved many stages requiring exhaustive testing and evaluation before arriving at the successful pilot scale solution. “What differentiates us from others is that we not only understand the chemistry but also have in-depth technical knowledge of the mechanical and solid separation steps that are often needed for these kinds of processes,” he continues. “We can come in at virtually any stage; whether it’s a problem that needs a solution and then testing, or a client that has a solution but doesn’t have the facilities to take it further.” Axion’s work on a number of projects for hazardous waste management company Augean has also delivered ‘excellent results’, according to Group Development Director Martin Snaith. For more information contact Axion Consulting, Bramhall, Cheshire Tel: 0161 426 7731 E-mail: info@axionconsulting.co.uk | Web - www.axionconsulting.co.uk

PROCESS INDUSTRY INFORMER September 2016

WELDING ESAB LAUCHES REBEL, A MULTI-PROCESS WELDING SYSTEM THAT PROVIDES INDUSTRIAL QUALITY ARC PERFORMANCE IN A COMPACT & PORTABLE PACKAGE ESAB recently introduced the Rebel EMP 215ic, a 120V-230V, CC/CV welding system that offers true multiprocess arc performance, location flexibility, lightweight portability and a groundbreaking operator interface. A unique sMIG (“smart

MIG”) function enables users to begin MIG welding – with an extremely stable arc – just by setting metal thickness and wire diameter. Unlike competitive units, there is no need to enter information for shielding gas mix. The Rebel provides an industrial quality arc for MIG, flux-cored, Lift TIG and Stick welding, including excellent performance with difficult-to-weld E6010 electrodes. In fact, ESAB encourages side-by-side weld test comparisons and believes that the Rebel will provide a superior experience for welders of all skill levels. The Rebel has two operating modes, Basic and Advanced, that make welding easy for beginners or lets those with more experience fine tune parameters. Operators interact with the Rebel using a unique control that combines traditional weld parameter adjustments with the functionality of a smart phone (in fact, the 4.3-inch color display uses the same thin-film transistor (TFT) LCD technology found in smart phones). No other welder combines this level of simplicity, performance and control. ESAB offers two Rebel models. The full-featured Rebel EMP 215ic offers all of the capabilities noted above. The Rebel EM 215ic provides MIG, sMIG and flux-cored welding outputs and features a more traditional interface with digital meters (coming soon). Available on the European market, the Rebel’s interface can be set for 22 different languages. functions.

For more information contact ESAB Group (UK) Ltd, Upshire, Essex. Tel: 0800 3893152 | E-mail: info@esab.co.uk | Web: www.esab.com.

CHANGE MANAGEMENT: MAKE THE CHANGE by Andy Archer, Regional Vice President, Epicor Software, UK and Ireland

The manufacturing industry in the UK is no stranger to change and the need to be flexible and responsive has never been more apparent than in our current climate as we enter a withdrawal period from the EU. Some commentators have stated that Britain’s exit could result in opportunities for its manufacturers, proposing that a drop in the value of sterling could make the UK a magnet for trade and the need to reshape trade policy may result in quicker decision making and reduced red tape.

egardless of what’s happening at home international industry pressures can be a force to be reckoned with, the macro-economic climate has significant input. However, if adventurous companies view these macro-economic changes as opportunities, whilst their competitors are looking inwards and being cautious, they can react faster to sector trends and outperform their competitors. Of course the ability to be adaptable and responsive is heavily reliant on companies having effective technology in place to facilitate this kind of flexibility.

GROWTH MEANS CHANGE Epicor undertook a survey into growth last year, which demonstrated just how many business leaders were concerned about the impact that growth had on their business. Half (48%) said they worry that business growth puts excessive pressure on operations, damaging quality and customer satisfaction. A substantial number of businesses (42%) were also concerned that their business IT systems may prove unable to cope with managing a larger, more complex, business model. To support business growth, and prepare for its challenges better, 79 percent of businesses believe that an effective and integrated IT infrastructure is essential. Echoing the Epicor research, the Annual Manufacturing Report 2016 revealed that ERP systems have been given top priority by the highest number of companies this year (25%), followed by upgrading IT infrastructure (16%) and manufacturing execution systems (11%). Enterprise Resource Planning (ERP) is a fundamental part of the IT infrastructure supporting growth. Today, it is used as far more than a transactional tool. UK manufacturers use ERP to gather data throughout production, analyse machine performance, gain efficiencies in design, review and improve production processes and manufacturing. The reinvention of business processes in the industry has eliminated wasted time and focussed on creating huge productivity improvements. ERP can also be vital in managing workforces effectively through transition periods. During times of expansion it is inevitable that additional pressure can be put on staff and ERP can effectively highlight where additional resources may be needed, prepare teams for periods of intense production and provide employees with the reassurance that management understand the wider impact that their company’s transition may have. Managing change is a constant, ongoing process that needs to start from the very beginning and continue throughout the implementation to the end-user training for all relevant staff.

MANAGING THE CHANGE

result in organisational resistance to the new system, even to the point of operational risk.

Business expansion and digital transformation is positive, but can bring with it the problem of a complex web of IT systems, old and new, operating in silos and preventing an end-to-end view of the business that is so crucial to true productivity. Consequently, whether change comes through acquisition, merger, planned or unplanned growth, it is often followed by improvements in IT and ERP systems. This change needs to be managed effectively. As we implement ERP systems for small and medium-sized manufacturing operations up and down the country, we see that the introduction of these systems can be the most visible sign of change for a large part of the workforce.

C-SUITE BUY-IN It is important to gain broad organisational support during all phases of the project. A distinguishing trait of the best-in-class ERP implementations we see is that they have the full commitment of the company’s executives. Without this support, IT initiatives are more likely to be “starved” for corporate funds and resources. IT initiatives often begin with the CIO or IT director, but the buy-in of the CEO, CFO, and other C-level executives is critical.

PLANNING EQUALS SUCCESSFUL IMPLEMENTATION In addition, planning should begin during the earliest project phases. Companies get excited about the benefits of implementing ERP and want to “dive in” without a fully developed plan. The project plan should have time built into it for defining requirements, key performance measures, and vendor evaluation and selection. The best plans have buffers built into the schedule to account for activities such as testing, data migration, and unforeseen events that occur in every implementation. Companies that invest in comprehensive, upfront planning often experience shorter implementation times and spend less money overall than their peers.

EMPLOYEE BUY-IN Changing business processes can cause changes in familiar workflows for people throughout the organisation, whether they are directly involved in the project or not, and this process must be managed for the workforce. Employees need to be introduced to new processes and job roles over a period of time so that they can accept and internalise these developments. Neglecting this aspect of implementation or putting it off until late in the project may

CONTINUAL EVALUATION Finally, the establishment of regular reviews with the executive team or the project steering committee is critical to keep them informed about project progress. Changes should be made to achieve a strategic goal, whether that goal is operational effectiveness, improving customer service or simply cost management. Whatever change an organisation is required to effect, thoughtful planning, effective communication and employee acceptance will lead to successful change. Through investment in innovation, reinvention of business processes and the right change management processes, the future holds plenty of potential for UK manufacturing. We may not be the ‘workshop of the world’ in terms of churning out huge volumes of products, but our success lies in how we use skills and technology to create sophisticated, world-class products and services.

AN EXAMPLE: HAYWARD TYLER LTD: BUSINESSCHANGING TRANSFORMATION Hayward Tyler designs, manufactures and services fluid-filled electric motors and pumps for high-pressure, high-temperature applications and environments across the global energy sector. Last year they won an Epicor customer award in the category of business transformation, sharing a story of true business transformation. Keith Herring, Head of IT, at Hayward Tyler, explains:

“In 2013, we were close to going out of business. We had almost £1 million in warranty claims and in some cases were over 170 days late delivering customer orders. However, through a dedicated turnaround team who galvanised the whole company and introduced systems to succeed and deliver for our customers, the turnaround was immediate. “Among other initiatives, the turnaround team created the environment for Continuous Improvement, cleansed our ERP source data and ‘Leaned Out’ our processes, most importantly we engaged the whole workforce. We also upgraded our software to match our new methods of working. We saved jobs and allowed the business to grow and expand, celebrating our 200th anniversary in 2015, and remaining in a successful position in 2016. Being recognised by our peers with the award was a true reward for all the hard work every employee inputted into the turnaround process, it meant a lot to us all.”

PROCESS INDUSTRY INFORMER September 2016

MEETING THE INDUSTRIAL HEATING CHALLENGE By Rob Shuttleworth, chief executive of UKLPG There is a quiet revolution going on in industrial Britain, as businesses look to meet their heating requirements in a range of industrial applications.

rom firing furnaces and kilns at the optimum temperature in metal processing to powering industrial ovens that bake the perfect crunchy biscuit, there is a fundamental need for an affordable, efficient and environmentally friendly fuel source to keep the production lines moving. Whereas businesses in towns and cities have a number of fuel sources to choose from, those located off the gas grid have fewer alternatives and hence need to consider their options more carefully. It is true that energy consumption levels among manufacturing businesses have fallen considerably during the past three or four decades, with industry losing its crown as the highest energy user to the transportation sector. However, it still accounts for one of the most significant areas of cost for the majority of industrial businesses – especially those with heat-intensive processes. There is also constant pressure on this sector to reduce emissions and, with many organisations having exhausted their energy efficiency measures, the only option is to find a cleaner heating source. Renewables have enjoyed much of the limelight when it comes to clean energy, however, they don’t suit all environments and need to be assessed in terms of reliability for the type of applications they will be required to support. For industrial applications, security of supply is paramount and can sometimes rule out a renewable solution. With much-publicised constraints on the availability of electricity to service future energy needs, gas is becoming an increasingly popular solution for servicing businesses with high heat demand. The rise in energy efficient technologies to deliver gas across a range of industrial applications and growing interest in onsite generation to improve resilience means that LPG (liquefied petroleum gas) usage is attracting a growing number of advocates. Indeed, it comes as no surprise to hear our membership of LPG suppliers is currently reporting a surge in demand, with many citing as much as a 50% increase. For some time, LPG has been quietly delivering carbon reduction and improved cost efficiencies in a range of industries, from food manufacture and processing to kilns and furnaces, but with new drivers affecting businesses’ choice of energy, LPG is being heralded as the ideal solution. For off-grid locations that need a reliable, convenient and clean fuel source it can have a transformational impact. LPG has a low carbon to hydrogen ratio, which means that it

will generate lower amounts of CO2 while producing the same amount of heat as alternative options. It also has a comparably high heating value, which means that it contains more energy per kilogramme than most competing fuels, making it ideal for companies with a high energy usage.

BUT WHY ARE SO MANY BUSINESSES MAKING THE SWITCH NOW? The benefits and cost savings delivered byLPG have been welldocumented for some time, so there must be other factors at play. Alongside cost, legislation is often the other key driver for changing behaviours among businesses; and it is certainly driving the current trend towards fuel switching. Last September the EU’s Energy-related Products Directive (ErP) came into force, mandating that all heating and hot water products with heat outputs between 70 and 400kw are as energy efficient as possible. This new upper limit has meant that this directive now applies to commercial boilers that were not previously included. With few oil boilers available that meet the efficiency requirements and the upgrade work required to make existing boilers compliant, oil is fast losing its appeal as a long-term solution and businesses are starting to look at other viable alternatives. Electricity may be heralded by some as the solution, but the infrastructure required to meet the growing heat and energy needs of our manufacturing base has the potential to gridlock the UK landscape – literally. Grid connections are in short supply and the investment in new generation to replace decommissioned power plants is undergoing a period of uncertainty. Consequently, it is now widely accepted that gas will be a key part of the future energy mix and, as a highly flexible, low-carbon fuel source, LPG is already delivering both costs savings and energy efficiencies to thousands of diverse manufacturing businesses. When a leading UK packaging manufacturer wanted to reduce both its costs and carbon emissions they decided to make the switch to LPG. Unlike many other infrastructure projects, the benefits were visible within a matter of weeks. After just two months, their fuel costs were reduced by £42,000 and their carbon footprint was down by almost one third. Compatibility is also a big part of the increase in demand. In

short, LPG is the right tool for the job in many industrial processes. For example, it is widely used in many food processing systems because its clean burning properties deliver a higher quality product, particularly in baking. In metal processing, where some heat treatments require a highly controlled atmospheric environment, LPG-powered furnaces help to create a higher quality end product.

A VARIETY OF OPPORTUNITIES... The applications are so diverse and LPG is often found in the most unlikely places. When a new microbrewery was being established in Ireland, finding the right fuel source to power the steam boiler, which would boil the malted barley – and heat the premises – was a key challenge. Following a survey of the options available in this rural, off-grid location, LPG came out on top in terms of cost, efficiency and environmental impact. For this fledgling business, the option to use LPG significantly reduced operating costs. The consistency of product quality is vital and never more so in food manufacture where the risk of produce being tainted during the drying process is especially damaging for high-value crops such as herbs. Not only does LPG dry the crops perfectly, ensuring that yield is optimised, but as a multi- purpose fuel, it also powers all of the other commercial and industrial applications on site and minimises the risk of food products being contaminated by soot and other pollutants. Many companies with sites on the gas grid are looking for comparable systems for their sites that are located off the gas grid to ensure consistency of manufacture across the board. LPG behaves in an almost identical way to natural gas making it a valuable part of their multi-site energy mix. With the capability to cut carbon emissions, deliver cost savings, enhance production and energy efficiency for industrial businesses, it is clear to see why more and more businesses are choosing LPG. This has been further spurred on by the regulatory obligations impacting on commercial boiler usage making LPG a more energy efficient and cost efficient choice. Having spent almost two decades in the LPG market, I am proud to see it being recognised as an increasingly significant part of the energy solution for so many businesses.

PROCESS INDUSTRY INFORMER September 2016

NETWORK & COMMUNICATIONS FUTURE-PROOF CABLING FOR INDUSTRY 4.0 FACTORY UPGRADES HARTING Ltd today announced the latest developments in its support and advocacy for the ‘Industry 4.0’ initiative. This rapidly growing

movement is driving the trend towards the so-called ‘Smart Factory’ which is enabled by the connection of the real and virtual world with sensors and actuators interfacing to The Cloud via the Internet. New equipment to support this integrated industry approach needs to be compact, robust, modular and quick and easy to use. It also needs to be installed in a distributed and decentralised manner, and connected to the three Industry 4.0 lifelines of Power, Signal and Data. The latest additions to HARTING’s range of robust connector solutions provide support to these Industry 4.0 lifelines. However they also go one-step further by providing an installer user-friendly termination design option for the key Data lifeline. Thi preLink ® assembly concept is available in industry standard M12 and RJ45 connector styles. In many cases, Smart Factory solutions need to be integrated into an existing factory automation control system and its associated cabling infrastructure. preLink ® allows systems integrators/installers to achieve seamless data cabling integration to such an environment through its simple and repeatable, installer friendly assembly design principle. This requires no additional skills or training and allows greater installation flexibility, saving time to minimise installation cost. The preLink ® design concept is based around using a one-step double-jaw hand press-assembly tool, terminating individual wires within an IDC terminal block. The terminated module can then be simply loaded into either an RJ45 (male or female) or M12 male connector carrier and then parts click together to complete an assembly. preLink ® also permits future site cabling modification upgrades at minimal cost. The low cost plastic IDC terminal block modules can easily be removed from the reusable connector carriers and placed into new connectors. preLink ® supports Fast, Gbit and 10Gbit Ethernet in both RJ45 and M12 style connectors. For RJ45 connections, HARTING also offers preLink ® Extenders enabling simple cabling extensions, maximising installed flexibility. Where installations allow pre-defined cabling lengths, HARTING can provide pre-terminated end-to- end preLink ® terminal block patch leads. These can be very easily fed through trunking-runs in tight, difficult spaces before being quickly hand inserted into appropriate connector carrier-ends, alleviating time-consuming field assembly cabling.

For more information, please contact John Law (EC Product Manager) at HARTING’s Northampton sales office on 01604 827500 or go to www.harting.co.uk

HARTING’S MICA RUGGEDISED COMPUTER NOW AVAILABLE HARTING has announced the UK commercial availability of its ruggedised computer, CA (Modular Industry Computing Architecture). The

device was displayed for the first time in the UK at the ‘Drives and Controls’ show in April, and is now fully supported by HARTING Ltd for commercial use. The HARTING MICA ruggedised computer provides a platform for system integrators and software developers who need to deploy bespoke software applications to manage systems. It uses a LINUX operating system to provide a secure, stand-alone infrastructure needed in industrial and other demanding applications. MICA is installed in the ‘Rinspeed Etos’ concept car displayed on the HARTING stand (visited by Germany’s Chancellor Angela Merkal and President of United States of America, Barack Obama) during the Hannover Messe event in April. The car was also displayed at the Geneva motor show in March to great acclaim. Rinspeed uses a HARTING MICA for emissions and status monitoring. The Rinspeed Etos then transmits this data gathered by the MICA device to a neutral 3rd- Party (Dekra), for independent analysis. This illustrates how the Internet of Things could be used more widely in the future to monitor and evaluate emissions and performance data in real-world driving conditions. This same technique could also be applied to a range of other industrial and logistical equipment to help monitor performance and maintenance. Gavin Stoppel, Product and Applications Manager at HARTING UK, said; “Companies deploying large scale automation solutions using ‘Industrial Internet of Things’ networks and distributed control systems need this type of device. Ruggedised computers are a key element in delivery of Industry 4.0, and since we showed MICA at ‘Drives and Controls’ we have had a lot of interest in it from companies working on various applications, especially RFID and performance monitoring.” For more information about HARTING’s new range visit www.harting.co.uk/MICA Or contact HARTING Limited, Northampton, Northamptonshire. Tel: +44 (0) 1604 82750 E-mail: gb@harting.com

SOLIDS HANDLING & PROCESSING SPIROFLOW ANNOUNCES HYGIENIC HEAVY DUTY CHAIN DRAG CONVEYOR FOR THE FOOD INDUSTRY In response to the ever increasing needs of the food industry, Spiroflow has launched the new Chainflow tubular chain drag conveyor. The hygienic heavy duty, totally

enclosed, dust-free chain drag conveyor economically conveys dry powders and granules particularly fragile materials such as coffee beans, cereals, specialty breakfast cereals, nuts, dried fruit, grains, dry soup mix, confectionery, small cookies, baby formula powder, pet food, animal feed, and more. Processors can easily convey or batch ingredients with the crevice free design. Chainflow is a tubular drag conveyor that, by definition, is configured in a loop or circuit. Ultra strong 304 or 316 stainless steel chain is fitted with moulded UHMWPE discs. It provides maximum chain life while gently moving fragile products through a homogeneous crevice free conveying path. The conveyor has a drive assembly at one end of the circuit and a return housing, fitted with an automatic tensioner, on the other end of the circuit. Processors can achieve intricate layouts with multiple inlets and outlets in complex three plane circuits. Chainflow components are designed for hygienic applications. The conveyor can be cleaned in place and is engineered to run 24/7/365. Chainflow delivers fast and efficient conveying with capacities up to 10.5m3/hour (370 ft3/hour). Processors can convey over long distances with maximum straight line lengths of up to 76m (250 ft) per conveyor and link multiple conveyors for longer distances. The conveyor can typically run empty, be stopped and started under load, and flood or meter fed for operational flexibility. ‘We saw a very specific need in the food industry and the Chainflow conveyor is an important addition to our product line,’ explains Spiroflow’s Sales Director James Podevyn. He adds, ‘Our goal has long been to provide the widest range of mechanical conveyors for dry bulk solids and ingredients so that our engineers can evaluate our customers’ needs objectively and provide the ideal conveyor for their applications.’ See Chainflow in action. Spiroflow is a global leader in powder handling for process industries and an emerging leader in control systems integration. Throughout our 45-year history, our design engineers and process automation team have provided customers with the safest, most efficient, innovative and most reliable process solutions available. We were an early inventor of the flexible screw conveyor, but we’ve grown significantly since those early days as have our products and service offerings. Spiroflow delivers engineered solutions designed to solve your greatest powder handling and processing challenges, whether it is a single conveyor or a complete powder handling system with integrated controls. With our flexible screw, Aeroflow ® aero mechanical, Cableflow ® cable drag, Chainflow™ and Dynaflow ® chain drag conveyors, hands down, we offer the widest range of mechanical conveyors for dry bulk solids and ingredients. We are also known for our expansive line of Spirofil ® bulk bag fillers, bulk bag dischargers, control systems, bulk bag conditioners, customized hoppers, bin activators, and bin, bag, box and drum emptiers, as well as end-of- line robotic palletizing solutions. Primary markets include: the food, dairy, snack food, confectionery, beverage, pet food, pharmaceutical, packaging, industrial, chemical, plastics, minerals, cement, environmental, waste, and recycling. To learn more visit Spiroflow’s website www.spiroflow.com E-mail sales@spiroflow.com or call +44 (0) 1200 422525

PROCESS INDUSTRY INFORMER September 2016

UV SYSTEMS HANOVIA’S PURELINE UVEO UV SYSTEMS ARE SPECIALLY OPTIMISED FOR FOOD & BEVERAGE APPLICATIONS Hanovia’s PureLine Ultraviolet Energy Optimised (UVEO) medium pressure UV system uses up to 60% less power than conventional UV systems with just a single UV lamp. This delivers a guaranteed, consistent UV dose with reduced life cycle costs for the food, beverage and brewing industries. Energy and cost reductions

Building on Hanovia’s 90 years’ experience in UV treatment, the PureLine UVEO takes advantage of an optimised hydraulic design to provide up to 60% improvement in the treatment capacity over conventional medium pressure UV systems. This means reduced running costs without compromising on bio-security. A prime benefit is that treatment is performed with just a single medium pressure UV lamp, eliminating the need to install a bigger system with multiple lamps at higher flows. This saves on up front capital costs and lifetime spares costs. The system utilises a smart control system that reads the process water conditions using flow, transmittance and chlorine sensors to control the electronic ballast with ‘stepless’ power, which can then automatically adjust the power from 100% to 30%. This feature helps increase the life of the medium pressure lamp and provides further savings on power costs. Designed for the food and beverage industries

PureLine UVEO systems come in three ranges: •The ‘H’ Edition is designed specifically to meet the highly stringent food, beverage and brewing industry regulations. All wetted parts use food grade-approved materials, while a UV chamber with a high specification internal finish is available if required. •The ‘Standard’ edition, which provides required levels of disinfection and prevents downstream contamination before reverse osmosis (RO) filters and at the point of use. •The ‘Dechlor’ edition, based on either H or Standard chamber designs, which provides guaranteed levels of dechlorination coupled with strong disinfection to protect downstream processes such as Reverse Osmosis (RO) from premature aging and biofouling. Medium pressure UV lamps provide the highest possible UV output at the specific wavelengths required to destroy microorganisms. Medium pressure UV is especially effective against chlorine-resistant pathogens such as Cryptosporidium and Giardia. Reduced reliance on chlorine helps protect downstream contamination of filters early on in the water treatment process. Medium pressure UV is also very effective at removing ozone from process water, ensuring product quality before bottling. UVEO technology provides the food, beverage and brewing industries with optimised UV systems in line with requirements. The PureLine UVEO’s chamber size, lamp power and control systems have been tested to ensure not only that high levels of process water disinfection are achieved, but also that green initiatives are met by lowering power consumption. Safe, easy maintenance

The PureLine UVEO is provided with Hanovia’s patented ‘UVGuard’, which allows safe checking of the UV sensor (performance monitoring instrument) using a unique ‘eyelid shutter’ design, which protects the operator from exposure to UV light. The UV system is available in a range of sizes and treatment capacities to meet typical process requirements. It is designed for easy installation into existing pipework and can be fitted with an internal auto-wiper which maintains UV output efficiency by regularly cleaning the quartz sleeve housing the UV lamp. Lamp replacement is also quick and easy, with the system designed to allow easy access, even in small plant rooms. For more information contact Hanovia Ltd, Slough, Berkshire Tel: +44 (0) 1753 515300, Fax: +44 (0)1753 515301 E-mail: gunvinder.bhogal@hanovia.com | Website: www.hanovia.com

PROCESS INDUSTRY INFORMER September 2016

PROCESS MEASUREMENT

& INSTRUMENTATION

DON’T GET IN A FLAP ABOUT FLAP SWITCHES Flap switches are often unreliable, wear out and break down, with consequences that can disrupt production and cost money. Pulsar’s PulsarGuard 2010 is a robust, non-invasive sensor with no moving parts that mounts easily to the outside of the process pipework and gives either a simple flow/no flow signal or a flow rate indication for solids, granules and powders. Maintenance-free and non-wearing, PulsarGuard 2010 is a sophisticated device that harnesses Pulsar’s world-leading acoustic engineering expertise. The PulsarGuard 2010 offers reliable acoustic impact detection and, apart from flap switch replacement, can detect filter bag bursts, warn of impending blockages or pump cavitation, and indicate bridging or ratholing in silos. It can also be used to check on correct valve operation or warn of bearing failure. Completely non-invasive, PulsarGuard 2010 simply bolts to the exterior of the process, and Pulsar’s highly sophisticated acoustic algorithm separates the sound of process material transmitted through the structure from other process noise and vibration. A 0-10V output signal proportional to flow can be fed directly to the DCS or converted to alarm or control relay function through an interface. The standard sensor is part of a range that includes high temperature and hazardous area versions. For more information contact Pulsar Process Measurement Ltd, The PulsarGuard 2010 ‘listens’ for Tel: 01684 891371 material flow and provides a flow/ E-mail; info@pulsar-pm.com no flow alarm or flow rate indication Web: www.pulsar-pm.com

ECONOMICAL ONLINE PROCESS METERS FROM SENSOREX MEASURE pH, ORP, OR CONDUCTIVITY TX-

Control mass flow & pressure better. Save time, reduce costs. • Fast, accurate mass flow measurements and 50-100 ms control mean improved outcomes — increasing pride. • Ease of use without a PC saves time, which soothes frustration. • Multivariate control and readings reduce process complexity and cost, making you happier.

Alicat: “The fastest flow controller company in the world.” ™ With offices in UK:

Phone: + 44 (0)1223 472804 Email: europe@alicat.com

and CX- models direct fit alternatives for discontinued Eutech Instruments equipment

Sensorex has expanded its family of water quality and online process transmitters, adding four new models to provide basic monitoring and control. The TX10 pH/ORP and CX10 Conductivity and transmitters offer simple monitoring, while the TX20 pH/ORP and CX20 Conductivity controllers can also be programmed for process control. These small-footprint panel-mount transmitters provide reliable data and control of process fluids, in a cost-effective package. Applications include water quality, chemical, electronics, food production, environmental and wastewater treatment. The TX10 measures pH or ORP and temperature. The CX10 transmitter measures conductivity, resistivity, and temperature. Both provide convenient local display of values and easy access to calibrate online process sensors. The primary measurement 4-20mA signal output can be integrated into a range of process control systems. The TX20 monitors pH or ORP, with temperature compensation for accurate measurement and control. The CX20 monitors conductivity or resistivity, also with temperature compensation. Both provide local display of values with relay output for alarm or control of process conditions ideal for use with chemical feed systems. All four models are simple to operate, with push button interface and clear LCD displays. They are designed to save panel space with a small footprint 1/8 DIN enclosure. The devices are 100-240 VAC line-powered. • Sensorex TX10 replaces Eutech Instruments pH 190 • Sensorex CX10 replaces Eutech Instruments Cond 190 • Sensorex TX20 replaces Eutech Instruments pH 200 • Sensorex CX20 replaces Eutech Instruments Cond 200 To learn more about the Sensorex family of process instruments, visit www.Sensorex.com, emailinfo@sensorex.com or phone +1 714-895-4344. *Eutech Instruments is part of Thermo Fisher Scientific Inc. No affiliation, endorsement or sponsorship is stated or implied

PROCESS INDUSTRY INFORMER September 2016

4000 SLPM MFC

mass flow controllers mass flow meters pressure controllers

http://alicat.com

PROCESS MEASUREMENT

& INSTRUMENTATION

ALL THE BENEFITS OF RADAR LEVEL MEASUREMENT FROM ONLY £360! Introducing the new Micropilot FMR10 Endress+Hauser’s new Micropilot FMR10 free-space radar offers all the benefits of non-contact radar level measurement at a fraction of the cost. From only £360, our new Micropilot FMR10 radar device offers reliable continuous level measurement in a multitude of applications such as storage tanks, open basins, pump stations and utilities. Save time and money

Micropilot FMR10 features Bluetooth wireless technology, meaning you’ll save time, energy and costs with simple commissioning, operation and maintenance via our free SmartBlue app (available for Android and iOS devices). Signal curves can be displayed on any Bluetooth-enabled smartphone or tablet. More punch for your pound

With its compact design (only 140mm tall) and wireless remote access, Micropilot FMR10 is easy to install in difficult-to-access applications with limited space e.g. stormwater basins, wet wells or pump chambers. And there’s more… not only does its full PVDF body guarantee a long sensor lifetime but also its hermetically sealed wiring (including 10m cable) and fully potted electronics eliminate water ingress (IP66 protection) to offer even more punch for your pound! For more information contact Endress + Hauser Ltd, Floats Road, Manchester Tel: +44 161 286 5034 E-mail: lisa.rothwell@uk.endress,com Web: www.uk.endress.com

SENSOREX FAMILY OF TRANSMITTERS FOR pH, ORP & CONDUCTIVITY MONITORING Cost-effective monitoring to meet a range of process challenges

Sensorex’s family of online process transmitters offers a range of options from basic monitoring to advanced digital communication. The TX and CX transmitter families eliminate overspending on overly sophisticated models, allowing end users to choose just what fits their application needs–from local display of effluent pH, or controlling boiler condensate, to networking a group of water disinfection ORP loops. For the most sophisticated functionality, the TX2000 and CX2000 Intelligent pH/ORP and Conductivity Transmitters have an advanced user interface. The large backlit display features easy-to-navigate text and graphic illustrations, supplied in a compact NEMA 4X/IP65 enclosure. The optional -RS models offer additional display features including data charts and trend graphics, a real-time clock with logbook function, and advanced serial RS-485 MODBUS RTU or ASCII communications for digital interface to plant SCADA or DCS control systems. The TX3000 and CX3000 pH/ORP and Conductivity Transmitters are no-frills workhorses, delivering great value. Line-powered, they are easily user-programmed for online measurements with dual 4-20mA current outputs and two adjustable alarm or control relay contacts. A large backlit LCD screen displays both the measured parameter and temperature, and easily delivers results to automated process control systems. For end users needing simple local indication of pH values and easy access to calibrate online process sensors, Sensorex offers the TX100 Loop-powered pH Transmitter. This budget-friendly unit features an array of user-selectable options, as well as an isolated output and a multitude of mounting options. When these transmitters are paired with Sensorex’s process pH or ORP sensors with easy-to-clean flat surface technology, or one of a broad range of conductivity sensors, the resulting system provides treatment plant operators with unmatched analytical tools. To learn more about Sensorex’s full range of transmitters, visit www.Sensorex.com, emailsales@ sensorex.com or phone +1 714-895-4344.

PROCESS INDUSTRY INFORMER September 2016

PROCESS MEASUREMENT & INSTRUMENTATION ABB INTRODUCES MEASUREMENT CARE SERVICE AGREEMENTS FOR PROCESS PLANTS ABB creates new cost-effective set of instrumentation and analyser maintenance service agreements for process plants

ABB creates new cost-effective set of instrumentation and analyser maintenance service agreements for process plants ABB Measurement and Analytics has introduced a new set of service agreements aimed at helping process plant operators to maximise the performance of their installed instruments and analysers throughout their working lifetime. Called Measurement Care, the service agreement bundles tiers of maintenance services tailored to the particular needs of a plant. ABB’s customized service agreements for plant instrumentation and analyzers help secure long-term peak performance, minimize unexpected plant downtime, and provide realistic budgets. The Measurement Care modular service arrangement incorporates three maintenance service categories: Rapid Response, Lifecycle Management, and Performance Improvement. Rapid response includes timely technical support and swift workshop repairs. Lifecycle Management offers spare parts recommendations, regular inspections, and preventive maintenance. Performance Improvement monitors asset conditions on site or remotely using data to predict maintenance needs and optimize operations. Measurement Care service arrangements offer competent and affordable maintenance solutions to keep processes and plants running at optimum levels. For more information, email enquiries.mp.uk@gb.abb.com or call 0870 600 6122 ref. ‘Measurement Care’

PROCESS INDUSTRY INFORMER September 2016

FLUKE INTRODUCES CUSTOM CHEMICAL METROLOGY PACKAGES Fluke is customising a package of instruments and HowTo guides for the chemical industry. There are individual packages for maintenance personnel, reliability engineers, instrument technicians, and electrical and mechanical engineers.

The guides cover areas like preventive maintenance, safety and power quality. The Fluke HowTo guides can be downloaded from goo.gl/R1LKkZ

Accurate metrology is central to improving chemical processes. Just inspecting the process outputs is too late – things will already have gone wrong. Manufacturers need to continually inspect their processes to know that they are running smoothly. Every stage needs attention: from pre-treating raw materials, converting them with a reactor, cracker or kiln, to mixing and purification. For effective inspections reliable test tools are needed, for calibration, installation, testing, reliability analysis and preventive maintenance. Manufacturers need stable, continuous operations at highest efficiency and safety levels. For this, a good understanding of the potential issues and the most suitable metrology methods is required, and the instruments used must also be rugged enough for demanding chemical processing environments. For more information contact Fluke UK Ltd, Tel: 0207 942 0700. E-mail: industrial@uk.fluke.nl Web: www.fluke.co.uk

TAKING THE TEMPERATURE OF THE PROCESS INDUSTRY By Chris Roberts - Application Consultant Pressure & Temperature with Endress+Hauser Temperature is one of the most common points of measurement in process automation and is often the most critical in terms of safety, product quality and efficiency across a wide range of industries. In todayâ&#x20AC;&#x2122;s marketplace there are many device styles to choose from, ranging from basic sensors and bimetallic gauges through to complex control systems operating on bus networks. Selecting the correct instrument for an application can be daunting with so many alternatives available. The best products will provide a stable, accurate, fast and reliable measurement, combined with a robust and high-quality build as well as an easy-to- use, intuitive operator interface.

any low-cost systems using long-standing technologies are effective in basic applications where few process stresses are present and low performance is accepted. However, with recent high levels of advancement and development in temperature measurement technologies, many traditional style components are being increasingly outperformed by their modern counterparts (especially in terms of response speed and ease of calibration, two of the biggest problems faced by operators). The consumer benefits that were motivators to select an instrument yesterday are expected as standard today, increasing demand for higher-performance products with fresh developments. These newer, groundbreaking designs are quickly absorbed and utilised by the marketplace to help provide a more efficient automation process and help maintain optimum performance in process automation.

ELEMENTS For process control purposes, the traditional methods of an RTD (Resistance Temperature Detector) or thermocouple element are still a best-fit solution. RTDs rely on the linear relationship between the electrical resistance of a metal and its temperature (known as thermal resistivity) to produce a signal that can be interpreted as a temperature reading. As the temperature of a metal heats or cools, the electrical resistance will raise or lower simultaneously and measurement of this resistance, cross-referenced through recognised standards, can be interpreted as a temperature. There are two main styles of RTD element commonly used in process measurement. The first takes the form of a wire wound platinum element (where a length of resistive wire is formed in a helical shape around a ceramic body) and the second comprises a thin film element (where a thin resistive platinum coating is applied to a flat ceramic substrate). Development of the latter design has led to higher performance in response times and vibration resistance, making it the preferred style to date. In both designs, the element legs are then extended away from the point of process for measuring purposes. Conversely, thermocouple sensors simply use two different types of metals in cable form connected together. This point of connection (the hot junction) is placed at the process measurement point while the extended leads are terminated away from the process (the cold junction). When the temperature at these two points differs, a small voltage is generated (known as the Seebeck effect) and as the temperature differential changes so does the voltage in a near linear manner. In this way the measured voltage can be interpreted as a temperature. Either the extended RTD cables or the thermocouple cold junction end can be terminated for direct measurement or conversion to a process signal via a signal transmitter.

TRANSMITTERS While many temperature instruments are read simply as RTD or thermocouple outputs, the majority are connected to transmitter electronics in order to produce a processed signal. Available as compact units that fit into the temperature instrument head, remote panel- mounted items (door or DIN rail) or larger wall- or pipe-mounted items, these intelligent transmitters can be scaled and programmed to tailor their output signal for the required application. Many have the option for a connected display and common signal outputs are in the form Transmitters can be used to convert an RTD of milliamp (with or without a HART signal), or thermocouple reading into a commom FOUNDATION Fieldbus or PROFIBUS. process signal such as Am or PROFIBUS. As with all measurement devices, the quality and

performance of the transmitter can differ from one manufacturer to another. Premium manufacturers will generally produce transmitters with greater stability, accuracy and repeatability, allowing for an overall superior performance. Where possible, all components in the measurement loop should be purchased from the same manufacturer. It is critically important for the transmitter used to be of the highest possible quality as this section of the pathway in the measured signal will have a significant impact on the performance of the sensor in what could be a critical measuring point in the application or process.

THERMOWELLS Both RTD and thermocouple elements are relatively fragile sensors and to be used successfully in general applications they can often require protection from the very process they are measuring. This protection is offered in the form of a thermowell, a pocket that houses the element and safeguards it from potential damage caused by corrosive chemicals, high pressures or solids in the measured medium. Furthermore, the thermowell acts as an integral component of the process, allowing the temperature element to be removed without breaking into the pipe or tank in which it is fitted. Connected to the process by a thread, flange or direct weld, a thermowell can be supplied in any style. Where necessary, a bespoke Bespoke design design will offer perfect compatibility with the process requirements. thermowells offer perfect Manufactured from either machined barstock or fabricated components, compatibility with process these protective pockets can be straight, tapered or stepped, produced requirements while from a variety of materials or even coated to guarantee performance protecting the fragile and compliance with the measured medium. sensor within. It is also important to ensure that the fitted temperature element connects snugly with the inside tip of the thermowell in order to gain positive thermal transfer. This can be achieved with a spring loaded probe or with thermoconductive paste to help bridge any gap.

FUTURE DEVELOPMENTS As transmitters are further developed with increased accuracy, resolution and repeatability, we can see the way the technology will advance. Similarly, the evolution of measuring elements, especially thin film sensors, has shown that quick response and resilience to process effects is a trend that will continue in future years. Flexibility of application and ease of consumer involvement are the new, fast-growing fields of development for temperature sensors. With intelligent application of the technology, temperature measurement is being used for such diverse purposes as conveyer belt alignment detection and bearing monitoring alongside more traditional measurement purposes. Consumer influence is also helping to shape the future of temperature instruments. Quick release mechanisms for faster removal of probes from their process has been a welcome development for those with regular calibration needs in hygienic applications, exponentially reducing the downtime required for calibration. In the same vein, the development and future launch of a self-calibrating temperature probe from Endress+Hauser will almost eradicate the need for operator involvement to produce accredited calibration certificates on a regular basis, increasing savings both in cost and time. This type of development is set to revolutionise the position that temperature probes hold within the process industry and align them with the capabilities and features seen in larger instruments such as flowmeters and level sensors. However these products develop in future years it can be seen that major manufacturers of temperature probes are pushing the limits of technological development to create instruments that are fit for purpose now and in the future.

PROCESS INDUSTRY INFORMER September 2016

PROCESS MEASUREMENT & INSTRUMENTATION SENSOREX DIFFERENTIAL pH/ORP SENSOR – DIRECT REPLACEMENT SERIES

TINYTAG DATA LOGGERS: VERSATILE TEMPERATURE MONITORING SOLUTIONS

SD7000 Series pH/ORP Differential Sensors from Sensorex suited to water, wastewater, environmental scrubber and other challenging process applications

Sensorex’s new SD7000 Series Differential pH/ORP sensors provide industrial and municipal water treatment operators with a unique, yet proven sensor technology, with overall low cost of ownership. The SD7000CD and SD7000CD-ORP are a cost-effective and chemically-resistant direct replacement option for Hach/GLI and Water Analytics/Aquametrix analogue 5-wire pH and ORP sensor models. These differential pH and ORP sensors are ideally suited for industrial and municipal wastewater treatment and neutralization; metal finishing and plating, wet fume scrubbers; chemical processing; and other online water quality and process applications. SD7000 Series sensors are highly accurate, with three electrodes instead of the two found in conventional combination pH and ORP sensors. Solution pH is measured differentially with process and inner reference (surrounded by a known concentrated pH 7 buffer) electrodes, compared to a third ground electrode. This provides optimal measurement accuracy, minimizes reference junction potential, and eliminates sensor ground loop effects. Less maintenance for operators, minimized down time, longer sensor life and overall greater reliability are hallmarks of this differential sensor design. SD7000 Series sensors offer unmatched accuracy and reliability with an encapsulated preamp to eliminate moisture problems and allow for mounting up to 3000 feet from installed pH/ORP transmitters and remote monitoring systems. Their 1.5” NPT convertible threads are provided for sensor mounting into flow tees or adapting to a pipe for process submersion. The Ryton sensor body provides outstanding chemical resistance and the double-junction reference resists contamination to ensure measurement stability. The internal reference electrode is electrically connected to the process solution by means of a field-replaceable double junction salt bridge which reduces the possibility of contamination. The salt bridge and standard pH 7 cell solution can be replaced periodically at a very low cost, making the SD7000 differential sensor very economical to maintain. To learn more about the SD7000 Series Differential pH/ORP Sensors, visit www.Sensorex.com, emailsales@sensorex.com or phone +1 714-895-4344.

The Tinytag range of data loggers includes rugged, waterproof devices designed for temperature monitoring in industrial and outdoor applications.

Accompanying probes are available for monitoring extremes of temperature such as those in manufacturing, processes and cryogenic areas, for comparing ambient and process temperatures, and for awkward to reach areas such as pipework. A range of thermistor probes, PT1000 very low temperature probes, and PT100 very high temperature probes is available to meet specific applications. Tinytags are accurate and easy to use: stand-alone loggers record information which is downloaded to a PC via a USB cable for analysis. A Radio Data Logging System is also available for premises with multiple monitoring points: data is gathered automatically and sent via a receiver for direct viewing on a PC, across a LAN, or remotely across the internet. For more information contact Gemini Data Loggers, T: +44 (0)1243 813000 E-mail: info@tinytag.info Web: www.tinytag.info

FLOW METERS FOR CRITICAL APPLICATIONS For critical flow measurements – Titan Enterprises Ltd. has established itself as a leading manufacturer of off-theshelf meters or fully bespoke OEM flow systems for challenging applications.

Drawing upon over 40-years experience of flowmeter innovation, Titan Enterprises is able to today supply innovative flow measurement solutions into a broad range of sectors, including automotive, food and drink, industrial, laboratory, medical, petrochemical and pharmaceuticals. All flow meters produced by Titan are designed and manufactured to ISO9001 and calibrated to an uncertainty of ±0.25%. The company produce chemically resistant, high accuracy digital flow meters that are not only competitively priced but are engineered to give long-term reliable performance. The portfolio of flowmeters offered by Titan Enterprises includes: high performance solutions such as the Atrato ultrasonic flowmeter, Oval Gear flowmeters, Turbine flowmeters and an extensive instrument range. With over 40 years’ experience in flowmeter innovation and manufacture, Titan Enterprises philosophy of “pushing the envelope by trying to do things a little different and better” has resulted in sales of over 500,000 products into 40 countries worldwide and a repeat purchase rate of 95%. For more information contact Titan Enterprises Ltd, Tel: +44-1935-812790 E-mail: sales@flowmeters.co.uk Web: www.flowmeters.co.uk

PROCESS INDUSTRY INFORMER September 2016

PROCESS MEASUREMENT & INSTRUMENTATION ASCO EXPAND STAINLESS STEEL FILTER REGULATOR RANGE WITH ADDITION OF A COMPACT OFFERING Boasting the highest flow rates on the market for its size, the ¼ in stainless steel regulator is ideally suited for the control of process actuators. ASCO introduces a compact stainless steel filter regulator as an addition to their existing range.

Boasting the highest flow rate on the market for its size, the new product is ideally suited for the control of process actuators when a compact solution is required without compromising on actuator opening and closing speeds. The compact Filter regulator complements an existing range of high flow stainless steel and aluminium filters, regulators and filter regulators. Suitable for harsh environment applications such as offshore and onshore oil & gas, chemical & petrochemical plant and power generation applications, the new compact version is available in ¼» size (with the existing range available in ¼» and ½»). The ASCO stainless steel filter regulator boasts excellent flow rates - double that of others of its size on the market. This is made possible thanks to an optimised flow path plus a reinforced rolling internal diaphragm design, which also increases the product´s longevity, particularly when combined with the high quality construction materials of the SSFR. ATEX 2014/34/EU, CUTR and SIL certifications complete the offering to the process industry. Business Development Director for the Process said »Adding a reduced size stainless steel filter regulator to our range provides more options to meet our customer´s diverse requirements» The ASCO stainless steel filter regulator options complements the company´s extensive range of direct and pilot operated solenoid and pressure operated valves and is available on ASCO Express for reduced delivery times. Renowned for their high standard of engineering and reliability, these products and wider solutions are installed globally across many industries. For more information visit www.ascoworld.com/media-centre

EMERSON ADDS THERMAL ENERGY HARVESTING TO WIRELESS PRODUCTS Thermoelectric Power Pucks reduce operating and maintenance costs and further simplify wireless technology adoption

Evolving the world’s largest industrial wireless portfolio, Emerson announced today the adoption of advanced thermal energy harvesting as a power source for its wireless products. Power Puck® thermoelectric energy harvesters convert ambient heat commonly released in industrial processes into electricity for powering Rosemount™ wireless transmitters. Perpetua’s Power Puck energy harvesting solution is especially advantageous to wireless devices in power intensive applications, where a conventional power module may require replacements more frequently. The company’s Power Puck thermoelectric energy harvester provides continuous, reliable power for the life of the transmitter and includes an intrinsically safe power module for back-up power. “We have been working directly with Emerson and their customers and are pleased with this expanded relationship and the vote of confidence in Perpetua products,” said Jon Hofmeister, president of Perpetua Power. “We look forward to supporting Emerson’s mission of driving customer value through widespread adoption of industrial wireless technologies.” A heat source is all that is required to fully power wireless transmitters at their fastest update rate using Perpetua’s Power Puck. Configurations allow connections to most heat sources, including flat and curved surfaces with temperatures up to 840°F/449°C. Power Puck solutions are intrinsically safe and classified for use in hazardous areas. Power Puck certifications include ATEX, IECEx, USA, and Canada. For more information on Emerson’s wireless technologies, visit www.EmersonProcess.com/SmartPower.

SINGLE INSTRUMENT FOR REACTOR GAS DOSING Alicat Scientific Mass Flow Controllers offer multiple parameter control and reporting in a single instrument; mass flow, volumetric flow, pressure and temperature are simultaneously visible via the on-board display and each have their individual output signal via the electronics interfaces.

Perhaps more important, however, is the capability for the user to select and change their preferred control method for a particular experiment or application. Not only can the instrument control on flow (mass or volumetric) whilst measuring and outputting the pressure but, by means of the front panel interface, the instrument can be instantly changed to control on pressure whilst measuring and reporting the flow. To achieve the same, other solutions on the market require a combination of several more instruments, with the complication of convoluted wiring leading back to a control panel, PC or lap-top. Not only is such a solution relatively expensive and time consuming to configure, but it is also fixed in its control mode and more limited in its capability. Traditional methods might include manual pressure regulators and mechanical flow measurement devices, but these are affected by changing ambient conditions, require constant vigilance, and provide no data-logging capability. Alicat Scientific has been successfully designing and manufacturing precision instruments for over 25 years and this success can be attributed not only to industry-acclaimed instruments but also the company’s core ethos of providing affordable complete solutions to complex control and measurement problems. Alicat understands that there are seldom “off the shelf” solutions to a dilemma, an important stance which ensures that they are always willing to customize their core products to perfectly fit any given application. The unique design and measuring technologies of Alicat flow and pressure control products allows their instruments to be used in applications where competing devices may not have the flexibility or durability to survive. Alicat’s technological advantages can be seen within the following application example. Reaction vessels require the addition of gases under a controlled pressure regime within such industries as chemical, pharmaceutical and biotechnology, to name but three. Multiple gas species are commonplace, across a wide flow regime, with accuracy and precision often being important – especially for characterization within research and development. Rapid control response and accuracy across a broad range of gases is often critical to a successful process. Standard features of the Alicat product line are of great assistance to this application. • A standard turn-down ratio of 200:1 ensures that the wide flow regime can be covered by just one instrument. Depending upon the application, an even wider turn-down is possible. • A lowest flow rate measurement capability of 0.0025 mln/min ensures that all gas added is accounted for – especially towards the end of the reaction. • With up to 130 gas calibrations stored on-board, the direct selection of different gases maintains accuracy, reduces inventory and eliminates the issues caused by conversion factors employed by other technologies. • Fast control response of between 30- and 100-ms from sensing a change to settling, ensures stability and high precision. • The ultra-low pressure drop available across the instrument eliminates disturbance of the process regime—especially within low pressure systems. • Standard solutions, which eliminate pressure overshoot, maintain highly stable conditions for the precise control of dead-ended, non through-flow systems. • Additional software packages are available for programmable pressure profiling and batch control. Scripted programming is available as part of the Flow Vision™ software package. The control software’ graphical user interface (GUI) provides automatic configuration; session saving for easy reloads of configuration and experiment setup; data capture, logging and graphing; and script building for automating command sequences. All told, single-instrument measurement and control of flow and pressure are available within open flow and dead-ended systems for applications across a whole host of process industries, research, an development. These standard instruments employ time-proven, unique technology advantages to reduce cost, improve yield and save time within gas dosing and/or batching processes. For more information contact Alicat Scientific, Cambridge, Cambridgeshire. Tel : +44 01223 E-mail : europe@alicat.com Web : www.alicat.com

PROCESS INDUSTRY INFORMER September 2016

NEWS

SEPTEMBER 2016

2016 MARKS THE 75TH ANNIVERSARY OF THE BRITISH PUMP MANUFACTURERS ASSOCIATION

The preceding three quarters of a century has borne witness to enormous changes in both the world of pumps as well as the wider world. Back in 1941 in the UK, we were in the firm grip of World War 2 with all the inherent difficulties that it created. Although many aspects relating to pumping have changed in that time, some of the fundamental engineering principles behind the technology remain today. The current BPMA President is Mr Peter Reynolds of Grundfos Pumps Ltd, who has been at the helm since the start of the year. We recently caught up with Peter and asked to sum up his experience in office to date. “I was delighted with my appointment as President of the BPMA. This was a great honour for me that has been heightened by my having the added good fortune that my term in office coincides with the 75 the Anniversary of the BPMA. With a story that goes back to 1941, the foundations of the BPMA are traceable back to Peat Marwick Mitchell (who provided the P M cornerstones of today’s global accountancy giant - KPMG). Their role was to control the allocation of strategic materials to the industry. By 1965, the BPMA had established its own offices and officers with Sir Peter Parker being the first President. With only five Directors at the helm E.F.E. Howard until 1972, F.D. Outridge until 1982, B.F.Glanfield until 1993, B.Huxley until 2013 when our current Director Steve Schofield took the role, this has allowed for a seamless direction throughout a period that has witnessed great technological change. Such continuity has not been quite so visible and marked in the pump industry itself, as member

Redu ce en ergy c onsum ption

Eliminate ex cess seal wa ter

liability Improve pump re

companies have come and gone as well as it witnessing a range of take-overs and mergers as has also been reflected in other key industries in modern times, something we can see continuing into the future. Moving from being a standalone institution, the BPMA has joined forces with Europump and this has allowed us to work closely with as well as to influence European strategy. This has led to the deployment of important new standards that have had a major impact on EU legislation including the instigation of important Directives. Indeed the BPMA has historically taken a lead within Europump to develop a variety of strategies, of particular note is the Energy strategy, which drove the greatest change the industry has seen to date from both a national and European perspective. We also maintain a healthy working relationship and share key information with our American Colleagues, the Hydraulic Institute. Since my appointment, there have been some significant political decisions made which will mean more opportunities as well as more challenges for us all as well as the industry. We are already taking steps to ensure that our voice continues to be heard at the highest levels to cement our position of being at the vanguard of change. The role of the BPMA however, goes beyond addressing issues relating to legislation, but also for the past 20 years has provided pump technology training for the wider industry in order to satisfy member and non- member requirements and maintain the highest standards and best practice within the industry. However, I firmly believe that we can look forward to the future with more confidence, as today we have a strong membership base, a firm strategy for the future and the willingness and drive to see projects through”.

AESSEAL Water Management

AESSEAL Water Management Systems save in excess of 95 billion litres of water for customers each year

ent vironm n e e h ct t Prote www.aesseal.com

BPMA & EUROPEAN SEALING ASSOCIATION SIGN MUTUAL COOPERATION AGREEMENT Established in 1941, the British Pump Manufacturers’ Association (BPMA) is a not-for- profit trade association representing the interests of UK and Irish manufacturers and suppliers of liquid pumps and other pump related equipment. Established in 1992, the European Sealing Association is a not-for- profit trade association representing the interests of manufacturers and suppliers of sealing devices and materials across Europe. Recognising the core values of each organisation and the fact that that they already follow very similar technical, standardisation, training, energy and environmental protocols across their respective product areas, it has been determined that a great deal of mutual benefit can be derived from such an undertaking. The agreement will allow the exchange information between the two associations in areas of common interest affecting pumps, pump sets and sealing products , which could include but will not be restricted to:• Technical issues • Standards (UK, European and International) • Legislation information (European) • Energy and Environmental issues across Europe • Training Programmes (and their respective promotion) Having been approved by the Council of each organisation, the agreement was formally signed by BPMA President, Mr Peter Reynolds of Grundfos Pumps UK and ESA Chairman, Mr John Morton of John Crane. Commenting on the signing, BPMA Director and CEO, Mr Steve Schofield said, “this is an exciting development for both organisations, and one which I’m sure will quickly deliver important benefits for our respective memberships”. He added, “with the agreement coming into effect in our 75th Anniversary year, it is a further indication of our commitment to ensuring pump systems excellence across the international arena”

BPMA ADVISORY SERVICE E.U. DIRECTIVES & REGULATIONS Do you know whether your documentation supporting the placing of your products on to the UK and European market is legally compliant? Not being legally compliant can lead to large fines against your company and if a noncompliant product leads to an injury or death, possible imprisonment. The BPMA for many years has provided generic information to its members on EU Directives affecting the pump industry, either through guidance documents, position papers or information given at meetings. The BPMA believes it is the only UK organisation that specifically concentrates on the effects of EU legislation on liquid pumps. As a New Service the BPMA will; • Site visit your premises in the UK • Carry out an Evaluation of on-site Technical File, CE Marking, Declaration of Conformity, compliance procedures etc. • Provide an Information folder • Offer specific advice and information • Submit a report * *the follow up report will consist of a summary, indicating compliant and non-compliant findings during the visit and advising of measures and appropriate actions to be taken to ensure products are legally placed on the market within the UK and also Europe. THE COST OF THIS SERVICE IS £1,000 +VAT PLUS EXPENSES FOR BPMA MEMBERS AND £2000 + VAT FOR NON-MEMBERS If further visits or specific Directive information are required these will be priced separately. The BPMA actively promotes a “Buy with confidence from BPMA members” ethos and this new service aims to support this statement If you are interested in this service please contact:Steve Smith on 0121 601 6691 or email s.smith@bpma.org.uk

SITUATION IN THE UK POST BREXIT IN REGARD TO CE MARKING It’s likely that it will be at least six months before any clear view of how Brexit will be achieved emerges, and two years before we see any significant changes in UK legislation. Even then, all of the Directives on which CE marking is based are single market measures which are exactly those that the exit campaigners wish to preserve. By voting for exit, the UK has now forfeited a substantial proportion of its influence over how those measures will be developed in the future, but the legislation will remain in place in Europe and UK companies will have to abide by it if they wish to continue to sell into the single market across Europe. As things stand at present, the exit will have no effect on the UK’s participation in the European standards bodies, CEN and CENELEC. The current presumption whereby British Standards are withdrawn in favour of Harmonised European standards has never been mentioned in the debate about Brexit and it seems likely that it will remain for the foreseeable future. Since the majority of the detailed design measures for CE marked products come from standards, there will be little practical change so far as equipment designers are concerned. In the long term, clearly there will be some divergence between UK and EU requirements for product safety. BPMA will continue to work hard to identify what’s actually required in the EU market and inform all our members, what they need to do to legally sell their products. We are confident that our pragmatic approach based on a sound technical understanding of the requirements and a unique strategic understanding of the CE marking process will continue to ensure that our customers’ needs are met.

BOWER BOWS OUT & HOLLINS HOPS ON-BOARD After holding the position for the past 10 years, John Bower of Flowserve has recently retired from the role of BPMA Technical Committee Chairman. As part of this important industry role John also held positions within British Standards Institution as BSI MCE/6 Chairman and as ISO TC 115 SC 1 Chairman. He also sat on many technical committees within Europump as well as updating BPMA Council on various technical matters throughout the past decade. John has been a significant figure in the pump industry who has worked tirelessly for the benefit of all, and he will be sorely missed. The supporting photograph pictures BPMA Director & Chief Executive Steve Schofield wishing John a long, happy and healthy retirement, whilst offering a card and token of gratitude with other members of the BPMA Technical Committee. This presentation took place at the June Technical Committee meeting held at the offices of Collyer Bristow Solicitors in London. The person replacing John Bower in this important role is John Hollins, who holds the position of Engineering Manager of SPP Pumps. Although he has significantly large shoes to fill, John has been a member of the BPMA Technical Committee for a number of years already and so is well versed with the workings of this important group. He is currently responsible for all SPP Pumps products and technical risk. This includes the design, development and testing of new products as well as engineered to order projects with values in excess of £4million. He also has responsibility for risk assessing new products for CE marking and reviewing new designs. He is a member of various industry technical committees and sits on several standards writing working groups for both ISO and BSI. Commenting on the changes, Steve Schofield of the BPMA said, “John’s commitment to the role over the past 10 years has been nothing short o tremendous, and we are enormously grateful for all he has achieved on behalf of the BPMA and of course the wider pump industry. We wish him a wonderful retirement. But at the same time, we welcome John Hollins to the role, who know will continue the important work of the BPMA Technical Committee, as we navigate the unchartered waters of Brexit”.

BPMA POSITION PAPER ON WEEE DIRECTIVE 2012/19/EU “The Directive” means Directive 2012/19/EU of the European Parliament and of the Council of 4th July 2012 on waste electrical and electronic equipment (WEEE) which replaces Directive 2002/96/EC as amended by Directive 2003/108/EC and Directive 2008/ 34/EC of the European Parliament and of the Council of 8th December 2003 on waste electrical and electronic equipment. This can also be referred to as electrical and electronic equipment (EEE) The goals of the WEEE directive are to establish an ecologically sound system for the disposal of waste from electrical and electronic equipment, e.g. computers, washing machines, irons and electronic tools. The directive covers both privately and commercially used electrical and electronic equipment. The revised Directive has increased the scope of WEEE , however an open question still remains as to what extentmechanical engineeringproducts are covered by the WEEE directive. In order to answer this question, and after a more precise analysis of the core text of the directive, members of the British Pump Manufacturers Association agreed the following position. Core Statement: Pumping installations are not covered by the WEEE directive Rationale: Within the revised Directive of 4th July 2012 under Article 2 SCOPE the reference to electrical and electronic equipment (EEE) within paragraphs 1 (a) and 1 (b) and subsequently the Annexes I , II , III IV do not refer to any type of pumping equipment. Furthermore within Article 2 ( scope ) under 4 (c ) it stipulates that ; large-scale fixed installations, except any equipment which is not specifically designed and installed as part of those installations; Under Article 3 (Definitions) under 1 (c ) points i to iii it stipulates the following; Large-scale fixed installation* means a large-size combination of several types of apparatus and, whereapplicable, other devices, which: (i) are assembled, installed and de-installed by professionals**; (ii) are intended to be used permanently as part of a building or a structure at a predefined and dedicated location; and (iii) can only be replaced by the same specifically designed equipment; * We agree with the Environment Agency interpretation of a large scale fixed installation ; “a combination of several pieces of equipment, systems, products and/or components (or parts) assembled and/or erected by a professional assembler or installer” Specifically – Large fixed installation is defined by the pump industry as a complete installation consisting of , pipework , pump and all other related components required to deliver the specified parameters. This industry description also conforms to the Environment Agency interpretation of Components, accessories and consumables. ** A product deemed as requiring professional persons with suitable qualifications for correct installation and commissioning shall be referred to within the manufacturers installation and operation manual which must be supplied with all pumps placed on the market . Conclusion: After careful study of the Directive 2012/19/EC dated 4th July 2012 on WEEE, BPMA and its members come to the conclusion that pumping installations are not included within the scope of this Directive.

ECONOMIC VIEWPOINT - GLOBAL Oxford Economics The surprise UK vote on 23 June to leave the EU caught markets on the hop. There was a strong initial equity sell-off but this has faded – world stocks are already back at their pre-referendum level. Moreover, key global financial stress measures such as equity volatility are not sending danger signals; so this does not look like a ‘Lehman Brothers’ moment. We nevertheless expect economic uncertainty to linger for a while. The new UK-EU relationship will take time to flesh out and – perhaps more significantly – the UK vote seems to have re-focused investors on weak spots in the global economy that have been glossed over in recent months. Our new global forecasts see the economic fall-out from the UK vote concentrated in the UK. GDP growth there is now expected at 1.1% in 2017 and 1.4% in 2018 versus 2.3% and 2.2% a month ago. There will also be negative spillovers to the Eurozone and Japan. In the Eurozone, trade with the UK will be weaker and there may also be a negative impact from heightened concerns about structural weaknesses such as bad loans at Italian banks (18% of loans, equivalent to €360 billion). We expect Eurozone growth to be 1.5% in 2017 and 2018, some 0.2 percentage points lower than three months ago. We also expect weaker growth in Japan. The Brexit vote has added to existing upward pressure on the yen, which is now 21% stronger on a trade-weighted basis than a year ago. We now see Japanese growth at just 0.1% this year and 0.3% in 2017 – despite the delay in the consumption tax rise (previously planned for next year) to 2019. In the emerging markets, the recent pattern of forecast changes has featured some upgrades, in part thanks to improved commodity prices. As a result, despite our UK, European and Japanese downgrades, our latest world GDP forecast for 2016 is unchanged from a month ago at 2.3%, but projections for 2017 and 2018 have been nudged down slightly to 2.6% and 2.9% respectively. UK financial markets endured a period of significant turbulence immediately after the EU referendum, with sterling and equity prices dropping sharply. However, sterling has stabilised over the past few weeks, while most equity indices are now higher than they were immediately prior to the referendum. It will be some time until we have hard data on the impact of the referendum result on the economy, with the July retail sales data set to provide the first indication. There has been a series of sentiment indicators published during July, most of which show a sharp deterioration compared with prior to the referendum. Uncertainty on hold... The rapid appointment of Theresa May as Prime Minister should help to reduce the degree of uncertainty. She has made it clear that she will not trigger Article 50 of the Lisbon Treaty until the government has decided upon its negotiation strategy. Her appointment of high profile Brexiteers to the cabinet positions tasked with negotiating the UK’s departure has strengthened our conviction that we are likely to see a ‘hard Brexit’ resulting in the UK and EU reverting to a relatively loose relationship. Our short-term forecasts for UK GDP growth are 1.8% for 2016 and 1.1% for 2017. Post-referendum we expect heightened uncertainty to dampen business investment, while the weaker pound will push up inflation and hamper consumer spending. But in our view, the UK is likely to endure a slowdown in growth, rather than a technical recession. The Bank of England unveiling a four-pronged package of monetary policy moves to support the economy. While the impact of the individual measures may be relatively modest, taken together they are towards the upper end of the range of what could have realistically been anticipated and reinforce our confidence in our above-consensus forecast for GDP growth.

BPMA ANNUAL REPORT, DIRECTORY & BUYERS GUIDE The BPMA Annual Report, Directory and Buyers Guide aims to promote the British pump industry and the members of the BPMA. It is acknowledged as an authoritative, high quality publication which ensures maximum awareness of the association, its members, their products and capabilities, throughout the world. It contains information about BPMA activities, useful articles, UK pump market data and details of the products and services offered by members. Latest Directory and Buyers Guide for 2016/17 is now available. To order your copy, please go to: www.bpma.org.uk/buyers-guide or email 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

ENGINEERED FOR ENGINEERS

GRUNDFOS CAN THE CAN

The Grundfos for Engineers Hub is specifically developed to keep our engineering partners with an interest in pump technology informed about the latest developments in the industry, as well as briefed on the wider subject of fully integrated pump systems. One interesting aspect of this new engineering hub allows visitors the opportunity to see and hear from many Grundfos product specialists who discuss a number of industry related topics. The range of topics discussed is broad and covers areas such as heating systems and boiler feed; iSolutions – the Grundfos total systems approach – that offers the opportunity to make a significant impact on overall system efficiency; sensors are also in the spotlight as a topic as is the fact that through differential pressure, they can help reduce costs. This means there will be something just for you whether you are an engineer working within commercial building services, process industry applications or in water supply and/or treatment industries. In addition to these interesting insights there are also a range of technical White Papers, case stories and access to engineering tools that will all help to keep you informed and up to date. This is only a part of the wide range of information that is available at the touch of a button; check it out for yourself by visiting www.grundfos.co.uk/engineers

One of the leading beverage can manufacturers in the UK wanted to find out about the possibilities of saving energy on their installed pump systems so approached Grundfos to undertake an Energy Check. The can wash lines were chosen to be the focus and an Energy Check was undertaken and a comprehensive report on the findings produced. This resulted in an order being placed with Grundfos based on the savings projected by the Energy Check as well as also because of the strength of reputation of the suggested replacement pumps. The order included 6 MTRE 64-8/2 and 8 MTRE 45-2/1 pumps. These MTR pumps are vertical multistage centrifugal pumps designed for pumping of cooling lubricants for machine tools, condensate transfer and similar applications. In addition to the return on investment of just 18 months, the customer will achieve operational savings of £53K per annum and industry-leading reliability for years to come. In fact, so impressed were the customer with the results of the Energy Check, energy savings of 590,000 kwh/y, that they decided to change the pumps, not only on the original can wash line, but on their second line as well. For more information or a Literature request contact Grundfos Ltd, Leighton Buzzard, Bedfordshire. Tel: 01525 850000 E-mail: grundfosuk@grundfos.com | Web: www.grundfos.co.uk

Motors | Automation | Energy | Transmission & Distribution | Coatings

Energy Efficient Motors for all Pump Applications.

WEG congratulates the BPMA on their

www.weg.net

supporting the British Pump Industry

5-YEAR SERVICE AGREEMENT WITH SABIC GELEEN Leading petrochemical company SABIC has awarded AESSEAL ® a 5 year managed reliability contract for their mechanical seals and seal support systems at Geleen in the Netherlands. The fixed fee contract is based on the Mechanical Seal Reliability Strategy set by SABIC across all of its sites. This includes the supply and repair of the mechanical seals used on over 600 rotating equipment assets. Martin Lister, International Contract Manager at AESSEAL ® said: “We are extremely pleased to receive this contract from SABIC. We have been working with SABIC now for many years and the awarding of this contract reflects the appreciation of the services we have delivered to the SABICfacilities we work with.” SABIC is one of the world’s largest petrochemical manufacturers with operations in 50 countries with a worldwide workforce of more than 40,000 employees. The Geleen facility in the Netherlands is one of SABIC’s 5 largest petrochemical production sites in Europe (the others are at Teesside in the UK, Bergen Op Zoom in the Netherlands, Cartagena in Spain and Gelsenkirchen in Germany) and houses two naphtha crackers and several polymerization plants for the production of polyethylene and polypropylene. For more information contact Aesseal Plc, Rotherham, South Yorkshire. Tel: 01709 369 966 E-mail: marketing@aesseal.com Web: www.aesseal.com

AXFLOW INTRODUCES THE NEW ECLIPSE SERIES OF METALLIC GEAR PUMPS AxFlow has introduced Pulsafeeder’s new Eclipse Series of Metallic Gear Pumps. With 12 different metallic and nonmetallic pump models, the Eclipse family of gear pumps addresses a wide variety of chemicals, connection sizes and flow ranges for water treatment and chemical processing applications. The Eclipse family of gear pumps features a patented front pull-out design that makes routine maintenance faster and easier, with a minimum number of tools required. The Eclipse series features the fewest number of parts compared to any other external gear pump on the market. Pulsafeeder’s KOP (Keep-on-Pumping) kits provide all of the spare parts required to further simplify maintenance and minimize downtime. The new versions of Eclipse offer enhanced performance and new flange options. Eclipse now comes in two different types of metallic gearing - Alloy C and 316LSS - for addressing higher temperatures up to 232°C and wider viscosity ranges for process chemicals. Each member of the Eclipse series is magnetically driven, with no seals to wear or replace, providing the safe and leak-free handling of highly corrosive fluids in a wide range of temperatures. “The true value and advantage of the Eclipse line is realised when customers consider the performance, the reliability and the simplicity of maintenance required over the life of the pump,” says AxFlow Product Manager Richard Charlton. “With the Eclipse family, we’re providing customers in the water treatment and chemical processing industries with a flexible solution to address any of the chemicals they need for their processes, and we’re doing this at a price point and total overall value that no other pump manufacturer can match.” The complete line of Eclipse Gear Pumps (www.axflow.com/en-gb/site/products/category/ pumps/gear-vane-pumps/eclipse1/) includes the 02, 05, 12, 25, 75 and 125 models in metallic and non-metallic configurations. For more information contact AxFlow Ltd, Ealing, London. Tel: 020 8579 2111 E-mail: info@axflow.co.uk | Web; www.axflow.co.uk

A GUIDE TO ENERGY EFFICI

Here, Richard Smith at AESSEAL, looks how appropriate selection the energy effic In Europe and the United Kingdom it is estimated that around 10 percent of electrical power is used for pumping equipment 1 , which is a significant part of running a manufacturing operation. One of the consequences of this is that regulatory bodies in the UK as well as plant owners themselves are focussing on improving the energy efficiency of pumps and pumping systems.

MECHANICAL SEALS Mechanical seals can have a significant influence on the energy efficiency of a process. Their purpose is to seal the process fluid - whether it is toxic or expensive, the objective is to keep it within the system and pipe work to avoid it seeping out and resulting in a cost for lost process fluid and clean up. And, of course, if the liquid or process fluid that is leaking is heated, it is losing costly energy from the system. So, be it with flanges, valve stems or pump seals, it is necessary to think of the seal not only as preventing process fluid contamination and leakage to external atmosphere but as an important part of conserving energy within the system.

Figure 2: Energy efficiency of the most popular flush plans. 3 www.pumpsystemsmatter.org/uploadedFiles/Pumps/Membership/Member_Services/ Meetings/AZIBERT%20-%20Sealing%20Systems%20Energy%20Efficiency.pdf 4 www.api.org/publications-standards-and-statistics/standards/whatsnew/publication-

Figure 1: Frictional power consumption of Mechanical Seals

updates/new-refining-publications/api_std_682

If you are looking at relatively small seals, around 1 to 2 inch (25mm - 50mm) diameter, energy consumption is relatively low 1 HP (0.75Kw) as a maximum 2 . Larger sealing mechanisms can consumer over 3 HP (2.24Kw), as a maximum power absorption. In the grand scale of things this is relatively low, however if the focus is on the thermal inefficiency of seal flush plans the energy that can be lost with inefficient systems can be significant.

ALTERNATIVE FLUSH PLANS FOR SINGLE SEALS

1 www.youtube.com/watch?v=FvPRTowCK-E

2www.maintenancetechnology.com/2010/01/saving-energy-with-sealing systems-344/

Mechanical Seals, to function correctly, need to be flushed with an fluid to lubricate and keep the seal faces cool. This is accomplished through the use of sealing systems and the various configurations of seal flush plans (API Plans) that can achieve this. Mechanical seals on pumps are probably the most delicate components and we use seal flush plans to change the environment that the seals operate in and that makes them flourish and provide reliable operation. So, in simple terms, flush plans are used to create a stable and idealised environment for the seal, and are formalised by the American Petroleum Institute in their standard API-682, the custodian of the flush plans, where they are detailed in standardised formats. A survey 3 was carried out by the Fluid Sealing Association (FSA) for pumps incorporating a total of 28,000 seals where the process temperature exceeded 200°C (400°F). Figure 3 shows the most popular flush plans used and, by comparison, the energy absorption of each. It is interesting to note that flush plan 32, the second most commonly specified in the survey, is by far the highest energy user. Understanding the flush plans is critical to make an impact on energy efficiency in seal systems and seeing how they control the seal environment. Currently API 682 Standard is in its 4th edition and details over 30 plans to choose from 4 . The Standard has evolved over 20 years and serves as a representative sound engineering practice in the application of mechanical seals. The latest edition has incorporated many of the improvements from the previous editions as highlighted by users. Looking at studies on different flush plans undertaken by the FSA, we compare some of the plans with a hypothetical case study. The single seal flush plans are plan 21, 23, 32 and 62. We will look at dual seals and the appropriate seal flush plans in a separate study.

This is commonly used for high temperature process fluids. API plan 21 takes a simple side stream from the discharge, which is at higher pressure than the seal chamber (at the eye of the impeller). The higher pressure drives the hot liquid through an orifice plate which controls the flow, then through a heat exchanger before this cooler liquid is injected on the seal flush over the seal faces and then is fed back into the process – an open loop cooling system. An issue with API Plan 21 is that the seal flush liquid enters the process and with the process fluid being of a higher temperature this additional cool flush liquid dilutes the process. By comparison, API Plan 23 can be described as a closed loop cooling syste and is probably the most efficient way to remove heat from a mechanical seal. The seal chamber is closed down by throat bushing at the neck of the seal chamber and within the seal chamber is a secondary, very small, impeller, to circulate liquid though the heat exchanger. Plan 23 is significantly more efficient than Plan 21 because only heat from the seal faces and any heat that comes through the pump casing are removed, and no heat is being removed from the process. Plan 32 involves injecting a clean, cold liquid from an external source, through various controls,

IENT SEALING SOLUTIONS

n of mechanical sealing systems can have a significant impact on ciency of a plant. be difficult – often you see installations where the steam is escaping to the atmospheric side of the seal, which dramatically increases the energy requirement, quickly making the system inefficient. Most issues with API Plan 62 steam quench energy efficiency are therefore a result of poor maintenance.

APPLYING THE PLANS TO A TYPICAL CASE STUDY:

through the seal faces and into the process. The flush liquid is generally significantly cooler than the process fluid & effectively this liquid is diluting the process having a significant effect on the thermal efficiency of the process. This scenario can be linked to constantly running the cold water in the bath, whilst trying to keep it warm with the hot tap – the bath water quickly loses temperature.

This is an atmospheric plan commonly used on hot oil type applications for a single seal. With a plan 62, steam is taken across the atmospheric side of the seal and down to a drain system. The steam isn’t really used for cooling but for carrying away any hydrocarbon particles that congeal on the atmospheric side of the face, removing them before they start carbonising and causing the seal and seal faces to ‘hang up’. Plan 62 is a relatively energy efficient method of sealing a hot oil pump. Generally only a very small amount of steam is required however, controlling the steam flow on a steam quench can

It is possible to apply the above API Plans to a hypothetical hot oil pumping application, which illustrates the relative energy efficiency of each. This configuration would be a single stage, end suction centrifugal pump (API 610 compliant), based on: Pumped fluid: hydrocarbon at 315°C (600F) Specific gravity: 0.8 Specific heat: 1.67 kJ-°C (0.4 BTU/lb-°C) System pressure: 345 kPag (50psig) in seal chamber Pump driver: 50 HP (typical) Sealing devices: Compression packing Mechanical seals Assumptions: Heat lost at the pump must be replaced at the system boiler / heat exchanger

To put these figures into context, if a pump is running 24 hours a day, 365 days a year the difference between flushing a seal using API Plan 32 and API Plan 23 can see a business save around 400,000 kW of energy a year. When this saving, which equates to a 96% reduction in energy costs, is spread across multiple pumps and multiple locations thepotential savings are huge.

CONCLUSION To conclude, potential sealing system savings can exceed the energy savings obtained from switching to, for example, variable frequency drives, improving pump hydraulics or trimming impellors, or re-sizing pumps in many applications. Selection of inappropriate sealing systems can have very significant impact on the thermal efficiency of a plant and plant utilities. Sealing systems found in many industrial applications, even when functioning as intended, are extremely wasteful of energy. However, the sealing industry has technologies that can overcome some of this energy wastage and there is increased awareness about these solutions. Improved technology sealing systems available today can reduce the need for energy-wasting systems that result in cooling/dilution of the process and the need for downstream separation/evaporation, re-heating and/or effluent treatment. Being able to choose between different sealing systems or flush plans requires a good understanding of the principals of their operation and why they’re used. The best way to access this knowledge is to work with a sealing partner that has the understanding of this specialist area.

FOR MORE INFORMATION ON MECHANICAL SEALS AND AESSEAL®, VISIT: WWW.AESSEAL.COM 7

THE CLEANEST PUMP FOR FOOD & BEVERAGE APPLICATIONS YOU’LL EVER NEED

Perfected Sealless Pumps Continuous innovation means Sundyne HMD Kontro magnetic drive technology is now even more robust, reliable, economic and suited to even more applications ZeroLoss™ Composite containment shell / shroud that significantly reduces power requirements meaning smaller motor sizes and less energy consumption.

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

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

+44 (0)1323 452141 vince.lee@sundyne.com www.sundyne.com/hmdkontro 8

•New Sine® pump offers 3A and EHEDG Type EL Class I certification •High viscosity food product handling with low shear and zero pulsation •Requires up to 50% less power than other pump types The new from Watson-Marlow Fluid Technology Group has been designed to set a new benchmark in clean pumping for all food and beverage industry applications. Certa TM is latest innovation from MasoSine, the creators of Sine® pump Technology. Its launch sets even higher pumping standards in food processing. Offering EHEDG (Type EL Class I) and 3A certification as standard, Certa is extremely easy to clean for minimal maintenance and downtime. Furthermore, this advanced new innovation in food pump technology not only delivers high suction capability to handle viscous products, it offers significant advantages over alternative technologies. Unlike traditional pumps with rotors that cut through the fluid, Certa’s sinusoidal rotor gently carries fluid through the pump to dramatically reduce shear while cutting power consumption by up to 50% with high viscosity fluids. Engineers in food and beverage plants are frequently faced with pumping high viscosity products, ranging from frozen orange juice, deli salads and bakery produce, through to cheese curd and savoury pie fillings. For many years, Sine® pumps have played an important and highly successful part in conveying foods with viscosities of up to 8 million cP. CertaTM now completes the existing product range by offering users a fully CIP capable pump at flow rates up to 99,000 l/hr. Users can be assured that media is pumped safely and without degradation. FDA and EC1935 compliant Food and beverage plants the world over understand that equipment can play a key role in reducing the risk of contamination and maintaining high quality levels. With this in mind, all contact parts on the CertaTM sine pump are FDA and EC1935 compliant. With the high demand for cleanliness also comes the requirement for simple and fast cleaning, typically through CIP procedures. CertaTM significantly minimises the cleaning time which results in a more efficient production procedure. As well as minimising downtime, this quick procedure also means that chemical and water use is reduced, while less wastewater requires disposal. Performance and reliability Of course, the food-contact compliant Certa Sine® pump also offers all of the typical advantages and high performance levels delivered by proven MasoSine sinusoidal technology. Gentle pumping with virtually no pulsation, superior viscous handling, simplicity, reliability, energy efficiency, interchangeable parts and low cost of ownership all help food and beverage plants compete in a highly competitive marketplace. These benefits apply to all stages of the process, from unloading of the raw material to a storage tank, through transfer to a mixer/agitator/ reactor/cooking vessel, to final transfer to the filling line. Significant benefits over less efficient pumps CertaTM Sine® pumps offer a far better proposition than circumferential piston pumps, for example, which are difficult to clean in their standard configuration. Indeed, for CIP, users will find they have to subject circumferential piston pumps to modifications by drilling the rotor hub which ends up in a performance loss. Certa can also offer significant benefits over less-efficient lobe pumps, as well as twin-screw pumps, which exhibit high internal slip due to bigger internal clearances and therefore offer less gentle handling. Importantly, different applications – resulting in changes to viscosity, temperature, and flow rate - can be easily deployed with one pump setup. This mean there is no need for modifications such as bigger clearances for high temperature applications. Along with certified innovation for food industry applications, the new CertaTM Sine® pump series will provide an ideal solution for F&B, cosmetic or at any facility that requires the highest cleaning standards. For more information contact Watson- Marlow Fluid Technologies Group, Falmouth, Cornwall. Tel: 10326 370370 E-mail: info@wmftg. co.uk Web: www.wmftg.com

STUART TURNER INTRODUCE FLOMATE IBOOST, THE ULTIMATE SOLUTION TO LOW MAINS WATER PRESSURE Flomate iBoost has been developed to boost the mains supply to larger properties with multiple bathrooms, using high flow combination boilers or an unvented cylinder system, where higher pressure and flow are required. This fully integrated system combines a 200 litre cold water break tank which overcomes restricted mains water flow with a high performance multi-stage pump to dramatically boost pressure. Flomate iBoost is capable of delivering water up to 4.5 bar and flow rates in excess of 100 ltrs/min and is designed to sit alongside other appliances within a kitchen or utility room or can be concealed within any standard 600mm kitchen larder cabinet. For more information contact Stuart Turner Ltd, Henley-on-Thames, Oxfordshire. Tel: + 44 (0) 1491 572 655 Email: info@stpumps.co.uk Web: www.stuart-turner.co.uk Stuart Turner Ltd are delighted to congratulate the BPMA on their 75th Anniversary.

Stuart Turner Ltd are proud to be a member of the British Pump Manufacturers Association for the simple reason that they provide a respected resource to increase sector awareness on the industry in which we thrive and provide a valuable opportunity for Stuart Turner to demonstrate our products to the industry. As the market leading manufacturer of water boosting pumps in the UK we feel the BPMA represents not only our interests but that of companies within our industry, large or small, as established as Stuart Turner with over 110 years of engineering experience or a new business just starting up.

NEW IMPELLER COMBINES RELIABILITY AND EFFICIENCY Against a back ground of growing demands from the water and wastewater treatment industries for submersible motor pumps that resist clogging, deliver reliability and contribute to improving energy efficiency, KSB AG has developed a new centrifugal pump, the Amarex-KRT F-Max (Fig.1)that addresses these issues. Improved hydraulic system and motor performance are delivered through the design of a new vortex impeller and a motor that offers efficiencies currently calculated according to the same IEC 60034-2 measurement method as that used for motors of dry-installed pumps. In order to attain a pump’s optimum operating point, it is essential to select the correct impeller and size of impeller for the application. Whilst free-flow or ‘open’ impellers enable suspended solids in wastewater to pass more easily through the pump than closed single channel or multi-channel impellers, they do not compare favourably when it comes to performance. It is for these reasons that KSB has focused on designing an open impeller that can achieve and even exceed the efficiency levels associated with single-channel impellers. To improve overall efficiency, KSB has looked optimise the motors & efficiency in anticipation of future standards and market requirements is in compliance with IE3.This has enabled KSB to markedly reduce energy consumption.

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

Our technology. Your success. Pumps Valves Service •

•

Summary The Amarex KRT F-Max offers the capabilities to handle wastewater, river water, stormwater, municipal waste water, sludges, industrial waste water, seawater and brackish water. In order to accommodate this extensive range impellers are available in cast iron, stainless and acid-resistant duplex steel. The pump has the capability to deliver flow rates of up to 130m³/h and heads up to 60m. Manufacturing is now underway at KSB’s factories in Lille, France and Halle, Germany and plans are in place to extend manufacturing to its operations in India, China and Brazil thereby ensuring this new pump is available on a global basis. For more information contact KSB Ltd, Tel: +44 (0) 1509 231 827 E-mail: sales@ksb.com Web: www.ksb.com

LOOKING FOR AN ISO PUMP THAT REQUIRES URGENT DELIVERY? WE SHIP IN 5 DAYS WITH A 5-YEAR WARRANTY - CHECK OUT THE GOULDS IC I-FRAME PROCESS PUMP, IDEAL FOR CHEMICAL OR INDUSTRIAL PROCESS APPLICATION Gould Pumps’ IC i-FRAME model comes with an i-ALERT monitor (i-LAERT2 as an option). It is readily available and we can ship to customers in the United Kingdom, Benelux and Scandinavian counties within 5 business days* upon receiving a confirmed order. Specifications • 34 Hydraulic Sizes • Capacities to 450 m 3 /h (1980 USgpm) • Heads to 160 m (525 feet) • Temperature Range -40° C to 280° C (-40° F to 530° F) • Pressures up to 25 bar (360 psi); • Materials - Ductile Iron, 316 Stainless Steel, Duplex SS, Alloy 20, Hastelloy, Titanium Design Features • Full ISO 5199\EN 25199 Compliance • Patented Cyclone Seal Chamber for Extended Seal Life • Heavy Duty Bearing Frame, with Large Oil Sump Extends Bearing Life • Enclosed Impeller with Optional Wear Ring for Renewable Efficiency Ease of Maintenance • Modular Design For Maximum Interchangeability Between All 34 Pump Sizes • Back Pull-Out Design Makes Maintenance Activities Safe and Simple • Complies With ISO 2858\EN 22858 For Retrofit Capability Goulds Pumps products are well-known for providing low maintenance and operating cost solution to our customers. In fact, customers get extended Mean Time Between Failure (MTBF) and lower life cycle costs(LCC)… with a 5-year warranty for parts!! Check out the Goulds IC i-FRAME model at goo.gl/o51ZIV and place your order by phone or email Tel: +44(0)1256 311900, Email: gouldssalesuk@itt.com Learn more about the i-ALERT2 Equipment Health Monitor (www.ialert.com) and how it continuously monitor the health of your pumps.

GLOBAL EVENT FOR PROCESS & ENVIRONMENTAL MONITORING Professionals from around the world will come to Telford (UK) on 2 nd and 3 rd November to learn about the latest developments in regulations, technologies, methods and standards in process and environmental monitoring. Featuring a wide range of conferences, workshops, demonstrations and an international exhibition, WWEM 2016 (www.WWEM.uk.com) will build on the success of six previous events that began in 2005.

WEM organiser Marcus Pattison says: “WWEM 2014 saw a 15% increase in visitor numbers, but this year’s event will be even busier due to the number of new partnerships that we have made with organisations that will run their own conferences and workshops alongside WWEM 2016. All of these co-located events contain themes that align with WWEM, so 2016 is set to be by far the largest event yet, and advance registrations have already greatly exceeded those for previous events.” WWEM visitors come from a broad spectrum of industries and sectors including regulators, government, manufacturers and process operators, water utilities, accreditation organisations, commercial laboratories, instrument manufacturers, consultants, analytical service providers, researchers and academics. WWEM 2016 Conference (2nd and 3rd November 2016) The first day of the WWEM 2016 Conference will address a laboratory environmental analysis theme; entitled ‘Priority Pollutants Legislation: Issues for Industry and Potential Solutions,’ (delegate cost £50). Speakers from ALcontrol, DEFRA, Atkins, United Utilities, Southern Water, Welsh Water, Arcadis and Flameless Energy Solutions will discuss regulations, compliance, analytical issues and remediation solutions. The Conference on the second day, organised by SWIG, will address the ‘Resilience of Sensor Networks’ in the morning session, and the ‘Maintenance of Sensors’ in the afternoon; (£27.50 per session). Speakers will include technology providers and water industry experts. SWIG is also running a Poster Competition for the Early Career Researcher Prize, which is intended to raise awareness of technological development and novel applications related to water measurements and thereby promote innovation in sensor

WWEM 2016 EXHIBITION – SEEING IS BELIEVING The Exhibition will feature organisations from around the globe, offering an opportunity to see the whole sector in one place. This year, the exhibition will be bigger than ever, featuring over 140 stands representing more than 250 of the world’s leading providers of testing, analysis and monitoring equipment and related services. The Exhibition will be FREE to enter for any pre-registered visitor, which includes anyone registered for any of the co-located conferences and anyone simply wishing to register to visit the Exhibition and its associated workshops, poster displays and the demonstration area. Parking, lunch and refreshments are free for those that pre- register for WWEM 2016 at www.WWEM.uk.com .

NEW PROCESS MONITORING PRODUCTS AT WWEM 2016 – FOR EXAMPLE AMONG THEM ARE... ATi will launch a new range of water quality sensors and monitors, which says are “set to have a profound impact on the way the UK

water industry works,” adding: “this is the first time the water industry will have an opportunity to see this revolutionary new approach to smart sensor technology... along with its amazing capabilities.” ABB’s stand will feature the new Aztec 400 digital sensors for turbidity and dissolved oxygen measurement, and Cooper Environmental will provide information on the first commercially available continuous multi-metals water analyser, which they plan to launch in 2017. In addition, Envitech will show the latest version of what they claim is the only in-situ auto-calibrating Ammonia monitor for wastewater. WWEM 2016 will provide an opportunity for the first UK viewing of the new Lovibond® PTV 1000 Online Turbidimeter and RS Hydro will launch the Proteus P and Proteus BOD portable water quality monitors. OTT Hydrometry’s stand will feature the HydroCycle PO4, the latest version of the Cycle-P remote, battery powered phosphate monitor, in addition to the latest version of the Pluvio 2 weighing raingauge and new products from group acquisitions Sutron and Lufft. PPM will show a new UV254nm technology reporting UVT and dissolved organics, a’ new low-flow final effluent turbidity monitor and a new digital technology allowing the integration of multiple sensors including pH, optical DO, Ammonium, Turbidity and MLSS. There will also be a large number of exhibitors displaying new laboratory products. For example, Xylem Analytics will showcase the latest WTW photoLab® 7600 laboratory spectrophotometer featuring OptRF reagent free measurement. Pulsar will be exhibiting their new non-contact microwave radar liquid velocity sensor on a purpose-built open channel demonstration rig and the VEGA stand will feature new contactless level radars. Technolog will demonstrate the Cello 4S, a new remote telemetry outstation which delivers a scalable machine to machine (M2M) solution, monitoring multiple site parameters and transmitting data over 2G (GSM/GPRS) or 3G networks. New to WWEM will be Bell Flow Systems’ Aqualink telemetry systems featuring a cloud based client portal providing a budget level M2M solution for remote data access and monitoring. Yara will use WWEM 2016 to launch a range of new products, adding to Yara’s Full Service Odour Control concept.

WWEM WORKSHOPS Over 80 free walk-in, walk-out workshops will operate from 8 different ‘rooms’ located within the Exhibition Hall. In general, the themes of the Workshops on the first day will be Process Monitoring and the themes of the second day will be laboratory analysis. The full Workshop programme will be available on www.wwem. uk.com and with such a large number of subjects to choose from, the organisers urge all visitors to plan their schedule in advance.

IWA CONFERENCE ‘Big Data’ and the ‘Internet of Things’ are starting to affect every industry, and the water sector is no exception. The IWA Conference will therefore provide an update on how data

collection and processing is affecting the management of water and wastewater, and how it will develop in the future. CIWEM CONFERENCE The CIWEM conference will also run over two days featuring leading industry professionals presenting their views on how the water and environment sector will look in 2050. Discussions will include the latest innovations including Built Environment SMART Cities, Energy &amp; Climate Change, Processed Water, Water Resources, Waste & Resources and Management & Regulation.

WORKSHOP: ‘MONITORING FOR HYDRAULIC FRACTURING’ Organised by British Water and Cranfield University with subtopics on setting baseline monitoring and ongoing monitoring, this workshop will be repeated on both days of the WWEM event.

ENVIRONMENTAL AND FOOD ANALYSIS SIG (EFASIG) MEETING EFASIG, a special interest group within the British Mass Spectrometry Society, will hold a meeting during WWEM 2016 in which speakers will address a variety of subjects within an environmental and food analysis theme. The keynote presentation with be given by Professor Luigi Mondello from the University of Messina in Italy.

FLOW FORUM (2ND NOVEMBER 2016) Hosted by Oliver Grievson - Director of SWIG, Group Manager of Water Industry Process Automation & Control (WIPAC) and Anglian Water. The Flow Forum will address a number of key themes including the correct ways to collect the right data, reaping the benefits of flow monitoring, and area velocity flow measurement.

SUMMARY “WWEM 2016 is set to be an enormous event,” says organiser Marcus Pattison, “An extraordinary number of exhibitors will be launching new products at the Exhibition and the core elements of WWEM have all grown significantly. This has attracted major organisations for which there is significant synergy in co-locating their events with WWEM. By doing so, they are providing their delegates with an opportunity to benefit from access to WWEM 2016 and as a result, this has become the major global event for anyone involved with testing and monitoring in the water sector, so we are expecting very large numbers of attendees.”

For more information and to register visit the WWEM website www.wwem.uk.com

PROCESS INDUSTRY INFORMER September 2016

FLUIDS & LIQUIDS HANDLING

incl. Pumps & Valves

EASY-CLEAN, QUICK-STRIP PUMPS FOR FOOD & PHARMA DUTY Transferring liquids in food, brewing, pharmaceutical and other similar hygienic process applications requires reliable, easyto-clean and easy-to-maintain pumps. Liquids handling specialists PUMP ENGINEERING offer a wide range of pumps which are ideal for these situations. For example their range of CSF CS, CSA and CSM centrifugal pumps are capable of handling capacities from 1 to 550 m3/hour at heads up to 155 metres. CSF pumps are manufactured in investment cast AISI 316L stainless steel, with stainless steel for all wetted parts. They also feature a 6 vane impeller which ensures gentle and effective handling of the ingredients used in many food and pharmaceutical processing applications, for example syrups for soft drinks manufacturing and those containing particles or small solids. The pumps are designed for CIP (Clean-in-Place) to ensure the absence of dead areas and feature electro-polished finishing of all surfaces. CSF pumps are available with standard or ATEX certified motors, these are back pull-out design and fitted with a quick-release clamp to enable fast and simple dismantling. The CSA version has an electro polished finish to 0.5µm Ra and is approved to US FDA 3A standard or European EHEDG standards, with an aseptic version available for pharmaceutical applications. Depending on the duty CSF-CS and CSA pumps can be supplied with an internal or external single mechanical seal or flushed double mechanical seal for handling high temperature liquids, or those with a tendency to crystallise. Elastomers are available in a choice of Viton, EPDM, silicon or PTFE. Typical applications for CSF-CS hygienic pumps include transferring syrups, sugar solutions, flavourings, salad washing, alcohols, beer, milk, oils, vinegar, fruit juices, high purity water, CIP solutions, suspensions, yeast and melted butter. Further details on CSF pumps are available from: Pump Engineering Ltd, Littlehampton, West Sussex. Tel: 01903 730900 E-mail: sales@pumpeng.co.uk Web: www.pumpeng.co.uk

ALICAT ADDS 20SLPM MODEL TO BASIS™ MASS FLOW CONTROLLERS Compact, reliable gas flow for OEM and process use

Alicat Scientific has expanded its BASIS™ line of mass flow controllers, adding a new 20SLPM model to fit a wider range of applications including sparging into liquids, sample dilution, and many gas mixing applications. Specifically designed for original equipment manufacture and process integration, BASIS is Alicat’s smallest footprint instrument, providing fast, accurate control of gas flow rates in an economical, easy-to-integrate package. Ideal for use in OEM gas analysers, automated gas mixing on process lines, and anywhere basic mass flow-only control is required, the BASIS family now offers models with full scale at 100 cubic centimetres per minute, 1 litre, and 20 litres per minute. Stocked and ready for quick ship on evaluation orders, all BASIS units are instantly on and performing at full accuracy in just 70 ms. A 100 ms control response enables BASIS to react in real time to upstream fluctuations. NIST-traceable accuracy is +/-(1.5% of the reading + 0.5% full- scale). BASIS is available with the following multi-gas calibrations: Air, Ar, CO2, N2, O2, N2O (selectable over serial connection); He, H2 are also available in single-gas units. Multiple communications options – RS-485, RS-232 and Modbus Serial; and 0-5 Vdc analogue – mean BASIS can be built into a broad range of end-user products. For process applications, the availability of analogue and digital feedback allows for both PLC and PC control options. To learn more about Alicat’s BASIS mass flow meters, contact Alicat Scientific, Tucson, Arizona, Tel: +1 520.290.6060 Email: info@alicat.com or visit www.alicat.com/basis

PROCESS INDUSTRY INFORMER September 2016

NON-NEGOTIABLE:

THE IMPORTANCE OF RELIABILITY IN VALVE ACTUATION By Richard Harvey of IMI Precision Engineering

For the optimal control of many processes, it is crucial that a valve reaches a certain position. The process of moving from one position to another is governed by the valve’s actuator, a type of drive that is responsible for moving or controlling it. For safety critical applications, the actuation of the valve (the ability of the system to move the valve to a safe condition in response to demand), is of fundamental importance.

neumatic or hydraulic actuators are a well proven means of controlling such valves and these fluid power actuators are, in turn, predominantly operated using an electromagnetic solenoid valve. Many solenoids operate within systems that can stay in one position for many years, with an overall lifetime of decades. They are often used in systems that ensure safety, for example to shut off, release or distribute fluids. As such, their reliability is of paramount importance. In these circumstances, any failure in actuation can have catastrophic results, so reliability is non- negotiable. Solenoid valves have many advantages. They are flexible, being made in many designs with various ports and fluid paths. When chosen and used appropriately they can provide safe switching, reliability, durability and resistance to extreme conditions, extensive lifespan and compact design. However, historically they have often been seen as the weak link in the final element assembly as they are often chosen based on cost and not design. Solenoid valves must be suitable for the environment in which the valve operates. The valve must be able to resist corrosion, dust, water and other environmental aggression, for many years, and must have suitable hazardous area and safety certification. But what qualities and conditions are required to achieve optimal operation? The answer lies in a combination of unit design and the management of operating forces, as we shall see.

IDEAL CONDITIONS The reliability or otherwise of a solenoid valve is largely dictated by the forces acting within it. Chief among these are the forces of magnetic flux, retentivity, friction and spring force. For a solenoid valve to be reliable, the optimum factors when it is closing, and those that are ideal during opening, are quite different. The ideal parameters for closure are a high force friction ratio (FFR), i.e. low internal friction and a high return spring force, and a low dangerous failure rate. On opening, the ideal conditions are:

• Low internal friction, • High magnetic flux to spring force ratio, and • A low safe failure rate.

Understandably, these parameters are not always achieved without effort and careful design.

• Core tubes reduce cooling efficiency, so an integrated core, armature and coil construction may also help.

DANGEROUS FAILURES

The second type of safe failure is when valves fail to open on demand, which may be termed a pull-in failure. Over a period of time, cable damage or termination corrosion can cause an increase in resistance which subsequently causes a reduced voltage at the solenoid valve coil. Under such circumstances, the voltage may fall to below the required pull-in voltage of the solenoid. During a PST, the solenoid coil is de-energised and then re-energised at the end of the test. However, whilst the coil voltage was sufficient to hold the valve in the open position, it is insufficient to pull-in (re open) the valve from its closed position. As a result, the process valve completely closes, causing an unintended trip. This can be avoided by checking the coil voltage prior to initiating a partial stroke test. One way to improve safe failure rates is to improve magnetic flux as this allows higher margin of flux over spring force. Fortunately, there are several ways of promoting optimal magnetic flux. Most solenoid valves use a wet armature arrangement where the internal magnetic components are exposed to the instrument media. Therefore a corrosion-resistant material must be used. Unfortunately, such hard magnetic materials reduce the maximum magnetic flux and increase retentivity. In contrast, a dry armature, where the magnetic components are isolated from the instrument media, allows for soft magnetic materials to be used which exhibit increased maximum magnetic flux and reduced retentivity. When looking to improve magnetic flux, the core design, and in particular the magnetic path integrity, should also be considered. A core tube design leaks magnetic flux as there are air gaps between the coil and the tube, whereas an integrated design maximises flux strength.

A dangerous failure is one that prevents the solenoid valve from performing its safety function when required, on demand. This type of failure often occurs because friction and stiction have’ increased over time. The load holding the valve in the open position increases to the point where the spring force is no longer sufficient to close the valve. A dangerous failure occurs when spring force &lt; friction + retentivity.

In order to improve performance against dangerous failures it is necessary to improve the Force Friction Ratio (FFR). This is the ratio of the spring force to the friction and retentivity within the valve. The following steps can improve the FFR: • Reduce the friction in the valve by minimising the number of dynamic seals. Dynamic seals add friction to the design, therefore using a poppet type valve rather than spool valve reduces the in herent friction • Increase the spring force. This requires improved magnetic flux, so the magnetic efficiency must be improved as the power available is typically limited by the PLC output card

SAFE FAILURES In safety related systems it is important to periodically test all of the final elements to prove that the safety function is working to the required performance. This means that it is essential to test the solenoid valve in addition to the actuator and process valve. Safe failures are the biggest concern when solenoid valves are tested. There are two types of safe failure: the spurious trip (which occurs during normal operation); and the failure to operate on demand, which causes a spurious trip during partial stroke testing (PST). One example of a spurious trip could be where the solenoid coil burns out, there is a loss of magnetic flux and thus the process valve closes. The safe failure rate will be improved if burn-out

APPLICATIONS To summarise, optimising solenoid valve design, and in particular ensuring reliable actuation, is absolutely crucial to ensure good outcomes both in PST (where it maximises the diagnostic coverage and minimises spurious trips) and in daily applications. In fact, it is in day-today use that reliable actuation becomes most important, ensuring safety, efficiency, product quality and productivity.

can be prevented, in which case the following may apply:

• Reduce the coil running temperature. • Ensure efficient thermal dissipation.

PROCESS INDUSTRY INFORMER September 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves

SOFT SEATED SHUT-OFF PINCH VALVE SOLUTIONS

AKO’s soft seated shut off valve is the best solution for isolating and regulating abrasive, corrosive and fibrous products.

Soft seated shut off pinch valves with a rubber bladder are being used more and more as an isolating or regulating valve for emulsions, sludge, dust, gaseous materials, compressed air, powder, pellets etc. As a result, the need for these valves in the industry is greater than ever so manufacturers are keeping high levels of stock. This aims to satisfy users of squeeze valves because they will have very low down time while replacing or repairing any existing valves in their systems. The rubber membrane inside a squeeze valve closes off extremely quickly, and always closes in the same shape which ensures a longer service life. Squeeze valve parts are efficient and effective, and also; • Compact • Low weight •Available with a large variety of different rubber bladders To learn more about AKO’s range of pinch valve products, please visit www.pinch-valves.com

PROCESS INDUSTRY INFORMER September 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves TOUGH, HEAVY DUTY GEAR PUMPS FOR INDUSTRIAL PUMPING The extensive range of Viking Pumps provides one of the widest choices of pumping technologies and designs available today underpinned by Viking’s breadth of fluid handling knowledge and application expertise in solving the most challenging pumping problems. These pumps are available from

MICHAEL SMITH ENGINEERS who are able to provide Viking pump users with a wealth of practical and technical experience for the complete range of Viking positive displacement pumps. The range comprises four pump types; External and Internal Gear, Rotary Lobe and Rotary Vane, so a wide span of flow rates and discharge pressures are covered. Internal gear options include a Universal Seal pump.These are available in 12 standard size options providing flow rates up to a maximum of 345 M3/Hr and are designed to meet the demands of heavy-duty, industrial pumping applications, even in the most challenging environments. An important feature of Viking Universal Seal Pumps is that they are designed to accommodate virtually all types of seal. These can be packing, component or cartridge mechanical seals which can be easily fitted, usually without bracket modifications and are easy to maintain as the simple design of their internal gear pumps means that there are only two moving parts. Heavy duty bearings & brushings support the extended life of the pump & seal. The pumps are available in a wide range of construction materials including cast iron, ductile iron, cast steel, stainless steel and alloy C allowing broad chemical compatibility with a huge range of liquids. They are ideal for high volume, continuous duty liquids transfer across many industry sectors including, general processing, chemicals, food & beverage, oil & gas, refining, plastics, resins and rubber and pulp & paper. For more details go to : goo.gl/7qRkCl Or contact Michael Smith Engineers, Tel: 0800 316 7891 E-mail: Info@michael-smith-engineers.co.uk

PARKER HANNIFIN INTRODUCES CHEMICAL & FLUID RESISTANT SOLENOID VALVES FOR DEPENDABLE USE IN HARSH & EXPLOSIVE ENVIRONMENTS The Fluid Control Division Europe of Parker Hannifin Corporation, the global leader in motion and control technologies, has announced the release of new stainless steel solenoid valves. The 221G range offers unrivalled resistance to corrosion and aggressive chemicals, and with its ATEX certification, is suited to use in explosive environments. With a durable high-grade 316L stainless steel construction plus fluoroelastomer (FKM) sealing to provide fluid and chemical resistance, the 221G series combines long life and reduced maintenance requirements in the harshest operating environments. Typical applications include those found in oil & gas, petrochemical, food processing and pharmaceutical installations. Due to their high flow rates of up to 170 litres/min., the new valves provide an opportunity to reduce the overall size of customer installations and cut costs by up to approximately 10%. 221G series valves are based on proven technology that has evolved over 40 years and is used in a popular sister family offered in brass.

The Fluid Control Division Europe of Parker Hannifin is a worldwide leader in solenoid valves that control motion, flow and pressure. More information is available at www.parker.com/fcde.

NEW DESIGN OF AIR OPERATED DOUBLE DIAPHRAGM PUMP RAISES THE BAR OF PUMPING PERFORMANCE A comprehensive range of Air-Operated Double Diaphragm pumps (AODD) which represent one of the most reliable, rugged and affordable of their type available on the market have been introduced by MICHAEL SMITH ENGINEERS. The all-

new Finish Thompson FTI AIR range has been meticulously designed using the extensive resources available to FTI and include all the benefits of AODD pumps in addition to FTI’s own innovative features. The FTI AIR range offers the important benefits of using AODD pumps; simple installation, easy to operate and run with low maintenance and running costs, self-priming, portable, dry-running, can handle abrasive, viscous and shear-sensitive liquids and even ‘dirty’ liquids with particles. In addition, a unique lube-free air valve design contributes towards the philosophy of a simple, rugged and reliable design. This design features significantly fewer components compared to other air valves, resulting in reduced servicing time and the associated maintenance costs and downtime. The air valve components include; a low friction slide valve on a ceramic plate to allow for long-life and superior sealing, a moulded Buna gasket which ensures total sealing and eliminates flat gasket tearing. Also, air is used through a slot in the diaphragm shaft to shift the valve, eliminating the need for a separate pilot valve or mechanically operated pilot valve. In addition to their rugged and simple design with fewer components, is a modular construction which also results in simplified maintenance with individually replaceable, lower cost wearing parts which do not require special tools for fitting. Single piece flow assembly procedures means that every pump is built to the highest quality of specifications and every pump is tested with a three point test for vacuum, leakage and run ability. FTI Air pumps provide outstanding installation flexibility. For example, while flooded suction is the most common installation, they can also be used in suction lift applications where the pump is installed above the liquid, or even submerged in the liquid. Thanks to the numerous benefits of using air-operated double diaphragm pumps they are ideally suited to a wide range of pumping applications in many industries such as; chemical manufacturing, mining, paints & coatings, ceramics, pulp & paper, electroplating & anodising and waste water. For more information contact Michael Smith Engineers Ltd, Woking, Surrey. Web: goo.gl/w3zpM3 or Tel: FREEPHONE: 0800 316 7891 Email: Info@michael-smith-engineers.co.uk

PROCESS INDUSTRY INFORMER September 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves NEW OILS DELIVER HIGHEST EVER UK FLASH POINT The UK’s process industries now have access to two new thermal fluids boasting the market’s highest ever flash point, offering an unparalleled degree of long-term safety and costefficiency. Thermal fluid system support, maintenance and risk management service provider to process industries worldwide, Thermal Fluid Solutions (TFS), has launched TFS Magma Ultima and its food grade sister, TFS Thermaltrans FGS, two semi-synthetic heat transfer fluids with a closed- cup flash point of over 260˚ C. A fluid’s flash point is the minimum temperature at which, in the presence of ignition sources such as light switches, pump failure or sparks, its vapours will ignite and it becomes classified as “hazardous”. TFS’ fluids’ market-leading flash point means that they may safely be used in systems operating at a bulk (highest average) temperature of up to 300˚ C and film (container boundary) temperature of up to 325˚ C. The chemical composition of these highly refined oils ensures a considerable level of stability, allowing the fluids to resist for longer the process of degradation and consequent flash point reduction. The fluids create a minimum of carbon deposits and varnishes, so permitting longlasting system cleanliness and efficiency. They are also resistant to water contamination. TFS’ two new oils have been launched following six months of stringent testing at the firm’s Derbyshire headquarters. Said managing director, Richard Franklin: “Our new oils present a very exciting opportunity for the UK’s 3,000-plus process manufacturers who operate thermal fluid systems to transfer heat around their plants. “They will enable companies to operate their systems safely and efficiently at high temperatures longterm, reducing the frequency with which oil needs to be reconditioned or replaced to ensure that vital parameters such as minimum flash points are maintained.” In addition to the supply of oils and HTFluidfit, TFS’ individual services include fluid testing, analysis and advice; water removal; drainage and refill. The company also offers a comprehensive, continuous risk management service, ensuring the safe and efficient operation of customers’ thermal fluid systems and legislative compliance, via the creation of bespoke improvement plans. For more information contact Thermal Fluid Solutions (TFS), Buxton, Derbyshire. Tel 01298 815862 Web www.thermalfluidsolutions.com

PROCESS INDUSTRY INFORMER September 2016

THE IDEAL PUMP FOR FOOD & COSMETICS APPLICATIONS Looking for a pump that can self-prime, stall under pressure, pump particles and run dry? Look no further than Graco’s new SaniForce 1040e. Here are the key reasons why.

The Graco SaniForce 1040e pump is the first electric double diaphragm transfer pump with all the advantages of an airoperated pump. The electric drive ensures energy efficiency, quiet operation, batching and dosing capabilities. While it consists of the same fluid parts as a conventional air-operated diaphragm pump, this pump can self-prime, stall under pressure, pump particles and run dry.

STALL WITHOUT DAMAGE

HOW IT WORKS

JUST WATCH IT BATCH!

The SaniForce 1040e has an innovative center section that is filled with air. With every rotation, the electric drive pulls the diaphragms, which are not mechanically connected with each other. The air in the center section pushes the opposite diaphragm out, allowing the pump to operate. This unique design not only reduces pulsation but also allows the pump to stall under pressure. The center section can be aluminium or stainless steel, while the fluid section can be aluminium, polypropylene or stainless steel. Maximum fluid working pressure is 4.8 bar (0.48 MPa / 70 psi). Air pressure operating range is 1.4 to 5.5 bar (0.14 to 0.55 MPa / 20 to 80 psi). Cart mounted systems are available. The SaniForce 1040e is available in brushless DC, AC and AC ATEX options. The brushless 2HP DC motor offers increased control, maintenance and alarm notification, batch operation, and meets API 675 and ANSI 7.1-7.5. The electric 2HP AC motor offers increased efficiency, ATEX options, and runs on 110V, 220V or 480V. “Its innovative features, combined with the quality and reliability of Graco’s high-class manufacturing standards, make the SaniForce 1040e an excellent choice for transferring a wide range of food and cosmetics products,” explains Walter Leeten, Product Marketing Specialist Process at Graco. “In addition, it runs quietly, which makes it ideal for

operations in close proximity to people, and its CE 1935/2004 approval is a key requirement in many food and cosmetics applications.”

The SaniForce 1040e can stall under pressure without installing any pressure sensors, and without damaging the pump or the production line. This means you don’t need to worry about blocked or clogged lines, or closed valves. Stalling increases diaphragm lifetime, and reduces the threat of contamination as there’s no hydraulic backing.

The SaniForce 1040e comes in two motor versions: AC and DC. With the Graco controls on the DC version the pump can deliver product and then stop pumping with 1% precision. In other words, if you need to accurately batch, it’s perfect.

SUITABLE FOR THE MOST SENSITIVE MATERIALS

You will undoubtedly know the unwanted effect of a centrifugal pump on sensitive materials. Feed your material into the pump – and you’re not always sure what’s going to come out, because the high rotational speed of a centrifugal pump can change the structure of the material. The low shear, low pulsation SaniForce 1040e is ideal for food and cosmetics applications in which product ingredients need to be transferred without any change to the consistency and structure of the ingredients.

NO WORRIES ABOUT RUNNING DRY If you are operating progressive cavity pumps, you know that you have to keep a careful eye on them in case they run dry. If they do, you’re in trouble. In fact, if a progressive cavity pump runs dry, you might soon be running out to buy a replacement. No such problems with the SaniForce 1040e. Install it and forget it. The pump is self-priming too.

NEED TO PUMP INGREDIENTS WITH PARTICLES?

Here too, this pump has an advantage over comparable progressive cavity pumps. It will pump ingredients with particles up to 3.2 mm in diameter. That’s more than adequate if your dosing station needs to receive peas, fragments of tomato, herbs etc.

ENERGY EFFICIENCY

Its energy efficient electric drive reduces energy consumption by up to five times compared to traditional air operated diaphragm pumps. In applications where saving energy is the key driving force, the SaniForce 1040e is an interesting replacement for AODDs running in continuous duty applications. It’s eye-opening to compare the SaniForce 1040e 1” EODD with a conventional 1” AODD. Let’s say that both are operating for 24 hours at a flow rate of 95 liters per minute and a fluid pressure of 3.5 bar. The air required for the 1040e is a paltry 0.6 liters PER DAY. Compare this to the air required for a conventional 1” AODD, which needs 700 liters PER MINUTE. This corresponds to an annual operating cost for the SaniForce 1040e of 460 EUR, compared to 2300 EUR for the conventional 1050 AODD: a 5x cost saving. You can find more information at www.esaniforce.com where you can download the product leaflet, or by contacting Walter Leeten at walter.leeten@graco.com

KEY FEATURES

• 1” pump size • DIN or Triclamp connection • Transfers up to 132 l/min • Max 3.2 mm particles • Max 4.8 bar fluid pressure • Stainless steel wetted parts • AC, AC Atex and Brushless DC motors • Aluminium and stainless steel center sections • CE1935 approved models

WATER & WASTEWATER VEOLIA WATER TECHNOLOGIES’ WATER MAPPING WILL HIGHLIGHT WATER USAGE & RECOMMEND TECHNOLOGIES TO REDUCE WASTAGE Veolia’s reco360° water management approach is helping more and more companies to achieve cost savings, by mapping water resource usage across their manufacturing operations. Water is a critical part of manufacturing processes and Veolia’s highly experienced reco360° team is committed to delivering a sustainable service by working with customers to optimise water quality and capacity, whilst reducing water and energy wastage. Veolia offers a range of water treatment systems together with specialist chemicals to improve the efficiency of boilers, cooling towers and conventional water and wastewater treatment equipment. All water treatment systems are supported by service technicians and engineers with in-depth specialist knowledge and expertise. Veolia’s unique Vision and Vision Air Online Portal allows remote monitoring and management of documents to ensure that it is running efficiently, whilst Veolia’s Reco Solutions online calculator tool demonstrates the cost savings that can be generated by sound water management. Based on the success of recoBLUE recovery systems (part of Reco Solutions) which allow cost efficient reduction waste streams from even the smallest reverse osmosis plants, the reco360° team has developed a range of High Recovery Reverse Osmosis systems for producing high purity water from industrial, brackish and even wastewater sources. Learn more about Veolia’s reco360° approach by downloading the white paper “Ensuring Stability and Resilience in Sustainable Process Water Technologies” at reco360.veoliawatertechnologies. co.uk and find out how you can manage water sustainably as part of the circular economy. For more information contact Veolia Water Technologies, Tel: + 44 (0) 1628 897000 Web: www.veoliawatertechnologies.co.uk

ENCLOSURES NEW: RITTAL ROOF-MOUNTED FANS The new range of roof-mounted fans which deliver superior efficiency, flexibility, protection and ease of use have just been launched by Rittal.

The new range is designed to reduce the costs associated with operation, installation and maintenance while better protecting the installed equipment that they are required to cool. Running costs are reduced as radial fans, together with optimised air routing, serve to maximise the installed air throughput and minimise energy consumption. The fan performs effectively against pressure in a housing that has been developed to reduce resistance to air flow to a minimum. Despite an air path with low resistance, the fans can protect the components inside the panel to an ingress protection (IP) category of IP 55. The entire range, which includes a passive vent and models that provide uninstalled air throughputs of 500 m³/h, 800 m³/h and 1,000 m³/h, utilises a single housing and hence a single cut-out, offering the flexibility to fit any unit to a single roof panel. What’s more, the fans with the largest air throughput incorporate electronically commutated (EC) motors to further improve efficiency. Mounting and filter replacement is quick and easy, thanks to a number of key innovations. These include a clamping mechanism that allows the fans to be fitted from either inside or outside the enclosure; quarter-turn fixings that permit access to the filters; and a plug terminal electrical connection. Collectively these design features help keep installation and maintenance costs to a minimum. Further information contact Rittal Ltd, Rotherham, South Yorkshire. Tel: 01709 704000 Web: www.rittal.co.uk E-mail: csd@rittal.co.uk and www.friedhelm-loh-group.com or on twitter @rittal_ltd.

CHOICE OF ENCLOSURES FOR NEW RATE TOTALISERS

REDUCE YOUR WASTEWATER & TRADE EFFLUENT COSTS Accurate monitoring and measurement equals savings for processing businesses

Flow measurement experts, Detectronic, are helping process industry businesses save money on wastewater and trade effluent charges using state-of-the-art monitoring and measurement. By providing accurate data to Water and Sewerage Companies (WASCs) and Environmental Agencies, companies discharging large amounts of wastewater to rivers, sewers and other water channels can correctly address their disposal charges and meet their obligations under the Integrated Pollution Prevention & Control (IPPC) Directive. Every business that creates wastewater and trade effluent is charged by its respective water company. Many organisations don’t have a clear understanding of how their charges have been calculated and the only way for them to know is by accurately monitoring and measuring volumes of water entering and wastewater leaving their plant. For more information contact Detectronic Ltd, Colne, Lancs. Email: industrial@detectronic.org Website: www.detectronic.org

PROCESS INDUSTRY INFORMER September 2016

New pulse input Rate Totalisers include the features and functions most frequently requested by users of previous BEKA totalisers, including smaller enclosures for applications where panel space is limited, rugged 316 stainless steel models for marine and severe environments and even larger displays in the 144 x 72mm models. All have IP66 front of panel protection and include a lineariser, with an optional display backlight, isolated synchronous pulse output, isolated 4/20mA output and dual alarms. Intrinsically safe models have ATEX, IECEx, US and Canadian certification allowing worldwide installation in gas and dust hazardous areas. For applications in Zone 2 or 22, Ex nA and Ex tc approval permits installation without the need for Zener barriers or galvanic isolators which significantly reduces installation cost. Although well documented and easy to configure on-site, these Rate Totalisers can be supplied configured with scale card marking to customers requirements for no additional charge. For further information including datasheets and certificates please visit goo.gl/PpTA48 or phone the BEKA sales office on 01462 438301.

WEIGHING TAKING WEIGHING TO NEW LIMITS: XPR MICRO AND ULTRA-MICRO BALANCES XPR6UD5, the first ultra-micro balance on the market, delivers unique 0.5µl resolution while XPR10 offers an extended 10.1g capacity. This new XPR balance model from METTLER TOLEDO offers 25% better repeatability than traditional microbalances through innovative features such as Active Thermoelectric Cooling (ATC) and ongoing quality-assurance checks.

METTLER TOLEDO is proud to announce the launch of its new XPR balance line. Offering both micro and ultra-micro models, XPR offers a welcome combination of usability, accuracy that is critical in industries such as pharma where sample sizes are small and productivity must be maintained. Notable in the new line is XPR6UD5, the first ultra-micro balance on the market. It offers 0.5µl resolution at 25% better repeatability than traditional microbalances using a blend of innovative design characteristics, including: • heightened stability via Active Temperature Controlling (ATCTM), which draws heat away from the balance for enhanced measurement accuracy and repeatability, • ongoing quality assurance through GWP Approved, which automatically checks tests, adjustments, leveling, and settings prior to weighing, and •user profile storage with Tolerance Profiles, which ensures that weighing tasks meet defined process requirements and applicable regulations. Usability is delivered by a small bench print and new user interface that, similar to a smartphone, allows users to swipe on programming and running tasks. A built-in result notepad simplifies documentation and lets users to store comments. Individual task methods can be stored and accessed via icons, saving time and enhancing process security. Additional XPR design benefits include a new weighing pan for easier cleaning and USB data transfer for quick export of task parameters or results. A two-screen system allows the main touchscreen to be placed wherever it is more ergonomic and convenient. Taken together, XPR’s productivityenhancing features and repeatable micro-range accuracy allow it to create a new level of productivity for companies working with small sample sizes. Learn more about how XPR balances take the worry out of micro-range weighing and ensure valid results every time. For more information contact METTLER TOLEDO AG, Laboratory Weighing Im Langacher 44, 8606 Greifensee, Switzerland Tel.: +41 44 944 20 39 Email: branko.radovinovic@mt.com Web: www.mt.com

PROCESS INDUSTRY INFORMER September 2016

LOGISTICS IN THE DIGITAL AGE: THE SECURITY IMPLICATIONS Kirsten Williams & James Pothecary, political risk analysts covering Europe, Russia & MENA at Allan & Associates The technology boom in logistics has had enormous benefits for businesses. Companies keen to ensure the safety of their cargo and improve the efficiency of their routes can now track shipments. Clients can see when their delivery will arrive and engineers can use mobile devices to control industrial processes. New technology will transform both business and society.

owever, with new technology comes a greater risk of sophisticated cyber attacks, especially against transporters in supply chains and programmes that monitor processes. Today, hackers can reveal and coopt tracking technology; port systems can be hacked to move or even remove containers; and entire control systems can be altered or taken offline. This poses a huge risk for logistics companies dealing in process engineering.

NOT-SO- SMART TECHNOLOGY Smart devices connected to digital networks tend to be insecure and unguarded. This leaves commercial and personal networks highly vulnerable to infiltration. On 5 August 2016, security researchers successfully hacked a Nest smart thermostat. Criminals replicating this feat could monitor when homeowners were away from the property. This incident is deeply concerning not just because it shows how devices can be rendered useless or otherwise manipulated by malicious hackers, but how such smart technology can be used as an entry point to a company or individual’s entire online network. Such hacks of thermostats and other “smart” control devices have the potential to cause ruinous levels of damage to a business. In December 2014, cybercriminals hacked into the emails of a German steel mill, stealing login information and using it to access the plant’s production systems. It forced the emergency shutdown of a blast furnace and caused major damage. Researchers believe that cyber attacks which cause physical damage are far more common than reports suggest, since companies are unwilling to publicise the cases. Attacks on control systems, when they cause physical damage, also make companies vulnerable to breaches of compliance standards. In a worst case scenario, a business could be exposed to massive litigation. Security researchers were even able to hack patient monitors in U.S. hospitals in February 2016, allowing them to gain access to confidential data and tamper with vital information. Were hackers to do the same, this could be even more damaging than their current approach, which is to lock hospitals out of their patient

files by encrypting them until a ransom is paid, usually in the virtual currency Bitcoin. One anti-hacking consultancy estimates that there has been a fivefold increase in cyber ransom attacks in Europe in the last year, from 131,000 to 718,000. Cyber-criminals have combined with pirates to stage audacious attacks. In 2016, communications company Verizon reported that the vessels of one of its clients, a global shipping conglomerate, were repeatedly attacked by pirates: they would board the ship, contain the crew in a particular area and then leave a short time later, after stealing from particular containers that they identified by their barcodes. Verizon discovered that the pirates had hacked into the company’s online content management system and downloaded the ships’ cargo manifests. Sophisticated hacks mean that logistics companies risk becoming unwittingly involved in serious crime themselves. Workers at the Belgian port of Antwerp had no idea that their location system had been hacked until entire containers started to disappear in 2013. It later transpired that a Dutch organised crime syndicate had been hiding drugs, guns and cash in legal shipments over a twoyear period. Hackers had changed driver credentials and schedules so organised crime gangs could arrange for their own drivers to smuggle the illicit goods out of the port in accredited lorries. One lorry driver with no links to the gang accidentally drove off in a container filled with cocaine and narrowly escaped being shot dead.

THE DYSTOPIAN NIGHTMARE: JUST A DREAM A primary concern amongst the general public and commercial entities, particularly those engaged in sophisticated and sensitive industries, is the threat posed by foreign hostile governments. However, as it currently stands, the realistic threat this poses to commercial entities is low. Government cyber attacks are primarily (although not exclusively) focused on hostile states. These occasionally take the form of the classic nightmare scenario – the U.S.-Israeli Stuxnet virus that was used against Iranian nuclear digital infrastructure is one example. The Lithuanian and Estonian

parliaments, and the Ukrainian power grid, all accuse Russia of employing hackers against them. The state-owned Islamic Republic of Iran Shipping Lines (IRISL) was targeted by hackers who stole information and crashed its tracking system in August 2011. The head of the IRISL said that the extent of the attack suggested it was being backed by ‘powerful sources’. The shipping line has long been affected by Western sanctions after being accused of transporting weapons, an accusation it denies. Yet such efforts are politically focused, and rarely target commercial interests. In the case of Iran in particular, the country has powerful enemies and is thus a special case. For the moment, businesses should not be overly concerned by state cyber-attacks. As it currently stands, such attacks, when they do occur, are limited to denial of service (DDoS) or distributed denial of service strikes (DDoS). These attacks flood company networks with traffic, causing them to crash, and in the case of DDoS, can be orchestrated by hundreds of thousands of computers. While superficially alarming, they do not pose a substantial long- term threat to commercial entities.

CONCLUSION The increasing reliance of companies on automated online systems simultaneously raises the security risk facing the company from hostile outside forces. Conversely, failure to take full advantage of such systems will leave a company at a competitive disadvantage. In order to find a compromise between these two positions, companies must invest in cyber security at the same time as they move more and more elements of their business online. The admittedly substantial costs of investment in cyber defence must be regarded by all businesses as an essential and non-negotiable aspect of moving commercial data and system functions into the digital realm, as the potential consequences of failing to do so could be catastrophic. However, with the right level of protection, the benefits of technological advances far outweigh the risks.

RUPTURE DISC

RATIONALISATION By Andrew Williams, Technical Sales Manager, Elfab Limited - Reduce stock holdings by 65% without increasing long-term costs Process Plants are coming under more and more commercial pressure. Reduction in spend without affecting quality or performance is playing a major role in the day to day running of many sites. The implementation of a rupture disc stock rationalisation programme is proving to be a cost-effective way of improving efficiency while reducing long-term costs and future-proofing the plant. Elfab Limited share its 80 years’ manufacturing experience and discuss the real benefits of rupture disc rationalisation to the modern process plant.

eading rupture disc manufacturer, Elfab Limited, has over 80 years’ experience in the pressure management industry, supporting major industry players in maintaining a safe process environment across the globe. Over this time, Elfab has developed industry-leading products to help implement a stock rationalisation program that has long-term sustainability and real benefits to the customer. In this article, Elfab discusses the common issues experienced across a range of industries and explain how a rupture disc stock rationalisation program can help overcome such problems and improve process conditions all while reducing overall spend.

THE PROBLEM Most industrial plants in the UK and Europe were built between 1960 and 1980 and were expected to operate for no more than 40 years. However, many are still operating today several years past their expected life span. Over time, process conditions within ageing plants can change dramatically. Even very small differences in process settings has resulted in plants holding an unnecessarily large variation of Rupture Discs onsite, or operating with product that was not specified or designed to operate under the current conditions. As a result companies have found themselves holding an unnecessarily large amount of stock, or replacing rupture discs at a more rapid rate due to the design no longer being suitable for the way the plant is being operated. Consequently, the risk of hazard and human error increases, as well as the complexity of stocking a large range of rupture discs with varying burst pressures and temperatures within disc specifications. As process plants have been changing, rupture disc manufacturers have also been developing. Over the past 40 years, rupture disc technology has changed significantly. Manufactures have developed rupture disc solutions with superior technical features that if used correctly could irradiate many of the issues these aging plants are experiencing. Elfab, shares its experience in working with major process plants and discusses some of the common findings that are leading to unnecessary overspending and high inventory levels.

OPERATING WITH OUT-OF- DATE TECHNOLOGY Plants can be operational for a number of years without the need (or the chance) to introduce any new technology. They simply run on the technology that was available at the time of commissioning. Over the past 40 years rupture disc manufacturers have significantly enhanced the performance

characteristics of their rupture discs but companies have not always taken advantage of these developments. Where once a single rupture disc specification was only suitable for a single location the development in tolerances and operating ratios may now allow companies to group similar product together. Companies are commonly making purchases off datasheets written 40 years ago and not reviewing whether a more modern solution is now available, this can lead to a build-up of unnecessarily high stock levels, potential for obsolete stock, higher purchasing costs and inefficiencies in how the process operates. Furthermore, in many instances operating conditions have changed significantly leading to a “creep” away from the intended functionality. Using a rupture disc that was designed for different process conditions can cause the product to fail early and incur higher and more frequent reordering levels or pose a danger to the plant, which should not go unaddressed.

LACK OF GLOBAL SITE DATA Procurement systems have often been setup to identify each individual rupture disc as a separate item with its own part code and separate stock level, without recognising that one specification may be suitable for use in multiple locations. Setting the system up in this way can lead to the purchase of additional stock when the system indicates that one of these parts requires replenishment, despite a suitable part being located elsewhere in the stock system.

LACK OF FORWARD PLANNING Products are often purchased without long-term planning. A buyer may not be aware of future demand or potential requirement that the plant may have, and often only consider what is required at the time of ordering. All rupture disc manufacturer’s offer quantity sensitive pricing, making it as cost effective to buy three rupture discs as it is to purchase a single unit. Rupture disc manufacturers recommended at least one spare rupture disc to be held in stores and a second is available as a backup during installation. Too frequently only one disc is purchased which significantly increases costs and higher frequency of purchasing the same part.

ADVANTAGES OF A STOCK RATIONALIZATION PROGRAM Today’s advanced rupture disc technology means that products have greater technical capabilities to suit a wider range of applications and installation points. Individual rupture discs can now offer a single disc solution for various process conditions which can eliminate up to 65% of previously problematic stock variation while significantly reducing long-term spend. Rationalisation programs not only enhance stock management but overhaul the site with the latest rupture disc technology enabling significant processing efficiencies at the same time as cost reductions. By investing in the latest technology, the plant will be able to run at maximum operating conditions without fatiguing the disc or affecting its life span.

REDUCED STOCK VARIATION

RELIANCE ON MRP STOCK LEVELS Relying on the data within a company’s MRP system can have a major impact on stock levels and unnecessary overspending as the system is only as good as the quality of information within it. In many cases, product is re-ordered without checking whether the product has been used. In-house MRP systems automatically produce purchase orders when stock levels reach a pre-determined level. In some plants, a replacement unit is ordered as soon as one is used, this system does not allow the plant to benefit from economies of scale, as no discount is being offered by the supplier due to the low volumes being purchased. Consequently, Stock controllers have been purchasing products to replace low stock levels without checking levels of demand or accuracy. Spare parts are being kept in stores that are no longer used or required, but simply because the company’s in-house system indicates that levels are low.

To introduce a successful stock rationalisation program and to allow customers to make significant stock reductions, advanced, reverse-acting, rupture disc technology must to be introduced across the process plant. Traditional, forward-acting or graphite, rupture disc technology had limited technical characteristics, commonly manufactured with >10% tolerances and >80% operating ratios it was understandable why such stock variation was needed. The characteristics of the latest reverse-acting rupture disc technology boasts advanced 3% tolerances with 97% operating ratios, the real driver behind the success of stock rationalisation. By rationalising the plant through the capabilities of advanced rupture disc technology combined with greater flexibility across a wider material choice enables stock holdings to be greatly reduced, which in turn allows for significant cost savings. One disc will be able to suit a larger amount of locations resulting

PROCESS INDUSTRY INFORMER September 2016

reduction in spares orders. With the most technically superior rupture disc designs being tested to over one million life cycles, reverse acting technology has significant benefits over traditional forward acting technology.

REDUCING THE RISK OF HUMAN ERROR

in a much smaller stock catalogue. This enables multiple part types to be grouped together and replaced by one product part type that is technically capable for the combination of various process conditions. A real reduction in stock value seen by customers who implement a stock rationalisation program in this way is typically 50-65%.

By rationalising the plant and reducing the variation, the number of transactions subject to potential error will decrease. A reduced number of different disc specifications simplifies purchasing processes and leads to fewer mistakes being made. This simplification is also of benefit to plant maintenance technicians and reduces the need for training, as staff will only need to know how to install one type of rupture disc. Overall, costs are reduced and installation quality improves.

HOW TO IMPLEMENT A SUCCESSFUL RATIONALISATION PROGRAM In order to implement a rationalisation programme successfully, there are certain aspects which need’ to be addressed internally to the plant to benefit from the advantages that a rationalisation scheme has to offer. KEY AREAS FOR CONSIDERATION ARE: Material Standardisation

PURCHASING COST REDUCTION Commonly rupture discs are purchased on a 3:1 ratio for each location (one disc and two spares). As all products supplied are quantity sensitive, large costs can be incurred when purchasing in such small numbers. By undertaking a rationalisation scheme and replacing multiple outdated design with a 3% tolerance rupture disc, greater quantities of the same disc can be ordered to cover more locations around the plant, enabling procurement to benefit from lower purchase prices through economies of scale. Furthermore, rather than hold two spare discs for every location, a small number of spare discs can be held in stores that will suit multiple locations therefore reducing the stock holding even further.

FUTURE PROOFING By implementing a rationalisation programme, all discs will be manufactured using the latest reverse-acting rupture disc technology, which boast tighter tolerances and operating ratios, smooth surface finishes and increased vacuum and cyclic resistance. As well as a reduction in stock such advancements in performance characteristics can significantly improve the lifespan of the product, reducing long-term costs through a

Rupture disc material selection has traditionally been dependent on the individual process conditions of each unique application. By standardising on material choice and opting for a material that suits every installation point, this will allow for combined purchasing going forward. By implementing this strategy, it will simplify the reordering approach as all tag locations will have a standard material specified compatible with the individual process conditions. Research has shown that Hastelloy rupture discs offer superior stability across temperature ranges, with a drift < 5% vs graphite >35% for temperatures of up to 200˚C. Reconfiguration of Process Conditions

Rupture disc rationalisation can have a significant impact if process conditions are streamlined across the plant. Most process plants require no more than a +/-5% tolerance for the rupture discs, reviewing conditions in line with rupture discs offering 3% tolerances can reduce the number of different disc types that are required to cover the site. If similar processes can be brought in line with one another, then two or more different tag locations can be addressed with one pressure relief solution. Change of Buying Habits

Rather than purchasing only what is required at the time, future demand forecasts should be taken into consideration to benefit from discounts for higher quantities. This will allow the purchaser to acquire the discs at a reduced unit price and save costs going forward.

PROCESS INDUSTRY INFORMER September 2016

INTRODUCTION OF A CONTRACTOR PROCEDURE Contractors on site have traditionally bought what they deem to be the best product for their specification and budget, without contacting the plant owners. This has resulted in a lack of consistency through the plant, with discs from different manufacturers being installed. By creating a standard procedure and catalogue for contractors, they will only procure items from the plant owner’s preferred supplier. New sections of the plant will be designed in accordance with the standard conditions already in place on the plant. Conduct a site survey with the rupture disc manufacturer Conducting a site survey it’s the most effective way to ensure all tag locations are identified and the most realistic cost savings can be offered. Such a survey will ensure that any issues with future obsolescence is irradiated, future proofing the site. Manufacturers can undertake the survey with a representative of the plant to ensure the correct data is gathered and analysed prior to rationalisation. This will eliminate any errors in the rupture disc register that might have occurred since the plant has been running. By looking over the data and combining tag locations with similar burst pressures and sizes, reduced list of rupture discs can be compiled. Manufacturers can then propose a site wide solution.

ABOUT THE MANUFACTURER The company have over 15 years’ experience in supporting its global customer base with standardising current stock holdings of rupture discs to help improve productivity and reduce overall expenditure. Stock rationalisation programmes are being adopted by many process plants who recognise the need for increased efficiency, reduced stock holdings and improved purchase costs. The programme works by undertaking a full site survey, looking carefully at the differences in process conditions and the amount of rupture disc variations on site to see whether a smaller variation of ruptures discs is applicable or required. Their industry leading Opti-Gard™ rupture disc is theirmost advanced design, and the real key to a successful rationalisation program. Being the only rupture disc on the market to combine a 3% tolerance with 97% operating ratio. Opti-Gard acts as a single disc solution across a range of demanding process conditions in aid of improving rationalisation and sustainability. This disc also has the additional ability to withstand full vacuum without additional support, eliminating the need to re- order outdated type discs that require additional support, further reducing costs and future-proofing the plant for the long-term.

HEALTH & SAFETY TESTING FREE CHLORINE WHEN SUPERCHLORINATING FRESH PRODUCE

When processing fresh-cut produce like lettuce, disinfection is often carried out by adding free chlorine, in the form of hypochlorite, to the wash water.

Many standards stipulate that free chlorine must be maintained in the wash water at concentrations greater than 50 mg/l. This process, known as ‘superchlorination’, aims to avoid the formation of chloramines (also known as combined chlorine), which are formed when free chlorine reacts with nitrogenous compounds in the water, such as ammonia. Chloramines are weaker disinfectants than free chlorine. Currently there is no one perfect method to specifically measure free chlorine at superchlorination levels. However, Palintest offers a number of options for users aiming for superchlorination. These include the ChloroSense® method, the Iodometric Colorimetric method and the DPD Colorimetric method. Which one is used will depend on local circumstances and requirements. 1. ChloroSense® method ChloroSense® uses an electrochemical technique called chronoamperometry and includes an instrument and a disposable pre-calibrated sensor, allowing non-technical users to rapidly obtain accurate results. Although the device provides a free chlorine reading (up to 10 mg/l), operators can use the total chlorine reading (up to 100 mg/l) to demonstrate superchlorination has been achieved. Additionally, ChloroSense® is glass- and reagent-free and ensures traceability with integrated data logging, making it ideal for use in high-care and GMP environments. 2. Iodometric Colorimetric method Another method for determining total chlorine can be carried out using Palintest’s Chlorometer Duo. This is a colorimetric version of a standard method allowing total chlorine readings up to 250 mg/l – again demonstrating superchlorination has been achieved. 3. DPD Colorimetric method The DPD method is also available on Palintest’s Chlorometer Duo and has been the standard method for determining free and total chlorine in water for over fifty years. However, it has a limited test range (0 – 5 mg/l), meaning dilution on the production line is required. In most applications where water is expected to be maintained at superchlorination levels, the ChloroSense® or the Chlorometer Duo are proven and straightforward approaches to demonstrating effective disinfection is taking place. For more information contact Palintest Ltd, Gateshead, Tyne & Wear Tel: +44 (0) 191 491 0808 E-mail: Tom.Aylward@Palintest.com Web: www.palintest.com Twitter: @Palintest

NEW NANOSPONGE SURFACE ENHANCED RAMAN SPECTROSCOPY SUBSTRATES FROM OCEAN OPTICS Gold-silver alloy on SERS substrates detects trace level explosives and pesticides

Ocean Optics has introduced a new substrate for Raman spectroscopy applications. The new RAM-SERS-SP Surface Enhanced Raman Spectroscopy substrates use a proprietary gold-silver nanosponge alloy to produce highly sensitive, trace-level Raman spectroscopy measurements. The applications for SERS range from detection of explosives and narcotics, to food safety, anti-counterfeit tagging and biological research. SERS substrates amplify very weak Raman signals by many orders of magnitude. Fast, repeatable measurements of SERS-active analytes are possible even to parts-per-trillion levels. Silver-only SERS substrates work best with 532 nm Raman excitation, and gold substrates are better suited to 785 nm Raman systems. By combining the silver and gold on one substrate, the new SERS nanosponge substrates perform well with either wavelength. Also, when used with 638 nm Raman excitation, the nanosponge substrates are enhanced to an even higher level of sensitivity. RAM-SERS-SP nanosponge substrates are more robust than other options and handle the deposition of sensitive samples more effectively. The higher sensitivity of these substrates opens up new opportunities for SERS applications - particularly in addressing the growing need for fast, effective detection of explosives and pesticides. The new substrates work with the complete range of Ocean Optics Raman instruments. For users to take full advantage of the RAM-SERS-SP nanosponge substrates’ sensitivity, Ocean Optics now offers 638 nm modular Raman solutions and 638 nm versions of its mini handheld IDRaman spectrometers. Ocean Optics’ proprietary plasma deposition permits affordable mass production with high repeatability and customization options. Standard substrates are microscope slide format with a 4 x 4 mm active area. Ocean Optics uses optical-grade borosilicate glass for compatibility with a wide range of solvents. To learn more about SERS substrates, please contact an Ocean Optics applications scientist at info@oceanoptics.com, visit the website at www.oceanoptics.com or call Ocean Optics EMEA on +31 (0)26 319 05 00.

SMITH FLOW CONTROL ENTERS CASTELL JOINS CPD CERTIFICATION NUCLEAR INDUSTRY WITH FLEXIDRIVE SERVICE REMOTE VALVE OPERATOR To improve the safety of workers in nuclear facilities, Smith Flow Control now offers the FlexiDrive remote valve operator. The

system can easily be adapted to suit any handwheel- or lever-operated valve in nuclear power plants, making them continuously accessible and safe to operate wherever

they are located. The FlexiDrive includes a new fully-integrated counter mechanism which displays the valve position (open/closed), providing the operator with a clear indication of the valve position from a safe vantage point. The system is capable of operating valves as far as 30 metres away and accommodating 540 degrees of bends in the cable run. This remote operation capability improves the safety and functionality of valve operations in nuclear facilities by reducing the exposure of operating personnel to hazardous materials. According to the Ionising Radiations Regulations 1999, Part II, Section 8, “every radiation employer shall, in relation to any work with ionising radiation that he undertakes, take all necessary steps to restrict so far as is reasonably practicable the extent to which his employees and other persons are exposed to ionising radiation.” FlexiDrive consists of two stations joined by a unique patented linear drive cable, which can be passed around and through walls, bulkheads, floors and any other obstacles to reach the host valve. A unique device for remote valve operation, FlexiDrive eliminates issues associated with valve access in potentially hazardous areas.

For more information contact Smith Flow Control Ltd, Witham, Essex Tel: +31 (0)26 319 05 00 | Web: www.smithflowcontrol.com E-mail: S.vandenBos@smithflowcontrol.com

Training material for switchgear and loading industries now available

Industrial safety specialist Castell has become a certified member of The CPD Certification Service. Continuing professional development (CPD) is used by companies to build awareness of the value of training & development in order to remain successful in the workplace. By 2017 every professionally-registered engineer will have to be able to demonstrate that they are actively pursuing and recording their CPD commitments. Castell has produced two sets of training material, ‘Trapped Key Interlocking in the Switchgear Industry’ and ‘Efficient and Safe Loading’, along with certified technical guides. The guides are used to build awareness of drivers within the industry, the benefits of using trapped key interlocking and how the technology can be applied to real-life situations. Castell plans to introduce further training material for other industries in the near future. Topics will include the safe isolation of LV switchgear and safety interlocking in food processing. For more information contact Castell Safety International Ltd, Kingsbury Road, London Tel: +44 (0)20 8200 1200 E-mail: pr@castell.com | Web: www.castell.com

PROCESS INDUSTRY INFORMER September 2016

HEALTH & SAFETY FORTRESS ADDS INDUSTRIAL ETHERNET COMMUNICATIONS TO ITS INTERLOCKS Industrial safety specialist Fortress Interlocks has added industrial Ethernet communications to its amGardpro range of safety interlocks. The new proNET communications module, which uses the PROFINET protocol and its extension PROFIsafe, integrates easily into the amGardpro range. This enables the amGardpro’s features to be distributed IO

(input-output) on a PROFINET network, with safety information exchanged using PROFIsafe extensions. Added benefits include reduced installation costs, easier maintenance and greater availability of data for improved diagnosis. Most safety interlocks are either not electrically connected (deliberately so in the case of some mechanical, trapped key interlocks) or are ‘wired at gate’, meaning all electrical connections go via a control PLC and safety relay. This can mean up to 20 wires from each device going to the control panel. The proNET module overcomes this by taking advantage of PROFINET and PROFIsafe, allowing operators to have just one power and Ethernet cable going from the control panel, allowing devices to be attached in a variety of topologies, depending on requirements. The amGardpro is a range of fully integrated safety interlocks, including solenoid and non-solenoid safety switches. It has an extensive range of additional options, including key control modules, internal and escape release, redundant sensors, lock out/ tag out, push buttons, estops and indication lights for enhanced functionality, all assembled in one device. The robust construction of the amGardpro makes it ideal for a host of industrial applications when safety, strength and reliability are of paramount importance. “Making our products compatible with industrial safety networks is an essential requirement for our customers,” comments Fortress’ Managing Director Rob Lewis. “With the launch of proNET, we’re ensuring we not only meet, but exceed what people expect from us when it comes to industrial networking.” For more information contact Fortress Interlocks Ltd, Wolverhampton Tel: +44 (0)1902 349000, Fax: +44 (0)1902 349090 E-mail: sales@fortressinterlocks.com | Website: www.fortressinterlocks.com

ADVERTORIAL COST SAVINGS IN CONFECTIONARY MANUFACTURING As we approach the TOTAL/ PPMA show at the end of September I felt that this would be a good chance to reflect on the work we have done within the Confectionary Industry over the last year says James Walton, Sales Manager of Bronkhorst UK. As with all new application solutions it is important to share and discuss what we achieve to allow our partners, both existing and future, to achieve savings that create a win/win allowing us all to feel the benefits of growth. Firstly, I will talk about the work we have done in dosing flavour and colour. It is always good to give people the chance to realise bottom line savings by managing the cost of additives, so often people have over-dosed to achieve the end result and over time that cost can become a real quantifiable amount. Secondly I have talked about the change in production through the addition of automated flow control providing both cost and work place benefits. Manufacturers in the sugar confectionery market have discovered that they can realise substantial savings on production costs by taking control of additions and dosing through utilisation of the Bronkhorst Coriolis instruments. These mini CORI-FLOW™ Series Mass Flow Meters and Controllers distinguish themselves by their capability to measure and control (ultra) low quantities of both liquids and gases, fast and accurately. Automating process control allows manufacturers to switch quickly and efficiently between production processes reducing down time and operator involvement. Bronkhorst Coriolis instruments using our own proprietary software, FlowPlot™, or by being added as part of an overall PLC controlled system will

add the functionality to include data acquisition capability. Both of these features allow manufacturers to make strides towards better final product quality and consistency while at the same time generating data to allow traceability and quality control. Standard weigh scale/volumetric methods have many limiting factors that can be both inaccurate and costly. These traditional ways of managing the addition of flavours and colours can require heavy involvement of operator knowledge and experience. This can lead to slow change over times and inconsistent/inaccurate addition of flavours and colours. Making the change to Bronkhorst Coriolis Mass Flow Meters and Controllers, utilizing CORI-FILL™ Technology can bring immediate bottom line rewards to the business. Bronkhorst Coriolis Mass Flow Meters have the added functionality of directly controlling a secondary instrument required to achieve the end result, either a pump or valve, using our on-board PID control provides quick and accurate response times at flow rates between 0.05 g/hr and 600 kg/hr. Finally,

PROCESS INDUSTRY INFORMER September 2016

by taking advantage of the control functionality provided by the Bronkhorst on-board PID control the integration of the solution into a current application or manufacturing process is simple and straightforward. In addition to the solution proposed above, we have worked in a second area, fruit gum manufacture and provided a steop change solution to production capability. Challenged by their outdated recipe mixing systems, budgetary constraints and a turbulent economy, a leading European candy manufacturer, who depends on accuracy and repeatability to maintain the quality of product, sought out Bronkhorst to help streamline and improve their processes and cut costs. Bronkhorst engineers identified current system weak points and recommended a CORI-FILL™ solution. By choosing to move forward with the Bronkhorst Coriolis mass flow controllers, the candy company immediately began to benefit from their ability to automate a wide variety of recipes and depend on advanced diagnostics that radically expanded their monitoring capabilities. The flow controller’s primary function is the dosing of three critical ingredients of the chewy treats; The aroma (fragrance), the flavour, and the colour. By communicating directly with a supervisory automation and control system, the CORFLOW™ instruments provide the precise dosing requirements for a particular recipe. The compact design of the Bronkhorst instruments, where the Coriolis meter and controlling shutoff valve are mounted in one compact unit, was a key factor in selecting the Bronkhorst solution as separation of the meter and the control valve creates dead volume which can lead to inaccuracy, erratic results, and inconsistent quality. The need for staff oversight was significantly decreased through a wide variety of new system features, production time was reduced as each ingredient is simultaneously added to the mix, and the precise dosing of ingredients reduced wastage. Additionally the digital communication with the supervisory system provides for automatic monitoring and recording for quality and regulatory purposes. To find out more, please see our confectionary video and literature below. Check out our YouTube channel: goo.gl/6Vm70Y Visit our Food page: goo.gl/5gdRz7 or call Tel: 01223 833222 or E-mail: sales@bronkhorst.co.uk | Web; www.bronkhorst.co.uk

THE FUTURE OF UK MANUFACTURING DEBATE HEATS UP AT THE PPMA TOTAL SHOW 2016 over the 27th – 29th September 2016, NEC, Birmingham

The PPMA Total Show incorporates three major exhibition brands – PPMA, Pakex and Interphex – highlighting the latest innovations in materials, containers and packaging design, as well as the very latest processing and packaging machinery, industrial automation and vision innovations. The UK manufacturing industry looks to the future with baited breath following the results of the EU referendum. As the wider UK economy remains unpredictable, the results of the referendum could represent a unique opportunity for the manufacturing sector should businesses consider the tactical, short-term implications and realise the importance of maintaining a focus on long-term strategic planning. According to KPMG’s EU Referendum advisory, manufacturers should be buoyed by the possibility that in the long term this result could lead to new opportunities for their businesses. A drop in the value of the pound could make the UK a magnet for trade, especially with the UK government looking to build relationships with the rest of the world outside of Europe. In addition, the need to reshape trade policy may result in quicker decision making, and reduced red tape that has previously hampered manufacturing when looking to export good1. KPMG – Managing Brexit www.home.kpmg.com/uk/en/home/ campaigns/2016/06/brexit.html 1

Speaking about the future of the UK manufacturing sector, the Rt. Hon Lord Francis Maude, former Minister of State for Trade and Investment will join visitors at this year’s PPMA Total Show to open the 2016 exhibition and deliver the opening address on both the challenges and opportunities that lie ahead. Appearing on the PPMA Total seminar stage on the first day of the show (Tuesday 27 September) Lord Francis Maude will discuss the outcome of the recent EU referendum and reveal the future plans for the government’s ‘Exporting is Great’ campaign. The PPMA Total Show 2016 will not only see headline speakers like the Rt. Hon Lord Francis Maude but a range of industry experts who can offer insight and advice on the future of the UK manufacturing industry. Since the PPMA shows returned to the Since the PPMA shows returned to the full control of the association in 2013, the size of these events has increased by circa 25% year-on- year. The latest edition – PPMA Total 2016 – is already 50% larger than the first show of the new regime in 2014. With over 400 exhibitors, the event has already firmly established itself as the industry event not to be missed with 2016 set to be one of the biggest and highly anticipated events yet. Speaking about its return, Grant Jamieson, Chairman, PPMA Group of Associations, said: “The PPMA Total Show

brings together buyers and sellers at one of the most visually dynamic exhibitions which showcases the latest processing and packaging machinery, materials, industrial automation and vision innovations. The event provides an ideal meeting place for decision makers from across a range of industries to network

with key manufacturers and distributors, all set against a back drop of innovation and industry expertise.”

FOCUS ON: FOOD HYGIENE, WASTE AND INNOVATIVE PACKAGING DESIGNS Also confirmed to speak at this year’s PPMA Total Show, Emma De-Alwis, Hygiene Specialist at Campden BRI will highlight how contaminated food products and food hygiene problems that go undetected along the supply chain have a serious negative impact on the UK manufacturing industry. Addressing another highly topical issue for UK’s food manufacturers, Claire Shrewsbury, Packaging Programme Manager for WRAP, will take to the stage to address the number of government programmes focusing on food and packaging waste that promote both environmental improvements and the cost benefits to industry, including current projects with GlassRite Wine, and the benefits of developing recycled food grade PP processes. In addition, Ashwin Moorthy, Head of Engineering & Innovation at Nampak Plastics, will take to the stage to discuss the latest packaging innovations in the FMCG world, and how packaging can both protect products and extend shelf life whilst being environmentally friendly. Joining Ashwin, additional speakers confirmed for the 2016 exhibition Ben Clarke, Training &amp; Education Manager at GS1; and Nick Kesterton of the International Society for Pharmaceutical Engineering (ISPE).

MANUFACTURING SKILLS GAP UNDER THE SPOTLIGHT According to business group EEF2 , three-quarters of companies say they have faced difficulties finding the right employees in the last three years. The skills shortage is putting productivity growth at risk and adding to pressure on manufacturers as they battle a host of challenges in domestic and overseas markets. The struggle to find the right people with the right skills is also being compounded by the recent news from the manufacturing sector that over three quarters of industry professionals believe that not enough is being done to make manufacturing an attractive career choice to young people. This is despite the fact that nearly three quarters of companies (69%) surveyed in the Manufacturing Advisory Service (MAS) Manufacturing Barometer 2016 revealed that they currently have two or more vacancies for young people.

2EEF Skills Report 2016: An up-skill battle - www. eef.org.uk/resources-and-knowledge/research-andintelligence/industry-reports/skills-report-2016

Addressing the ingredients for success and highlighting the

opportunities for an engineering future in food and drink, Emma McLeod, Principal Engineer for Process Solutions Global Chocolate R& D Team at Mondelez International, will give an inspiring insight into the engineering opportunities in the largest industry in the UK. Emma will discuss her own career starting as a factory process engineer through to her current role in global research and development. More specifically, she will discuss how Mondelez are responding to the skills gap ranging from capturing knowledge from experienced employees before they retire to mentoring young engineers from the beginning of their career to build their skills quickly to become chartered professional engineers. Exhibitors and visitors interested in hearing more about training and apprenticeship opportunities can pop along to the PPMA BEST (Business Education Skills and Training) stand (B138) to find out more. The charity, established by the PPMA Group in 2014, encourages young people to enter and develop a career in engineering within the processing packaging, robotics, automation and industrial vision supply industries through education, training and support. New PPMA Group CEO, Andrew Mint, who joined the association on the 1st February 2016, added: “The PPMA

Total Show 2016 is set to be biggest yet and the show is a great opportunity for businesses to get their brand, products and equipment in front of a high profile audience and celebrate the innovation that the industry has to offer. The show is a fantastic platform to highlight the latest innovations whilst also bringing some of the industry’s biggest issues to the fore such as the skills gap. I’m looking forward to seeing some the most exciting recent technological developments in our industry on show, as well as hearing from some of the industry’s leading figures at the PPMA Total seminar theatre.” The exhibition is free to attend – visitors may register via the website. Visitor badges are valid across all three days of the show and as this is a trade show, no under 16s will be admitted.

To register your attendance at the show please visit: http://bit.ly/28QsHuF . For more information on the PPMA Total Show 2016, please visit www.ppmatotalshow. co.uk/ or join the conversation on twitter @PPMATotalShow #PPMATotalShow or the PPMA Total Show LinkedIn page

PROCESS INDUSTRY INFORMER September 2016

PPMA TOTAL 2016 IS CHOSEN AS UK MARKET LAUNCHPAD FOR MASOSINE CERTA TM: FESTO & SIEMENS TO FOCUS ON SOLUTIONS FOR THE the cleanest pump you will ever need PACKAGING INDUSTRY AT PPMA TOTAL 2016 This latest innovation from the world leader in niche peristal-

tic and sinusoidal pumps and fluid path technologies promises to set a new benchmark in clean pumping for all food and beverage industry applications. Introducing Certa TM from MasoSine Certa TM is latest innovation from MasoSine, the creators of Sine® pump technology. Its launch has set even higher pumping standards in food processing. Offering EHEDG (Type EL Class I) and 3A certification, Certa is extremely easy to clean for minimal maintenance and downtime. CertaTM completes the existing MasoSine product range by offering users a fully CIP capable pump at flow rates up to 99,000 l/ hr. Users can be assured that media is pumped safely and without degradation. It not only delivers high suction capability to handle viscous products, it offers significant advantages over alternative technologies. Unlike traditional pumps with rotors that cut through the fluid, Certa’s sinusoidal rotor gently carries fluid through the pump to dramatically reduce shear while cutting power consumption by up to 50% with high viscosity fluids. Visitors to the stand will be able to see Certa for themselves: the company’s product management and food applications team will demonstrate how the food-contact compliant Certa Sine® pump offers all of the typical advantages and high performance levels delivered by proven MasoSine sinusoidal technology. SEE US ON STAND F30 or visit www.wmftg.com

FAST EFFECTIVE WEIGHING FROM HBM... FOR DYNAMIC AND BATCH WEIGHING APPLICATIONS

At this year’s PPMA Total Show, Festo, the leading supplier of automation equipment, will be showcasing exciting new developments and solutions for the processing and packaging industry on its stand B70 in Hall 5. For the first time in the UK, in collaboration with Siemens, Festo will demonstrate the Multi-Carrier-System, a new linear motor track system which delivers a flexible and modular transport solution for industrial automation. The collaboration brings together the extensive controls expertise of Siemens with Festo’s linear motor and mechanical guidance technology. Festo will also highlight some of its latest new products and demonstrate solutions for Industry 4.0. The Multi-Carrier-System addresses the acute need for flexibility in modern manufacturing and production environments driven by increasingly complex product diversity and high levels of mass customisation. Its freely definable and configurable linear transport rail can be easily integrated into existing intralogistics systems, with precise synchronisation and seamless infeed and outfeed of transport carriers. The movement of carriers within the system can be rapidly and easily adapted to deal with different formats, sizes and types of product – down to batch sizes of one. Applications could include cosmetics packaging with its huge number of product variants, food and beverage processing with quick seasonal changes or industrial manufacturing of customised one-off products ordered via online configurators. SEE US ON STAND B70 or visit www.festo.co.uk

With speed, precision, hygiene and price being some of the key considerations for manufacturers of production & packaging machines, HBM will be showcasing its world leading range of load cells and modules for dynamic and batch weighing ON STAND C86 at the PPMA Total Show, including the FIT7A and FIT5A Digital Load Cells for use in a wide range of production environments and the ‘Easy to Clean’ PW25 and the aseptic PW27 range of load cells, which have been developed to meet the strict hygiene regulations required in production. If you can’t visit the SHOW for more information contact HBM United Kingdom Ltd, North Harrow, Middlesex. Tel. 020 8515 6000Fax 020 8515 6002 E-mail: info@uk.hbm.com Web:www.hbm.com

DIXON ARE PLEASED TO BE EXHIBITING AT PPMA TOTAL AGAIN THIS YEAR & ARE LOOKING FORWARD TO SHOWING VISITORS THE EXTENSIVE RANGE OF HYGIENIC PROCESS EQUIPMENT Dixon offers FDA and 3A approved stainless steel fittings, unions, tube, pumps and valves for the food, dairy, beverage and brewery industries. We will be showcasing their range of hygienic fittings and actuated valves on a stainless steel fabricated display and new table stand engineered and built from their product range; along with a carousel of hygienic hoses assemblies offering odourless and taste free properties suitable for liquid foodstuffs. Additionally on show will be our hygienic hose range includes a range of rubber, silicone, PVC and PTFE hose assemblies which can be custom made to exact requirements with accessories including wash down guns and steam lances. Also there will be our newly launched Hygienic Breakaway Check Valve, which is proving to be ‘the right connection’, potentially saving companies thousands . Launched last year the new Dixon Breakaway Check Valve is an innovative solution that is designed to eliminate product loss too. It incorporates the Breakaway Coupling and a Hygienic Check Valve. It acts as a single unit that has a diverted breaking point which will break at a determined break-load. Then the check valve will close protecting the loading bay pipe system AND avoiding product spillage. SEE US ON STAND J44 or call 01772 232529 or visit www.dixoneurope.co.uk

PROCESS INDUSTRY INFORMER September 2016

THE NEW PYLON 5 CAMERA SOFTWARE SUITE RELEASE (VERSION 5.0.5) IS AVAILABLE NOW!

CSL REACH NEW LEVELS WITH INTEGRATED PROCESSING & PACKAGING SOLUTIONS

Release highlights... •pylon 5 for Mac OSX. This is the first pylon release which officially supports Mac OSX (versions Yosemite 10.10 and El Capitano 10.11). This release supports all Basler GigE Vision and USB3 Vision cameras. As other pylon releases it is based on the new GenICam 3 standard. •New C-API for pylon for Linux (x86 and ARM). Up to now pylon for Linux only supported C++ as programming language. With the new release pylon based applications can easily be developed in C language as well. C is still very popular amongst Linux developers •New .NET API for pylon for Windows. pylon now provides a new .NET API which eases the software development for developers in programming languages such as C# or VB.NET. The older “legacy” .NET API is still supported. •GigE driver news: The GigE Filter driver is now also available for Windows 10 (previous releases offered the performance driver for Windows 10 only). It is also now possible to operate pylon on all supported Windows versions without any special driver by installing the socket option. This significantly eases the pylon deployment for GigE applications where performance does not matter that much. SEE US ON STAND A 57 or Find out more about pylon 5 by visiting our website www.multipix.com

The high quality robust Prorunner Mk1 vertical product elevator is compact in design and requires a minimal footprint for installation. Available in multiple configurations to suit the application, the lift can easily elevate boxes, crates, totes and sacks weighing up to 100kg, with up to 650 movements per hour. The lift’s unique design ensures silent movement with minimum maintenance requirements and unlike chain lifts, does not require lubricating or tightening. CSL will also showcase the versatile, energy efficient, space saving spiral elevators/ lowerators from Ambaflex. The spiral provides a smooth continuous flow and high throughput of product within a very small footprint and has the capability to handle various sizes and types of products at the same time. It can also be used to provide accumulation and buffer storage, playing an important role in an integrated conveying system. Also exhibited on the stand will be the new energy efficient 24V non-contact accumulation conveyor (Zero Line Pressure/ZLP) in aluminum frames, which is ideal for transporting fragile, high value or irregular shaped products, providing smooth transfer and accumulation without the products touching. CSL will feature details of warehouse solutions involving the integration of both standard conveyors, switch sorters, transfers and the latest technologies to provide high speed merging/ conveyor sortation systems. From single conveying modules, through to turnkey projects with full integrated control systems, CSL have designed, installed and commissioned handling solutions across a wide range of industries. SEE US AT STAND D12 or visit www.conveyorsystemsltd.co.uk

A SPECIALIST DUST EXTRACTION FIRM IN THE UK HAS LAUNCHED ITS MOST POWERFUL SINGLE PHASE MOBILE DUST EXTRACTOR TO DATE The DC Tromb is designed to provide a clean and healthy working environment for those working with handheld power tools, and is of particular use for flooring contractors. Able to handle all types of fine dusts and materials created during the course of construction techniques such as cutting concrete, sanding, grinding and drilling floors and walls, the DC Tromb combines power, robustness and efficiency with versatility. It’s ability to handle high volumes of dust alongside its mobility makes it particularly useful for floor grinding. James Miller, Dustcontrol UK’s General Manager, commented: “The Tromb is a fantastic new addition to our range. It’s the most powerful single phase extractor that we’ve ever produced, which means it’s able to handle large quantities of dust with ease whilst also being highly mobile, making it perfect for use in areas and for tasks where both mobility and power is essential.” SEE US ON STAND A39 or visit www.DCSlimited.co.uk

NEW - THE KAWASAKI DU-ARO COLLABORATIVE ROBOT Following a Japanese launch for its Du-Aro Collaborative robot late last year, Kawasaki Robotics has introduced the unit to the UK market and is currently completing the installation of several operational systems. “The concept of Du-Aro is based around the need for ease of integration and flexibility”, explains Kawasaki Robotics UK Sales Manager Ian Hensman, “Integrating it onto a production line conveyor with other operators simply requires it to be wheeled into position and the arms to be physically guided through the required motions. Of course sensors are required to provide inputs to the controller but even this area has been simplified with the inclusion of optional vision cameras.” Catering for the non-robotics specialist, the Du-Aro’s controller can be supplied with embedded vision processing software. A range of application specific cameras, light sources and grippers are available that simply plug into the robot’s arms. SEE US ON STAND J78 or visit www.kawasakirobot.co.uk

MAGNET FILTER FOR FOOD & CONFECTIONERY INDUSTRY CLEANING The removal of the captured metal particles done in 3 ways: manually, whereby the operator can easily pull apart the magnetic bars covered by an extractor; manually + pneumatically, whereby the cleaning is done automatically and, according to the most recent method, pneumatically + CIP (Cleaning In Place), whereby in addition to cleaning also the rinsing of the magnetic bars is done automatically. The housing is constructed in such a way that after cleaning no products remain. The magnet filter can be used in tubes or piping in the food sector and serves to remove iron particles from products that are transported under pressure. Even the most minute iron particles can be filtered in this way from sticky products (sausage meat, chocolate, pastes, powders or fruit juice). Usually, these particles remain in the raw materials flow. The placement of a metal detector does not resolve the issue of iron because it cannot identify the smaller metal particles. The magnet filter is available in 7 standard dimensions ( Ø 50 - 200 mm) and has a flange connection according to DIN 11864. EHEDG Recently, Goudsmit has become the first magnet supplier to be admitted to the European Hygienic Engineering & Design Group. The EHEDG is a consortium of installation suppliers, companies in the food industry, research laboratories and national public health bodies that aim at the highest standards of food safety. EHEDG sets standards for avoiding contamination or the growth of damaging micro-organisms, cleaning and decontamination capacity, and the use of materials and surface finish. It tests the product designs in the field of cleaning, sterilization and bacteriological impermeability. Only those firms that comply with the standards set are eligible for the EHEDG certificate. SEE US AT STAND D92 or visit www.goudsmitmagnets.com

PROCESS INDUSTRY INFORMER September 2016