Process Industry Informer November 2015

www.processindustryinformer.com

NOVEMBER 2015 Volume 11 No. 6

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

IS 2016 THE YEAR OF ROBOTICS? In print | Online | Mobile - The UK’s No.1 Media for the Manufacturing Process Industries

CONTENTS. 4-5 News & Events 6-10 Applications 11 Materials Handling 14 Alarm & Vision Systems 14 Filtration 14 Analysers

FOLLOW US ON SOCIAL MEDIA!

43 Drives & Motors 43 Network & Communications 44-45 Process Measurement

21 BPMA News

& Instrumentation 49 Preventative Maintenance 49 Calibration 51 Products & Services Suppliers Directory

19 Cooling Systems

18

34-39 Fluids & Liquids

DEFINING ALARM MANAGEMENT

46

INTRODUCTION TO MACHINE VISION SYSTEMS

48

PREVENTATIVE MAINTENANCE… CAN YOU AFFORD NOT TOO?

50

pH MEASUREMENT THE ACID TEST

(incl. Pumps & Valves)

41 Energy Saving 41-42 Health & Safety 42 Stream Trap Monitoring 42 Roller Bearings

12

INDUSTRIAL VENDING: A LEAN APPROACH

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

15

2016 TRENDS: THE FUTURE OF ROBOTICS

36

MANUFACTURERS SHOULD EMBRACE THE VIRTUAL WORLD

16

HOW TO MAKE THE SWITCH TO ROBOTS

40

ENERGY EFFICIENCY IT’S A JOURNEY, NOT A DESTINATION

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EDITOR’S COMMENT

ROBOTS VERSUS THE HUMANS! It does not seem that long ago that robots were just the imagination of fiction writers and then in the world of film – but how things have changed…

Increasingly they are becoming much of factory workforces, initially in the motor industry but now they are progressively being used in a variety of industries and managing a range of tasks.

In a growing number of industries robots now take care of the ‘dirty’, the ‘technical’ hospital operations, safety issues such as bomb detection, education, assembly lines. The list is growing all the time.

Looking through the ’looking glass’ it is clear that there will be very little that they won’t be able to achieve and to some, there is concern about them taking over their jobs, in fact in certain tasks they have already done so – will this develop soon?

With the UK population growing rapidly is this a serious concern or just a myth?

Only time will tell.

On a separate note, we offer our sincere consolation to the friends and families of those who died and were seriously injured in the terrible happening on Friday November 13th and to the French Nation.

PhilBlack - Editor

NEWS & EVENTS SPIROFLOW’S CONVEYING SOLUTIONS TREADS THE ROAD TO DUBAI AGAIN Spiroflow Ltd showcased its latest conveying and weighing technology for the safe handling of food ingredients to a global audience at the Gulfood Manufacturing show in Dubai at the end of October.

A world-leading manufacturer of conveying, weighing, filling and discharge systems for the food industry, Spiroflow demonstrated a wide range of cost-effective solutions for handling bulk ingredients where the most rigid standards in hygiene and containment need to be met and maintained.

The award-winning UK business is teamed up at the show with its Middle East distributor, Himatrix, to promote Spiroflow’s flexible screw, vacuum conveyors and hygienic bulk bag dischargers.

Whether equipment is required for efficiently conveying food ingredients such as flour, cereals and coffee granules to mixers and packaging machinery, or accurately controlling the flow of difficult materials like chocolate crumb, which has a tendency to smear, Spiroflow were able to show visitors that their wide range of standard equipment or customised systems provide optimum performance and offer value for money.

Taking centre stage in Dubai was a multiple flexible screw conveyor demonstration set-up, complete with sack tip station, product agitators and loss-in-weight feeders, demonstrating their versatility in terms of feed rate, throughput range, consistency and accuracy of output, angle of elevation and quick release features.

Spiroflow’s technical team were also on hand to demonstrate the advantages of the vacuum conveyor, which is able to negotiate lengthy and tortuous routes and hygienically transfer materials.

The bulk bag discharger Model T2 is a market leader, installed by major food processors world-wide for dust-free and controlled discharge of ingredients such as sugar, flour and spices. Options include loss-in-weight product feed, patented massage systems to promote flow from bags, hygienic bag spout sealing device, integral hoist and other features to ensure hygienic emptying of 1-2 tonne bags.

Spiroflow’s marketing manager, Ben Ayrton, said: “Spiroflow was delighted to be back at Gulfood demonstrating fully working examples of their totally hygienic conveying systems. We looked to repeat the success of last year when the show generated a significant amount of new orders. Our engineers were again on hand to explain the advantages that our wide range of standard and customised material handling options offers both small and large volume users.”

As well as providing a comprehensive range of equipment and testing facilities, an outstanding level of customer service is integral to Spiroflow’s philosophy and is one of the reasons why companies in the food industry return again and again to Spiroflow for their filling, discharging and conveying needs.

In addition to Flexible Screw Conveyors, Vacuum Conveyors and Bulk Bag Dischargers, Spiroflow is also a manufacturer of Bulk Bag Fillers, Aero Mechanical Conveyors, Tubular Cable and Chain Drag Conveyors, Bin Activators, Ingredients Handling and Weighing Systems. The company’s technical and engineering expertise has led to it developing an international reputation for an unrivalled range of products with state-of-the-art control systems.

For more information on Spiroflow’s products and services visit www.spiroflow.com or call +44 (0)1200 422525 or E-mail: sales@spiroflow.com

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PROCESS INDUSTRY INFORMER October - November 2015

NEWS & EVENTS HANSFORD SENSORS EXPLAINS HOW TO BOOST MACHINERY EFFICIENCY FOR CEMENT MANUFACTURERS Hansford Sensors, the leading manufacturer and global supplier of industrial accelerometers, has released a free white paper that offers cement manufacturers valuable advice on using vibration monitoring to enhance the efficiency of production machinery.

The paper begins by looking at the challenges posed by cement manufacturing and why these challenges demand predictive maintenance, especially vibration monitoring. It then goes on to outline typical vibration monitoring methods on key components such as motor and gearbox assemblies. Cement manufacturing assets include kiln drives, crushers, screens, conveyor belts, raw mills, separators and blowers, and vibration sensors can be installed for all of these applications. The guide also provides valuable information for cement manufacturers on the importance of correctly specifying and installing the best vibration monitoring solutions, and provides a helpful list of tips for achieving this.

“Industry reports repeatedly show that world cement volumes will continue to grow over the next few years,” says Chris Hansford, Managing Director at Hansford Sensors. “This offers cement manufacturers a strong opportunity to capitalise on a growing market; however, to do this they need to maintain machine performance in what is an extremely challenging application. By using vibration monitoring to manage key equipment such as crushers, milling machines and rotary kilns it is possible to increase the efficiency and therefore reliability of the cement manufacturing plant.”

Download the new white paper from the Hansford Sensors website.

For more information on the extensive range of Hansford Sensors products, please visit Web: www.hansfordsensors.com Tel.: +44 (0)845 680 1957

BEKO TECHNOLOGIES UK ARE ON THE MOVE BEKO Technologies will be starting the new year in new premises. After nearly a year of searching BEKO TECHNOLOGIES UK will move to Redditch.

Not only will these new premises give a much improved work environment for the UK team, but we will create a first class training and education facility where we can educate current and potential customers, demonstrating our equipment in a live environment giving much needed practical hands on learning.

The UK team have had their first glimpse of the new facility, there was a lot of excitement and already there are plans for seminars for End Users in the pipeline.

The plan is that we will move in just before Christmas, over the next 6 weeks the contractors will be starting the refurbishment Martin, general manager at BEKO TECHNOLOGIES says ‘I would like to thank Monique and the family for supporting the move to this new building, I am personally looking forward to a very exciting future for BEKO TECHNOLOGIES UK. What a great way to start 2016”.

For those of you keen on Google maps, you can find us at Units 11 & 12 Moons Park, Burnt Meadow Road, North Industrial Estate, Redditch, B98 9PA.

PROCESS INDUSTRY INFORMER October - November 2015

HBM PROVIDES THE COMPLETE LINK TO TEST & MEASUREMENT CHAIN Following the recent acquisition of FiberSensing, a leading provider of Fiber Bragg Grating (FBG) based measurement and monitoring systems, HBM – a market leader in the field of test and measurement – is pleased to announce it is the only UK supplier to offer a complete range of products in the sphere of optical measurement technology.

Primarily used in structural testing and in the development of light weight materials - which are increasingly being used in the transport and building sector, mechanical engineering and the energy industry to significantly reduce weight - the inclusive range of products now available from HBM includes fiber optic Bragg sensors, such as strain gauges, strain, temperature and tilt sensors.

Also included within the range are accelerometers and interrogators which can be easily connected via TCP/IP to any standard PC using an Ethernet interface.

Featuring compact geometrical dimensions and high measurement stability, optical measurement technology is the ideal choice in materials testing at increased levels of strain and a high number of load cycles as, unlike electrical strain gauges, optical sensors offer immunity from these influences and are often the first choice for use in environments affected by strong electromagnetic interference. In addition to this, system downtime is also significantly reduced due to the extremely high stability and long service life of the optical measurement chain.

This exciting new development for HBM means that it is now able to offer customers a complete range of highly innovative products in the field of optical measurement technology, enabling them to build their own monitoring solutions using high end instruments, sensors and software.

For further information contact HBM on Tel.: +44 (0) 20 8515 6000 Email: info@uk.hbm.co.uk Web: www.hbm.com/en/

THE FUTURE OF BREWING: IMPROVING ENERGY EFFICIENCY, LOWERING EMISSIONS & REDUCING RISK IN BREWERY STEAM SYSTEMS Many breweries have tremendous scope to improve their operational energy efficiency, reduce risk, improve product quality and cut emissions by upgrading their steam systems, says Spirax Sarco’s latest white paper.

Using steam to provide brewing processes such as wort boiling, pasteurisation, Cleaning in Place, Sterilising in Place and bottling and canning is a significant contributor to the overall energy bill in a brewery. In addition to these process requirements, steam is often required for heating systems. Yet there is huge potential to save thousands of tonnes of emissions per year through the application of innovative steam system technologies.

The white paper outlines the options available and explains the savings that can be achieved. Examples include switching from plant or filtered steam to clean steam, and improving systems to optimise the return of condensate to the boiler feedtank.

For more information and to download a copy of the White Paper visit www.spiraxsarco.com/global/uk/ Resources/Pages/White-Papers.aspx.

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APPLICATIONS FOOD PROCESSOR IMPROVES EFFICIENCY WITH BABCOCK WANSON Babcock Wanson has completed a project for delicatessen meat producer Puredrive Fine Foods which includes integration of the heating systems for two of Puredrive’s production lines at its processing facility in Corby as part of an expansion programme that has seen a major new Frying and Oven cooking line installed.

In order to build greater flexibility into Puredrive’s plant and reduce downtime for scheduled maintenance, Babcock Wanson integrated the new processing line with an existing one to ensure the TPC 600B Thermal Fluid Heaters already installed can feed both lines with the heat they need. A contingency measure, it ensures the smooth running of the processing facility without the need to add costly ‘back-up’ measures that would also take up a lot of space in a relatively compact plant and it helps keep capital costs under tight control.

A long standing customer of almost 30 years, Puredrive operates two Babcock Wanson coil type steam generators and seven thermal fluid heaters in total.

Ian McQuarrie, Engineering Manager at Puredrive, is impressed with both the equipment and service supplied by Babcock Wanson: “During my three years here, the Steam Generators and Thermal Fluid Heaters have worked flawlessly. Babcock Wanson carries a good name in the business for both quality and equipment longevity. Their knowledge, company wide, is exceptional and the whole package from installation through to service is managed professionally.”

Puredrive has also recently signed up to Babcock Wanson’s Water Treatment Service which provides customers with exceptional Water Treatment programmes for Steam Boilers through its specialist partner Deep Water Blue.

For more information contact Babcock Wanson on Tel: 020 8953 7111 or Email: info@babcock-wanson.co.uk Web: www.babcock-wanson.co.uk

FLAME LIVES UP TO ITS NAME, JOINS ‘TRAIL BY FIRE’ EXPEDITION

FEED STUDY FOR INNOVATIVE NAPPY RECYLING SCHEME With absorbent hygiene products (AHP), primarily nappies, amounting to a massive 1.1 million tonnes of the UK waste arisings, Manchester and Redcarbased process engineering design consultants, Haden Freeman Ltd, are undertaking a Front End Engineering Design (FEED) study for an innovative process to recycle AHPs recovering valuable plastic and fibres on behalf of Knowaste Ltd. The Bromsgrove-based subsidiary of Knowaste International was the first UK company to recycle AHPs in 2011 at its development plant in West Bromwich. This plant closed in 2013 having fulfilled its purpose as a project to test the technology and evaluate the market opportunities for recyclables/ plastic and fibres created from the process.

The new FEED study will be for a proposed far larger £14m recycling plant to be located in Hayes, West London, which will recycle almost 100% of AHPs with the plastic destined to make waste containers and the fibre a high quality pet litter.

This new plant will utilise patented technology and know-how that Knowaste has developed over the last 10years.

Roy Brown, Chief Executive of Knowaste, explains how the new study will introduce an innovative element which makes the process economically viable, “In essence, whilst we always had a market for the recycled plastic liners of nappies, incontinence pads and other AHP’s, the absorbent fibres within these products were still unwanted either being incinerated or going into low value products such as construction fibre board. We now have the technology to convert these cleaned and sterilised fibres into valuable pet litter producing a complete process, including reusing the heat produced to dry materials.”

“It’s a fantastic step forward which will hopefully drastically reduce the amount of AHPs going into landfill sites and, if our application is successful, we would start production at Hayes in early 2017, providing both environmental benefits and employment opportunities within the area.”

Stuart Dow, Technical Director of Haden Freeman Ltd, explained the project, “We do a great many of such front end studies to ascertain the feasibility and costs of projects.

The Knowaste project is typical involving the modeling of a process to see what it needs to take this up in scale to sustainable level and what costs are involved. The study involves many engineering disciplines from civil, structural, mechanical and electrical right down to instrumentation design to see what the optimum size plant will be for this site.”

For further details contact Haden Freeman Ltd, Denton, Manchester Tel: 0161 304 5900 E-mail: sdow@hadenfreeman.com Web: www.hadenfreeman.com

Ocean Optics spectrometers to be used in aerial study of volcanic emissions.

Ocean Optics has sponsored a team of volcanologists on a mission to study volcanoes in the South American Andes, providing Flame miniature spectrometers and accessories. The’Trail by Fire’ project, funded by a grant from Land Rover and the Royal Geographical Society, will attempt to quantify the total amount of volatile chemical elements released by volcanoes in Chile and Peru. Ocean Optics’ Flame spectrometers will be flown directly below volcanic plumes on UAVs, taking differential optical absorption spectrometry (DOAS) measurements to quantify sulphur dioxide (SO2) levels, with the goal of better understanding volcanic effects on climate.

The Flames will be part of world’s first mobile volcano observatory, a specially outfitted Land Rover Defender 110, reaching some of the most remote and hard to study volcanoes on earth. Faced with difficult to navigate terrain and high altitudes, the team chose TurboAce Matrix UAVs to carry the Ocean Optics spectrometers to the volcanic plumes for measurement. Using UAVs allows the researchers to get closer to the plume and collect a full cross section of measurements. This will provide higher accuracy than the ground-based measurements typically used in DOAS. The Flame’s small size and low weight (265 g) were key factors in its selection, as payload weight, always an important consideration for UAVs, is especially critical at high altitude.

More importantly, despite its small size, the Flame offers the high resolution and thermal stability required for DOAS measurement, allowing the team to measure very small fluctuations in SO2 content. The spectrometers are controlled by the UAV’s onboard microprocessor, integrated with Ocean Optics’ open source SeaBreeze drivers.

Spectra collected by the Flame are saved to the UAV’s onboard memory and wirelessly beamed back to the ground station. This real-time feedback will allow the team to verify operation and make measurement adjustments as the UAV is in flight. The spectrometer’s modular design, with interchangeable slits to adjust resolution and throughput, will enable the team to respond quickly and easily to changing conditions in the field.

“This is truly a great application for our next generation miniature spectrometers”, explains Ocean Optics product manager Henry Langston. “We love the opportunity to partner with our users, helping them take our science to new places. This is why we have a team of applications engineers on staff, to work with customers to solve challenging measurement problems. It’s been so exciting to see the Trail by Fire project come together.”

To follow the Flames’ adventures on this mission, sign up for Ocean Optics’ monthly eNewsWire, or follow the company on Twitter, Facebook, or LinkedIn. The ‘Trail by Fire’ expedition is being funded by a £30,000 grant from Land Rover, in addition to the Defender 110 donation. A number of other partners have donated equipment to the project, including Ocean Optics’ sister company, Crowcon Detection Instruments. Crowcon’s personal gas monitors will alert the team to any potential danger as they collect samples of toxic volcanic gases.

Ocean Optics’ spectrometers are no strangers to heat and flame. They’ve also been used in studying pyrotechnics, muzzle flashes from rifles, rocket plume emissions, and applications involving flame analysis of metals and other materials.

For more information contact Daniëlle Ravenshors, Ocean Optics, The Netherlands.

Tel: +31 (0)26 319 05 00 E-mail: info@oceanoptics.eu Web: www.OceanOptics.eu

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PROCESS INDUSTRY INFORMER October - November 2015

PROCESS INDUSTRY INFORMER October - November 2015

05

APPLICATIONS RECYCLING OF CARS MADE GREEN & CLEANER WITH VERDERFLEX PERISTALTIC PUMPS Did you know that 95% of car materials can be used again/ recycled?

At the end of its’ life, a car yields on average, 140 kilos of shredder waste: 26 kg of metals, 69 kg of plastics, 11 kg of minerals and 24 kg of fibres. In Tiel, Netherlands, a Post Shredder Treatment plant (PST) was built in 2011, for the recycling of cars.

The PST plant is one of the two plants in Europe that are able to recycle to approximately 95% of the waste materials. Aiming for 100% recycling, continuous research and development is conducted in the company. In 2015 their goal is to recycle 95 percent of end-of-life vehicles. The last valuable material recovered is from shredder waste in the plant, which is crucial in order to fully achieve the legal objective. Today ARN has already reached this goal by separating about 40 percent of all shredder waste from cars. 56 percent of the remaining shredder waste is incinerated with energy recovery: just 4 percent at the most ends up in the landfill.

The separation process is accomplished by a large number of different techniques.

179 different machines are used to screen the waste, cut it in the hammer crusher and centrifuge the waste particles to enable separation of the shredder waste. Sink-or-swim tanks are also used to separate materials with different specific gravity from one another. Huge mega magnets are used to separate the larger metallic parts. Most techniques consist of innovative technical airflows in cyclones of different nature (eg, swirling, air blowing under or above or sideways), feeding or just by draining fluids. Also settling and circulation of fluid streams (for re-use of the process materials such as calcium carbonate) are recurring techniques.

SEPARATION THROUGH FLUID STREAMS CALCIUM CARBONATE In the last stage of separation, several materials are separated in fluid stream baths, using a difference in specific gravity. Calcium carbonate,powdered limestone, is circulated in a settling tank. Since this material is heavy, it will settle after 30 minutes. In order to keep the calcium carbonate from sticking to the bottom, a Verderflex Dura 45 hose pump is used to keep the fluid stream moving. Since its installation in 2013, the Dura 45 has been pumping around the clock, without requiring a single hose change.

SEPARATION OF COPPER PARTS IN A SETTLING TANK Copper parts are circulated by a stirrer in a settling tank. The copper parts are pumped into another tank by a specific movement of the stirrer. Due to the high gravity of copper, the copper parts settle at the bottom of the tank and every 2 weeks the tank has to be cleaned out manually. For this application, ANR purchased 3 Verderflex Dura45 pumps, and used them as circulation pumps. This prevents copper parts from settling process.

SEPARATION LARGER PLASTIC PARTICLES (>130 MM) Plastic waste is separated by circulating water. The plastic floats and is pumped out by a Verderhus screw channel pump. After many trial pumpings, the Verderhus, with its half open screw impeller, pumps plastic into the plastic containers. This works extremely well without clogging the pump.

EXTRA LUBRICATION FOR THE PLASTICS Verderflex Rapide tube pump doses a small amount of ecodish every hour to the circulating water. Ecodish is an organic lubricant, which lubricates the plastic even more to make it float away faster and smoother. Throughout this plant Verder Ltd is responsible for supplying 7 pumps, helping the World become a greener place!

CUSTOMER PROSPECTIVE Since the opening of the plant, ARN have developed a number of manufactured products from the recycled materials. As a result, BlueRoots was developed; this product is suitable for manufacture of street name plates and street furniture. A new promising product is sheet material, suitable for sheets being used in construction.

Emile Bregita (Head of Technical Department, ARN) says: “We are very satisfied with all the Verder pumps used in our plant. Without exception, the pumps run continuously without problem. We almost forget that they are there! We are so satisfied with the pumps that we have recommended Verder to colleague companies who experience problems with their waste process flows!”

For more information contact Verderflex Ltd, Castleford, West Yorkshire.

Tel: +44 (0) 1924 221020 E-mail: info@verderflex.com Web: www.verderflex.com

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RUSSELL FINEX HELPS NESTLÉ SAFEGUARD PRODUCT QUALITY AT THEIR NEW 26,000 TONNES/YEAR MILK POWDER PROCESSING PLANT IN CHILE Six Russell Compact Sieve® units enable Nestlé to screen milk powder on finer meshes without compromising flow rates.

With factories or operations in almost every country, Nestlé is the world’s leading nutrition, health and wellness company. Since Nestlé first began selling in Chile in 1934, the country now provides one of the highest per capita consumption and sales of their products. Nestlé’s continued commitment to developing operations in the country, and a change in society for a healthier lifestyle leading to increased demand of milk powder products, have resulted in the investment of a new factory.

Requiring the highest quality machinery, Russell Finex, a long term supplier to Nestlé, provided purpose built screening solutions for the new plant.

The new factory, based in Osorno, is one of the most Russell Compact Sieves® installed technologically advanced at the new milk powder factory. dairy factories of its kind.

The factory produces a range of milk products with added nutritional value targeted not only at the domestic market but also at overseas markets, including the United States, Central America, the Middle East and Asia. Having strict Good Manufacturing Practices (GMP) and Hazard Analysis and CriticaControl Points (HACCP) in place, Nestlé sought only the highest quality equipment for the new factory.

Having previously worked with Russell Finex at many of their factories worldwide, there was no hesitation in Russell Finex being the supplier of choice for their screening operations in the new factory. “The ongoing relationship is due not only to the high quality manufacture of all of Russell Finex’s separation equipment but also the accompanying documentation and certification that is provided”, states Jaime Sanchez, Maintenance Manager.

Traditionally rotary sifters have been used for the screening of powders.

However this method of screening presents many problems. With the impeller forcing the powder through the mesh, product quality can be compromised as very little oversize is collected. In addition, most rotary sifters are supplied with nylon mesh which is prone to breakage. Therefore there has been a move to use gravity fed circular vibratory sieves as an alternative.

Following a consultation with a Russell Finex Sales Representative, it was decided that the Russell Compact Sieve® would best meet Nestlé’s requirements. With three different milk product ranges being processed, each requiring different flow rates, different sized Russell Compact Sieves®, comprising of 600mm, 900mm and 1200mm diameter units, were supplied to each process line.

Recent changes in industry practices have resulted in the need to screen milk powders finer. Traditionally 4mm aperture mesh (5 mesh) has been used but 2mm screeners, the high performance Russell Compact Sieve® is able to screen the milk powder at this finer mesh size without compromising flow rates, preventing the sieve from becoming a bottleneck in the process. “We required a sieving system that would enable us to check-screen the milk powder to meet the standard set not only by Nestlé but also by Chile and the countries the milk powder is being exported to”, comments Sanchez. “With the industry moving towards 2mm screening, it was important to choose a sieve that would meet this criteria without slowing down the production process” continues Sanchez.

The Russell Compact Sieves® have enabled the new factory to meet its target throughput rate of 26,000 tonnes/year.

Constructed in the highest quality stainless steel, the Russell Compact Sieve® is easy to clean between batches, and its simple design allows operators to strip down and clean the machines without tools. With enclosed screening for total containment, dust and fumes are also eliminated, not only helping Nestle to meet their strict zero dust environment policy, but also to improve operators’ health and safety. The machines were also fitted with BFM™ connectors, a unique innovation designed to provide a hygienic connector system, allowing for easy removal for cleaning or replacement.

Sanchez concludes, “The Russell Compact Sieves have not only helped us to meet our required capacity, but have also provided a hygienic solution that is mandatory for the milk powder industry”.

For more information contact Russell Finex, Feltham, Middlesex.

Tel: +44 (0) 20 8818 2000 E-mail: sales@russellfinex.com / Web: www.russellfinex.com

PROCESS INDUSTRY INFORMER October - November 2015

PROCESS INDUSTRY INFORMER October - November 2015

05

APPLICATIONS BULK FUEL TANK MONITORING WITH REMOTE DISPLAY Pulsar Process Measurement have supplied non-contacting ultrasonic volume measurement equipment with associated remote plant mimic software to help solve an issue for Northern Rail at three sites; their Newton Heath LMD (Light Maintenance Depot) near Manchester, Blackpool LMD and Barrow LMD, allowing them to control the ordering, delivery and usage of fuel more efficiently.

Northern Rail’s contractor AustinLenika, who were engaged in a wider project on site, had identified that the existing level indicators were not suitable for the application and were, therefore, not reading the level correctly. AustinLenika approached Pulsar for a solution. They specified that new equipment should provide a measurement of the volume of fuel in the bulk tanks with a target of ±1% accuracy, allowing staff on site to monitor fuel usage and transfer and pinpoint the optimum time to re-order fuel. They also wanted to have both local display of level on the storage tanks and to be able to remotely monitor levels across the entire tank farm of eight fuel vessels, plus three additional bulk tanks.

Pulsar supplied Ultra 3 non-contacting ultrasonic level measurement controllers with associated dB series transducers. The transducers were mounted into flanges at the top of the fuel tanks, and operate on a ‘time of flight’ principle, an ultrasonic signal reflecting back to the transducer from the surface of the fuel. The measurement is reliable and accurate, with sophisticated signal processing by Pulsar’s dedicated DATEM software system. In addition, the Pulsar Ultra Controller can calculate volume based on almost any standard tank shape, taking the tank dimensions and making the calculations necessary to convert them into the volume of fuel in the tank.

Pulsar also supplied UltraScan software, which uses the RS485 Modbus output of the Ultra to provide a screen display of both levels and alarms. UltraScan can operate either on a site basis or can bring together measurements from a variety of sites.Staff at Northern Rail are using the system very effectively. Austin-Lenika tested the system by comparing delivered fuel from a tanker to measured levels from the Pulsar system, finding a variance from 6000 litre delivery of ‘within 60 litres’, achieving the ±1% target.

For more information please contact: Pulsar Process Measurement Ltd, Tel: +44 (0) 1684 891371, Email: samanthayoung@pulsar-pm.com

RILEY PLAYS MAJOR ROLE IN BRINGING REDUNDANT COSTUME JEWELLERY MANUFACTURING SITE BACK TO LIFE Riley Surface World has recently concluded a major project to dispose of and decommission a large electroplating facility in the south west of Ireland.

The company had two production sites in Vienna and Rathkeale, near Limerick, Ireland. In 2012 the parent company was placed in voluntary liquidation and purchased later that year by German venture capital company. Unfortunately, they were unable to generate the level of sales necessary to keep both Austrian and Irish sites open, so the company in Rathkeale was put into liquidation in September 2013.

CONVERSION TO NEW ENTERPRISE ZONE Riley Surface World became involved in 2014 Rathkeale site and its contents. The site was then intended to become a multipurpose enterprise zone.Before this could be realised, the electroplating facilities had to be sold and decommissioned in keeping with EU legislation for the safe disposal of industrial chemicals and other hazardous materials.

To this end, Riley appointed former Andersen employee and chemical engineer Neil Cremin, through his new company Chemical Surface Treatment Technologies, to act as project manager for the decommissioning and to assist with the machinery site clearance.

The first phase of the project resulted in the sale of a large Acid Copper electroplating line to a company in Canada. The entire plant was dismantled and re-assembled in Canada by the Riley Surface World support team.

The second phase took place during the winter of 2014 and spring of 2015, saw the remaining electroplating plants and all ancillary waste water treatment equipment sold by auction using Riley’s own, dedicated online bidding channel.

The final outcome is that Riley Surface World has returned significant value to Innovate Limerick. Together with Neil and his team, it has cleared the site successfully and rendered it ready for conversion to a mixed commercial development. This will help to create future employment prospects for the many people that lost their jobs following the closure of the company two years ago.

Commenting on the project, Neil Cremin said ‘‘It has been a rewarding and enjoyable experience working with Michael Riley and his team. They have a very hands-on approach to the sales and decommissioning process and their technical knowledge and attention to detail is second-to-none.’’

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

PROOF OF THE MIXING IS IN THE MAXIMISED GAS PRODUCTION Mixing specialist SYSTEM MIX LTD has made an important contribution to the operational success and environmental sustainability of Northumbrian Water’s advanced anaerobic digestion operations at their Bran Sands, Middlesbrough and Howdon, Newcastle sites.

Following the implementation of the Urban Waste Water Treatment Directive and the subsequent ban on the disposal of sludge to the North Sea, Northumbrian Water (NW) embarked on the construction of what was at the time, the UK’s largest thermal sludge drying facility. The project was part of NW TEES strategy to provide centralised treatment for municipal sewage and industrial effluents for the Middlesbrough and Teeside area on a single site at Bran Sands, along with dewatering with lime stabilisation at the Howdon site.

This was a significant project for System Mix, involving the supply and installation of 6 Vaughan HE12 chopper pumps operating on a duty-standby basis mixing 3 x 6000 cubic metre digesters. The mixers have been operating for 6 years, and as part of Northumbrian Waters recent programme of inspections and modifications to associated pipework, one of the digesters has been emptied and cleaned. The emptying and cleaning process took less than a month and ultimately confirmed a residue remaining of less than 5% of the total digester volume.

In terms of the mixing performance this is an excellent example of how the digesters have maintained their working volume to the guaranteed 95% which was required at the tender stage. As a consequence, Northumbrian Water has benefitted from maximised gas production throughout the 6 years of the digesters operation. Furthermore, during this period of operation, the pumps have required only routine maintenance. The performance of AD systems is a marked contrast to other ‘retrofit’ projects.

As the sole UK suppliers of the bespoke design ROTAMIX (Digester Mixing) and STM (Small Tank Mixing) tank mixing systems using the integral VAUGHAN chopper pump, System Mix are making an important contribution to the success of AD plants.

Andy Parr, Director at System Mix comments: “Today AD operators need to maximise the sustainable credentials of their plant and equipment even further and we are confident that the benefits of our mixing systems are becoming even more relevant and important, as illustrated by the results of our involvement at NW’s Bran Sands site”

For further information contact Andy Parr, System Mix Ltd, Huntingdon.

Tel: +44 (0) 1487 830123 E-mail: andy@pumpmix.co.uk Web: www.pumpmix.co.uk

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PROCESS INDUSTRY INFORMER October - November 2015

MATERIALS HANDLING NEW RANGE OF MODULAR DEMAG ROPE HOISTS • Modular design for versatile configurations • Choice of C-design or co-axial design • Optional smart control system Terex Material Handling has launched a new range of rope hoists based on a single design technology. The DMR range is of a modular design and is available with a broad range of complementary components, allowing multiple configurations to meet a wide variety of customer specific applications. This inherent flexibility allows DMR rope hoists to be manufactured to compact C-design or co-axial design.

The DMR range includes five models with SWLs from 1 to 50 tonnes. They are suitable for conventional cranes and crabs, as well as for stationary applications in the mechanical and plant engineering sectors where lifting, towing, travelling, holding or positioning tasks are required.

DMR modular rope hoists are available as foot mounted hoists, low and standard headroom travelling hoists and double rail crabs to meet specific customer needs. A choice of electrical equipment is available, including the smart Demag SafeControl system, conventional contactor controls or customers’ own control systems. The smart SafeControl system provides a high level of operating safety and reliability, fulfilling requirements for efficient production processes.

SafeControl enables many technical features, from by-pass control to tandem operation and load dependent speeds, to be implemented with ease.

The DMR rope hoists satisfy the usual FEM 2m market standard as a minimum requirement and are rated for IP55 protection.

Dr. Thomas Bönker, Senior Director of the Components’ Business Line at Terex Material Handling, explained: “The Demag DMR modular rope hoist makes it easier to select the most suitable hoist unit. Until now, hoist selection depended on the comparison of various options to find the right product for the given requirements. The DMR range offers solutions for all requirements with one basic technology. This means that operators have maximum freedom in the choice of design, control system, drive method and control concept.”

For more information contact Demag Cranes & Components Ltd, Tel: 01295 676100 Email: bnb-help@terex.com Web: www.demagcranes.co.uk

PROCESS INDUSTRY INFORMER October - November 2015

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FEATURE

INDUSTRIAL VENDING: A LEAN APPROACH

Adapted from a white paper by Ian Ritchie, Managing Director, Brammer UK Best practice in managing the supply of maintenance, repair and overhaul (MRO) spares, tools and safety products can be one of the most effective ways for manufacturers to reduce costs, improve cash flow and prevent unnecessary downtime.

It can contribute to improved plant productivity and help to optimise health and safety at manufacturing sites. But what is the best way to achieve these benefits without prohibitive start-up costs or a significant investment in time and resource?

M

RO spans a wide spectrum of products and services and accounts for a considerable proportion of total costs of supply¹. It is essential to retain sufficient product on site that is easily accessible, but keeping large amounts of poorly managed stocks in case of emergencies ties up cash. Furthermore, products are often bought in large batch quantities to negate the possibility of a stock-out or to achieve a supplier discount.

This stock can, over time, become obsolete. Conversely, failing to stock the right items can result in unplanned downtime with a major impact across the manufacturing process and supply chain - on both cost and customer service.

Traditionally, many manufacturing sites operate with a single central stores facility. Workers in individual production areas who need to access tools, personal protective equipment (PPE) or MRO items walk to the stores, and then experience a further wait to be served by a stores operative. The time taken to visit stores immediately impacts on productivity in their area. It can also cause knock-on effects in the overall manufacturing process with delays in subsequent stages of production. After requesting items, workers have to wait for the products to be picked. Meanwhile, stores staff are responsible for logging the transaction, re-and then putting away new stock on delivery.

However, in some facilities the central stores may only be open for set hours each day, even in factories operating 24/7 shift systems. This means key MRO items are not always available from the stores when needed. As a result, workers may end up requesting more of a particular item than they actually need, storing the remainder for easy access at their own work station. This “squirrel stock” cuts down on the time workers waste in making multiple visits to stores. However, it can result in over-procurement of highvolume items, reduced traceability of usage, and yet more cash tied up in MRO stock. The products held in these “rogue” inventories are also subject to a greater risk of damage, loss, misuse or theft.

One way to address this problem has been to use open access bin systems at the point of use. Unfortunately, this can create its own problems in terms of control, monitoring and cavalier product usage - and the possibility of stockouts of production essential items outside stores opening hours still remains.

Figures from Fastenal, a US-based company who have been pioneers in MRO vending, suggest that the cost of direct and indirect labour may be reduced – but that uncontrolled consumption typically results in product usage increasing by 15 to 30 per cent, creating a further disincentive to this

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approach.

Moreover, within the stores themselves, the tracking and tracing of inventory, processing of multiple orders and budget management consumes time which could be better spent on value-adding activity.

Meanwhile, failure to actively monitor the supply and use of PPE or health and safety items can potentially leave a company open to legal action in the event of a workplace accident or fatality. If an employee requires a particular type of PPE for certain tasks and is subsequently injured at work, it can be difficult for employers to prove that they took the necessary steps to protect their staff. The correct product might have been held in stores, but did the employee have access to it? Did they receive the approved PPE items for the task? Or did they decide not to wear PPE despite having been issued the required items?

Taking all this into account, it is easy to see how a more streamlined approach to MRO spares management, based on detailed monitoring of availability and usage, can deliver real operational and bottom line benefits.

A key initiative to help the transition toward a ‘leaner’ process is the use of industrial vending machines to hold and control the dispensing of fastmoving industrial consumables. Typically, items that are small, fast-moving, high-value or can easily go astray - such as abrasives, tools, PPE, cleaning products, adhesives, lubricants and greases - are particularly suited to vending.

TAKING A BITE OUT OF CONSUMER SERVICES…

Industrial vending takes technology previously only utilised for consumer goods, such as drinks and snacks, and applies it to MRO product supply.

Machines are situated in convenient locations around the manufacturing facility - meaning they are accessible at any time, even when the main stores may be closed - and configured to stock the items needed most commonly at each location. They use an internet connection to flag up the need for restocking, as well as providing real time management information on usage by user and cost centre. An initial evaluation by a supply partner will help to reveal which products need to bestocked in which areas and in what volume. This allows machines to dispense the most appropriate products to each individual or team and negates the need for an individual to leave their

PROCESS INDUSTRY INFORMER October - November 2015

work station to go to the stores.

With industrial vending, manufacturers can identify which products are suitable for a given production area and restrict access to those spares to approved employees. Machines are typically operated by a customer’s employees using a personalised barcode or individual numerical code, allowing full control and visibility of usage.

Using access-controlled vending machines ensures employees are more likely to take only what they really need. They have a shorter journey to the dispensing point - reducing the need to keep large stocks at their station to save time - while the machines can be configured to only dispense one product type at a time.

Knowing that products can be traced back to them also causes employees to think more carefully about their consumption of MRO spares. This makes them more accountable and careful with their usage whilst reducing the risk of product loss.

Beyond this, the availability of real time reporting on usage means companies can assess their working practices. For example, where an employee is found to be requesting an unusually high number of items, managers can determine if the correct methods and products are being used and whether that employee could benefit from, for example, extra training.

The implementation of industrial vending invariably means that companies are working with a single MRO supplier for a higher proportion of the product lines being vended, which may previously have been bought from multiple suppliers. This plays a key role in reducing the amount of time spent by stores staff in ordering, receiving goods and putting away stock. It also lowers the costs associated with raising and processing multiple purchase orders and invoices, reducing the transactional costs associated with indirect labour. This allows stores staff to focus on larger or more critical spares management, as well as maintenance and value adding activity.

Figures provided by Fastenal, using this approach in the US, put the saving range for procurement at between 10 to 50 per cent per individual item stocked, while overall inventory levels have been seen to be reduced by around 30 to 50 per cent.

Industrial vending certainly has the potential to drive continuous improvement in line with modern manufacturing strategies such as lean manufacturing and total productive maintenance (TPM), adding significant value in virtually any manufacturing or operational environment.

Switching to this system for fast moving MRO consumables and PPE products can significantly reduce product consumption and lower inventory costs.

Also, a significant number of working hours can be reclaimed by removing the necessity for workers to make long trips to stores. Time is saved within stores themselves as the need to process, receive and replenish products is drastically reduced.

UPFRONT COST IS MET BY THE VENDER

However, the issue of cost also needs to be considered. For a company to purchase its own vending machines and software represents a significant upfront capital investment for a company, to say nothing of ongoing servicing and maintenance costs.

Some MRO suppliers have attempted to make industrial vending more attractive to customers by renting equipment to them. However, the cost of the initial batch of consumables still has to be borne by the customer at start-up. Furthermore, in many cases, the monthly running costs charged by these suppliers can significantly reduce any potential savings achieved in terms of, for example, reduced product consumption.

The implementation of industrial vending has, until now, been accessible to only the largest companies, who are able to commit substantial capital investment and in-house resources in order to reap the productivity and cost-saving benefits.

An answer to this problem now exists in the form of Invend™, a fully managed industrial vending service. Invend™ effectively removes these financial barriers and makes the benefits of vending available to manufacturers of all sizes. The complete upfront cost of the industrial vending equipment and software is met by Brammer, with customers paying only for the items they use. All that is needed to install the equipment is a power supply and internet connection.

For manufacturers of all sizes seeking to enjoy the numerous benefits of industrial vending, Invend™ makes the service truly accessible - by negating the need for upfront investment by the customer while managing everything from initial installation to ongoing replenishment and support.

References: 1. Cost management across firm boundaries – a case study of MRO procurement, Anna Dubois and Lars-Erik Gadde,

PROCESS INDUSTRY INFORMER October - November 2015

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ALARM & VISION SYSTEMS NEW ENTRY-LEVEL MODEL INTRODUCED TO 14.5CM LCD TOUCHSCREEN FLUKE TIX EXPERT SERIES INFRARED CAMERAS With a full 180° articulating lens and 14.5cm touchscreen, the new entry-level Fluke® TiX500 Infrared Camera allows thermographers to easily navigate over, under, and around objects to preview and capture images.

The recently-introduced Fluke TiX Expert Series cameras are ideal for predictive maintenance, in R&D, and oil and gas applications, where flexibility and higher resolution are essential, and they enable users to share their data in real time via Fluke Connect™.

The responsive 14.5cm LCD touchscreens of the Fluke TiX Expert Series offer a large viewing area, which enables thermographers to quickly identify issues while still in the field, as well as easily edit images directly on the camera. Optional telephoto and wide-angle lenses add versatility to meet a wide variety of applications. The TiX500 is suitable for temperatures between -20°C and +650°C, while the other models cover up to +850°C (TiX520) and

+1200°C (TiX560).

To ensure consistently in-focus images, the cameras feature LaserSharp® Auto Focus, exclusive to Fluke, which uses a built-in laser distance meter to pinpoint the target. The cameras also feature Fluke IR-Fusion® technology with Picture-in-Picture, full visible light, and AutoBlend™ modes for easier identification and reporting of problems.

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

Purity through innovation Global sieving and filtration specialists

FILTRATION SPECIALIST PILOT PLANT TRIALS FACILITY HELPS MANUFACTURERS OPTIMISE THEIR FILTRATION PROCESSES Manufacturers wishing to develop or optimise their separation processes are benefiting from the comprehensive pilot plant testing services of membrane filtration specialists, Axium Process. Pilot plant separation studies help determine at an early stage process feasibility, plant design and an evaluation of likely operating costs.

Utilising its comprehensive range of mobile membrane filtration pilot plants, Axiums’ specialist engineers will carry out trials on fresh feed supplied by the customer at its state- of- the-art Swansea based laboratory and testing area or at the customer’s premises. Each customer is supplied with a test protocol prior to the trials and a sample analysis together with a detailed report is provided upon completion. A range of different membranes can be used througout the trials as the company is independent of any membrane manufacturer ensuring that the optimum membrane can be selected for a given application.

The company, which has a wealth of membrane filtration experience, specialises in product separation, clarification, purification and concentration which can provide processing and cost benefits helping manufacturers to achieve sustainability and energy efficiencies.

Operating across a wide range of industries, Axium routinely carries out trials for a wide range of applications including dilute sugar stream concentration, dyestuff desalting and concentration, process waste water and waste volume minimisation, effluent treatment, precursor purification, final filtration of bottled water, recovery of cleaning chemicals, enzyme concentration and purification, clarification of fruitjuice and quarg cheese production to name but a few.

The company, which has earned an international reputation for its filtration expertise and “can do attitude” also includes as part of its services, product and process development; suggestions where possible to reduce plant costs; design, build, validation, testing and qualification to the highest levels; technical and training support together with an after sales support package that will be tailored to accommodate customer requirements.

For more information contact Axium Process Ltd, Hendy, Swansea Tel: +44 (0) 1792 883 882 Email: info@axiumprocess.com Web: www.axiumprocess.com

ANALYSERS INTRODUCING THE NEW ZETASIZER WT AUTOMATIC, ONLINE MONITORING FOR STABLE AND COST-EFFECTIVE WATER TREATMENT

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• Improves product quality • Increases screening capacity • Reduces maintenance costs

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Customized solutions - Applying innovation to meet your requirements Comprehensive customer service - Technical support & global stocking Specialized testing facilities - Trial your products for total peace of mind

Call us on: +44 (0) 20 8818 2000 14

A newly launched, innovative online zeta potential analyzer for water treatment allows water plant operators to control coagulation processes with enhanced levels of accuracy and confidence.

The Zetasizer WT from Malvern Instruments is a fully automated analyzer that continuously monitors the properties of water during coagulation to provide precise and reliable data for optimizing chemical dosage levels.

Delivering absolute (no calibration), highly sensitive analysis the new system enables a proactive response to changes in the process, enhancing plant stability and reducing the risk of significant events.

The associated optimization of charge neutralization processes results in substantial financial benefits due to a reduction in chemicals usage, with savings in the order of 20% reported by existing users. The Zetasizer WT is a standalone system that can be installed on either new or existing water treatment plants.

For more information contact Malvern Instruments Tel: 01684 892456 / Email salesinfo@malvern.com

PROCESS INDUSTRY INFORMER October - November 2015

FEATURE

2016 TRENDS: THE FUTURE OF ROBOTICS & AUTOMATION

By Tom Bouchier, managing director, FANUC UK Over the next year the manufacturing industry will continue to transform as new challenges and opportunities are created. Let’s take a look at some of the trends that will dominate the rest of the year and the 2016 landscape.

T

HE RISE OF COLLABORATIVE ROBOTS

For a long time there has been a need for the manufacturing industry to address the inefficiencies associated with the way humans and robots work together. Up until recently, robots and employees were separated by large industrial metal cages, as machines did not have the ability to distinguish between objects and workers during the production process. Subsequently this led to downtime during loading and unloading which had an impact on the speed and efficiency of production output.

Manufacturers are beginning to harness collaborative robotics, with the FANUC CR-35iA among the leaders. Collaborative robots will be one of the highest areas of growth in the next year, and we’re already seeing heightened demand within the automotive industry. Soon engineers will be working hand-in-hand with these products every day, especially as the technology becomes more readily available and accessible from suppliers.

Servicing a variety of manufacturing industries, collaborative robots can perform both simple and complex tasks, allowing cost savings to be made through automation.

The removal of metal fences within the manufacturing plant floor eliminating a large cost associated with the amount of space used to house the robots and human workers. As a result of this, closer working practices increase manufacturing output and productivity, enabling production to be carried out in one long fluid activity, rather than a stop-start process.

Collaborative working practices also provide healthier and cleaner working conditions. This gives workers better access to pursue skilled jobs in different areas of the business, providing access to training and career development. In cases where simple handling manoeuvres have been carried out by human muscle power, these can now be performed by the robot. Collaborative robots open up a new era for manufacturing as an indispensable part of production, offering advancements in industry productivity. Further enhancing these machines with vision, force sensors, and artificial intelligence, greatly improves the rate of industrial production, making it more cost and energy efficient, and at the same time reduces waste and drives sustainability.

SAFEGUARDING INDUSTRY 4.0

We’ve seen considerable investment in industry 4.0 across the manufacturing industry this year and we’ll continue to see this implemented in 2016. Industry 4.0 technology has changed the face of manufacturing and is seen by many as the fourth industrial revolution, allowing manufacturers to fuse together automation and digitalisation to produce more efficient production models.

According to a report by Cisco, the number of Internet of Things sensors will grow to 50 billion by 2020. Intel has also predicted that there will be 200 billion Internet-connected things in 2030. The Internet of Things is becoming integral to the manufacturing process, creating huge volumes of data to give valuable insights around optimising the performance of overall factory operations. At the same time this creates a major issue which needs to be tackled, increasing the risks of remote hacking, with DDoS attacks becoming more widely reported over the last year.

A preventative approach must be taken in order to deal with potential cyber threats by implementing a number of low cost, PC-based, dedicated hardware and software controls. These can be installed for factory automation, machine tools and robots.

THE IMPACT OF FACTORY AUTOMATION

Factory automation is indispensable to manufacturing, offering advancements

in industry productivity. Using intelligent machines greatly improves the rate of industrial production making it more cost and energy efficient, and at the same time reduces waste and drives sustainability. Huge energy savings are also made from implementing servo controlled machines and motors, as opposed to hydraulics and squirrel cage uncontrolled AC motors.

A report published earlier this year by Graetz and Michaels at the London School of Economics shows empirical evidence of the benefits that robotics and automation are bringing to the global economy and factory workers. The research shows that the GDP of 17 countries rose by 0.37 per cent annually, and shows an increase in annual worker productivity by 16 per cent.

Despite speculation over associated job losses, Graetz and Michaels’ study has found that countries which invested significantly in automation between 1993 and 2007, such as Germany and Sweden, have experienced fewer job losses compared to countries that made lesser investments.

THE FUTURE

Up until recently, robotics and automation was most widely applied to the automotive and metals industries; sectors which have rapidly expanded over the last 40 years.

This is no longer the case - with investment in research and development, and advances in engineering capabilities, robots are equipped with a wider breadth of applications and are entering new industries, such as plastics and medical.

As industrial automation continues to be implemented across manufacturing, developments will continue to be driven by technological innovation. At the same time, complex adaptive systems and multi-processing will take over from real-time systems, further increasing productivity and profitability for manufacturers.

Global spending on robots is expected to jump from £9 billion in 2010 to over £43 billion by 2025. The speed of uptake is driven by a convergence of falling prices and performance improvements, and with automation moving beyond the manufacturing realm, businesses need to invest creatively and effectively in order to reap the benefits. The full impact of robotics and automation will likely take a generation before it becomes truly measurable. The research available today is the result of years of cumulated data, and reflects the impact of automation since the 1990s. Robotics and automation has boosted global GDP and overall productivity, while transforming the manufacturing workforce.

It is essential that manufacturers therefore prepare themselves for a change in working practices when adopting new technologies, planning effectively for the deployment and resulting impact on the workforce of automation equipment. Investments in robotics and automation are best coupled with training and development programmes that support the redeployment and associated upskilling of staff.

The challenge for companies is to attract and retain the best talent, while at the same time, investing in new and emerging technologies.

That dual approach can keep them ahead in a tough manufacturing landscape.

FEATURE

HOW TO MAKE THE SWITCH TO ROBOTS After a slow start, robotic automation is beginning to gain headway in the UK, with companies beginning to increase the pace of robotic automation in their processes. Mike Wilson, General Industries Sales & Marketing manager for ABB’s UK Robotics business, explains how UK manufacturers can make the switch to robots to help them stay one step ahead and the key steps that should be taken in developing the right solution for their needs.

D

uring the last 35 years, industrial production technology has developed at an astonishing rate. Nowhere is this more apparent than in the case of industrial robots. From just a handful of units with limited capabilities sold in the early 1970s, the take-up of robots has grown exponentially, with recent estimates from the international Federation of Robotics (IFR) pointing to 1,946,000 robots likely to be in use by 2017.

Here in the UK, there is growing evidence to show an increasing acceptance of robotic automation, with robots starting to appear on factory floors outside of their traditional automotive stronghold. However, for a variety of reasons, British companies remain slow to invest in robotic technology compared to their overseas counterparts.

Despite an increase in the take-up of robotic automation in the UK, the annual statistics from the International Federation of Robotics (IFR) show us continuing to remain stubbornly at the lower end of the global league table of robotic adopters, with just 27 robots per 10,000 employees. This compares with over five times as many in Germany.

Our own research indicates that much of this can be attributed to a lack of experience in robotic technology. In particular, a nationwide shortage of trained robot personnel has led many companies to misperceive robotic automation as being too complicated, risky and costly to introduce.

Furthermore, our own experience shows that those companies that are willing to move towards a switch to robot automation are often unsure about how to go about it.

STEP 1 – DEVELOP YOUR SOLUTION A successful robot installation starts with a proper specification. Knowing exactly what you need, and communicating it to a supplier, will avoid problems later on caused by miscommunication or a mismatch in the capability of your system versus your requirements.Foremost at this point will be to clearly define exactly what you want a robot to do and the tolerances you want it to accommodate.

Factors to consider include the types of products you need the robot to handle, how long you want it to operate for and any special conditions relating to the application itself, such as whether the robot will be operating in a sterile environment.

MAKING A SWITCH TO ROBOTS

The diagram below outlines the recommended steps for gauging the potential for robotic automation and specifying the appropriate solution for your application.

You should also give some idea of where you believe improvements in your existing process can be achieved. This should include information about the target efficiency levels you want from the robot, such as precision, speed, wastage reduction or some other target area, which can then be compared to what you are currently achieving.

A valuable first stage in developing a robotic automation solution is to gather any relevant drawings and documentation on the parts being produced or handled, together with basic details of the process itself. This will provide a supplier with an understanding of what you’re making and any special requirements regarding handling. Where a product line produces multiple products, this may also include any considerations arising from variations in product shape or packaging.

It can also be helpful to speak to anyone involved with the process that you are seeking to automate. Very often, people’s actions and judgments will introduce nuances into a process that you might not be aware of, which could affect the specification and eventual efficiency of a robot system.

Once equipped with all this information, a target cycle time can then start to be calculated, which can be used to assist in the overall design of the system.

STEP 2 – CREATE YOUR INITIAL CONCEPT DESIGN Very often, a decision to automate will have been prompted by someone having seen what someone else is doing, either in terms of producing a similar product or operating a process that could be adapted to suit their requirements.

In such cases, it is relatively easy to start to devise a solution by developing an

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outline concept based on the desired installation.

Where additional equipment may be needed, or where a different or bespoke solution may be required, it is also worth consulting with experts and / or suppliers such as robot manufacturers or system integrators who can advise on the best way to tackle a particular problem. These organisations can often use their experience to recommend the best way to tackle a given problem or to point to similar applications in other industries.

STEP 3 - CONSIDER SAFETY AND CONTROL Safety is a vital area that needs to be considered at the earliest possible stage. Selection of safety equipment will vary based on factors such as the risk involved in the process, the proximity of manual workers and any requirements for worker / robot collaboration.

Traditionally, the need to protect workers against the risk of collision with a robot in full motion has meant incorporating extensive guarding and other safety features into an installation.

Recent developments in robot control technology have opened up new possibilities for operators to work alongside robots without the need for extensive guarding. ABB’s SafeMove, for example, uses electronic motion detection and prevention measures, which can be reconfigured if required. In the event of an unanticipated obstacle being detected, SafeMove automatically brings the robot to an instant stop. In this way, operators now have greater freedom to collaborate with a robot, allowing them to interrupt the robot to perform tasks such as checking or adding or removing samples.

By reducing the requirement for conventional guarding equipment, SafeMove helps to cut both the cost of an installation and the overall footprint, ideal for laboratories and other locations where space is at a premium.

Another point to consider is the type of control equipment that will be used to control the robot. Many manufacturers, ourselves included, offer application software packages that greatly simplify the process of installing and configuring a robot, thereby removing much of the complexity and risk at the set-up stage.

Developments in HMI and integration technology are also opening up new methods for robot control. Many robot controllers feature their own easy-to-use HMIs, either built into the controller itself or using hand-held teach pendants, which allow even inexperienced operators to easily program and configure a robot.

Control in large-scale applications can also be achieved through a PLC communicating with the robot controller, which can help simplify configuration where there may be a large amount of peripheral equipment that needs to be integrated with one or more robots.

STEP 4 - TESTING AND SIMULATION A lingering concern when it comes to robotic automation is the perceived disruption caused by testing and commissioning a robot on the factory floor.

This concern can be addressed by using offline programing and simulation tools, which allow installations to be created and fully tested in a virtual environment before they are put into action. These tools can be either kinematic, where just the robot or robot cell is modelled, or discrete event, where a robot can be shown as part of a complete production process.

Using this software to simulate and test your proposed concept, either at the robot or plant level, will enable you to see whether it works and whether it can be refined further.

STEP 5 - REFINE THE CONCEPT Conducting the steps detailed above should help confirm the efficiency of the robot installation and whether any further refinements need to be made. Using

PROCESS INDUSTRY INFORMER October - November 2015

the information gathered, it should be possible to begin to calculate some potential cost savings, which in turn can be used to derive a likely return on investment figure that can be presented to your finance department.

To achieve the best possible ROI, it is important to factor in all possible cost improvements. As well as direct improvements arising from things such as improved production throughput and reduced wastage and labour, consideration should also be given to non-obvious areas. As a means of handling heavy payloads, for example, robots can reduce the risk of injury to workers, minimising the risk of injury-related compensation. Energy savings can also be achieved both by the ability of robots to work in unlit and unheated areas, and to achieve right first time production, which eliminates the extra energy incurred in correcting substandard product.

A key factor to bear in mind before finalising your concept is the need to cope with any future changes. Wherever possible, it is advisable to add in re-configurability at the outset, which will help to provide the flexibility both to accommodate future changes and to add extra tasks if required. This may include factoring in hardware such as exchangeable end of arm tooling or the latest software or controller that can be used to quickly switch between programs to handle new processes.

Building in extra flexibility will almost certainly push up the cost of the installation.

However, it may be better to spend a bit extra at the outset to achieve added flexibility rather than incurring the expense of carrying out modifications at a later date to shoehorn changes in.

CHOOSING YOUR SUPPLIER

As with all things, it pays to consult multiple suppliers before making your choice. Things to look for include price, capability and reputation, together with a proven track record of supplying solutions for your type of application.

A reputable supplier should also be able to help you comply with legal requirements relating to the robot. An example is CE marking, which stipulates a complete process for certifying a product as fit for use for a given application.

SUMMARY

The ability of modern industrial robots to achieve the high levels of quality and minimal wastage demanded in production processes is well proven.

For those companies looking to translate these benefits into their own processes, following the steps outlined in this article should help to provide a useful starting point in putting together a justification for a switch to robotic automation.

Regular seminars entitled ‘Switch to Robots’, which include presentations on the benefits of investing in robots; how to devise an automation strategy and how to present a financial case to your FD, followed by a workshop session featuring live demonstrations of robotic technology are available – for information e-mail: robotics@gb.abb.com ref. ‘Switch to Robots’. Other suppliers may also offer something similar.

ABBRobotics_UK

abbroboticsuk 17

FEATURE

DEFINING ALARM MANAGEMENT –

there is more than meets the eye!!!

By Andy Graham, Systems Architect at Wonderware UK and Ireland

Most manufacturers, whether they openly admit it or not, have too many alarms. Since the 1970s, the number of alarms configured per operator has steadily increased from hundreds to thousands. This can be attributed to a number of factors including more sensors with more potential signals and alarm states and the ever-increasing complexity of manufacturing environments.

T

here is often a default philosophy amongst manufacturers in which they take a ‘better safe than sorry’ or ‘if in doubt mark it as high priority’ approach. This can often be attributed to a lack of communication between those that design the manufacturing site and those that put in the SCADA or other systems. Alarmingly, a lack of a clear Alarm Management Philosophy is the most common cause.

However, following some high-profile disasters in the oil, gas and energy sector, industry-wide standards such as Engineering Equipment and Materials Users’ Association (EEMUA) 191 have gradually gained prominence.

The risks are not limited to those industries though. For food and beverage manufacturers, whilst issues may not result in disasters, they can cause other problems such as unexpected downtime, wastage and severely impacted performance, to name just a few.

What we’ve learnt from these disasters, large and small, is that more often than not they are caused by an operator making the wrong decision based on the information he or she thinks she has about what is going on in the process. So yes, it’s human error, but the cause of this human error lies deeper within the infrastructure.

Many disasters have been caused by cascades of alarms, referred to as ‘Alarm Storms’ –when multiple alarms are triggered almost simultaneously, leaving the operator no choice but to prioritise some over others.

To address this, EEMUA 191 recommends no more than ten alarms be configured per operator in a six hour period in order to reduce the risk of ‘cognitive overload’ – in other words, operators ‘not being able to see the wood from the trees’.

SO, WHAT ARE THE OTHER CHALLENGES PRESENTED BY ALARMS? • • • •

There may be alarms which appear and disappear before the operator can take action or even acknowledge the alarms have been displayed (chattering alarms) Some alarms may not provide sufficient time for the operator to take action before the process is stopped by the automation or emergency shut down logic Unmanaged alarms can result in downtime, off spec quality, waste, planning and logistic problems In some cases situations result in accidents, with equipment damage, injuries, penalties and fines.

However, the good news is that technologies now exist that enable manufacturers to measure themselves against alarm standards quickly. Alarm Management is an important way of measuring the workload of an operator, improving the control and HMI systems and analysing which equipment provides more problems than others and it is a valuable tool for reducing operational and capital expenditures. Alarm management experts can also provide recommendations that will not only help define a sensible alarm management

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philosophy tailored to the customer but also help implement these changes without the need for costly re-engineering.

Using modern software and technologies to better analyse and understand alarms is part of the bigger picture of Operational Intelligence (OI), presenting you with actionable information from real-time analytics. Importantly, OI can ensure that the right information is delivered to the right person in the right format and at the right time.

The next step for the manufacturing industry will see data from various nich manufacturing systems such as Manufacturing Execution Systems, Supervisory Control and Data Acquisitions, Maintenance Management Systems and Laboratory Information Management Systems, aggregated together. This can then be manipulated and analysed using accessible browser based, slice-anddice enabled technologies such as Wonderware Intelligence and Wonderware Corporate Energy Management.

This will become commonplace and allow those running businesses to see energy usage across the production process and how that data tracks back to the bottom line.

Additionally, Operational Intelligence can deliver valuable insights into other areas of the manufacturing process, providing further cut-through for a host of efficiencies outside including energy usage. With greater access to data on batch and quality management, manufacturers are able to ensure that productivity remains high, which in turn can help reduce surplus energy consumption.

For example our solutions allow the monitoring and controlling of quality in real-time, improving product consistency and compliance with both internal specification and external regulations. Again, this allows for performance abnormalities to be spotted instantly, ensuring that errors can be corrected and unscheduled downtime and other issues such as spoilage and wastage further prevented. What’s more, these solutions can sit alongside other monitoring software and offer manufacturers scalable functionality, from entry level targeting specific elements of performance to full scope integrating with and addressing all levels of operations. Having an alarm management strategy is vital to ensure you can monitor the workload of an operator; improve and control HMI systems; analyse what equipment is failing and enable your operators to prioritise their actions and deal with the alarms in an appropriate order.

Production sites, people and equipment do not always behave as expected.

And sometimes, when the three combine, the effects are unexpected and disastrous. As a result, well designed alarm systems and an alarm management strategy are essential to ensure those on the front line have everything they need.

Giving operators the opportunity to easily and quickly identify an alarm that requires response is essential to protecting both the productivity and safety of a manufacturing system. With a robust and logical response procedure in place, manufacturers can be confident that alarms will only sound when necessary, saving potential loss of earnings and at the more serious end of the scale, preventing disaster.

PROCESS INDUSTRY INFORMER October - November 2015

COOLING SYSTEMS UK LAUNCH OF RITTAL’S INNOVATIVE BLUE E+ COOLING SYSTEM A new generation of cooling units is being launched in the UK by Rittal, the leading global enclosure and climate control specialists.

The Blue e+ is a major advance for the sector and represents a quantum leap forward in terms of efficiency and cost effective operation. As well as being far more energy efficient than existing cooling solutions, Blue e+ systems use state of the art technologies, packaged in a unique manner, to also deliver greater flexibility, safety and ease of handling.

Blue e+ units are six times more efficient than a conven-tional cooling unit at a part-load of 15 per cent in heat-pipe mode. At a part-load of 65 per cent, in hybrid mode, with both the compressor cooling device and heat pipe in operation, Blue e+ is four times more efficient than a conventional unit.

The energy efficiency of the compressor cooling is also very high. DC motors power both the fans and the compressor, while inverter technology adjusts the compressor and fan speeds so the cooling output matches demand at any one time.

MULTI-VOLTAGE INPUT FOR THE GRIDS All Blue e+ units have multivoltage capability and so are suitable for all standard power networks worldwide.

Input voltages range from 110 V (single phase) to 480 V (three-phase) at grid frequencies of 50 or 60 Hz. SUPERIOR PROCESS RELIABILITY Demand based cooling eliminates both thermal stress and any temperature fluctuations within the enclosure. This, in turn, increases the service life of the cooling units and enclosure components and also means higher process reliability.

The Blue e+ range has cooling capacities that extend to up to 6,000 watts (the maximum available from the preceding Blue e unit is 4,000 Watts) and it can be used in ambient temperatures ranging from -30°C to +60°C. EASY HANDLING FOR FASTER SERVICE Standardised communication interfaces ensure easy integration into a production plant’s control systems. The 4.3” TFT touchscreen display presents users with key information at a glance, while system messages are plain text and multi-lingual. Moreover, a variety of protocols permit real time data transfer via the Ethernet interface. What’s more, all Blue e+ units are identical across all markets which means that spare parts are easier to get hold of.

For more information contact Rittal Ltd, Hellaby, Rotherham Tel: 01709 704000 E-mail: information@rittal. co.uk Web: www.rittal.co.uk or on

NEWS

NOVEMBER 2015

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.

During the course of this celebratory year we will be including a number of articles that will examine the role of the Association in relation to some important developments in areas including technical training, commercial energy and industry standards as they relate to the British pump industry. If you have anything you can contribute, including reminiscences of the industry and key people from the early days, these would be welcomed by

the Editor (peterullmann@piimag.com) and the BPMA Director (s.schofield@bpma.org.uk).

On the subject of change, we have grown to 76 members and embrace not only pump manufacturers & suppliers, but also pump related product & service providers. We now reach out to a greater audience to the benefit of our members via our fast developing website, our recently introduced marketing programme, participating at a variety of exhibitions, for the last 12 years, through BPMA News and now by the series of articles planned for the coming year .

2016 will see us welcome in our new President, say goodbye to the old, and sadly say farewell to a stalwart of our team and introduce our new team member – turn to page 2 to catch up with the ‘comings & goings’…

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PUMP INDUSTRY EMBRACES BIM British Pump Manufacturers’ Association (BPMA) provides clarification on conformity to Building Information Modelling Level 2 (BIM).

Although the pump sector has for some time recognised the need to fulfil its commitments to BIM, there have been many different interpretations as to how this might be achieved. Recognising the confusion that seemed to prevail across the sector, and in direct response to the concerns of its members, the BPMA convened a meeting to address the issue. But given the important work that the Chartered Institution of Building Services Engineers (CIBSE) had already been conducting in this area, and acknowledging its advisory role to UK government, the BPMA solicited its help and guidance.

The initial UK meeting led to further meetings across Europe, with CIBSE and many prominent pump manufacturers in attendance. The result of these meetings was to develop a Product Data Template (PDT) which could then be populated by any pump company. By completing the PDT for their products, manufacturers can effectively produce an ‘electronic catalogue’, directly usable in Level 2 BIM. The templates are written in Excel, so manufacturers will not need much BIM ‘know how’ to be involved. Another clear advantage is that the manufacturer will only have to describe and complete a product once to serve all BIM software systems and users.

It was agreed that the master template should be owned by CIBSE, so there could be no commercial interest in its curation. All completed Product Data Templates will then be owned by the respective Pump Manufacturers. Any changes to the template will need to be agreed and approved by the pump industry across Europe and dissemination of any revised version to members will be via National Associations such as BPMA. The purpose of this template will be to standardise the data required for a product category. As such, it is believed that this PDT for pumps will meet the requirements of the Building Services and MEPH (Mechanical, Electrical & Public Health) sectors across the European Union.

For further information and a copy of the Product Data Template please contact BPMA

BPMA CONTINUES THE FIGHT AGAINST NON COMPLIANT PRODUCTS Pumps may not be the first things you think of as a target for non-compliance issues. However, we in the pump sector have been in active dialogue about such imports for two years with the NMRO (National Measurement Regulatory Office) who are the responsible UK Market Surveillance Authority.

Market Surveillance is a key element of a fair and efficient EU internal market as it has a role to ensure that products placed on the community market comply with EU regulations and do not pose any safety or environmental threats for users and the public at large. This should ensure a level playing field and fair competition on the market as well as safeguarding the coherence of the European regulatory framework, the consistency of which depends on effective enforcement.

However, there continues to be growing evidence of the presence of illegal pump imports entering the UK that do not meet the strict demands of the ErP (the EU Energy Related Products Directive). The BPMA, supported by the CEO’s of some prominent member companies met with the Better Regulation Delivery Office (BRDO) during the summer in an attempt to put additional pressure on the National Measurement Regulatory Office (NMRO) in their role of UK Market Surveillance Authority to encourage them to take appropriate action.

Unfortunately the situation currently remains unchanged with no specific plan in place to remove illegal products from the market, as there would appear to be no cohesive methodology to clearly identify rogue imports.

We have grave concerns regarding these non-compliant products being available on the UK market, as they have the capacity to cost bona fide companies millions of pounds in lost revenue, whilst placing jobs and hardearned reputations at risk. But of course another real concern relates to their safety, as without proper testing they could also present a health & safety hazard.

But rest assured, having initially raised this issue with Government Ministers and MP’s some eighteen months ago, the BPMA is committed to bringing pressure to bear on all the agencies who are charged with maintaining standards for the greater good and will be continuing to canvas for change at every available opportunity.Market surveillance is an important subject and one that is likely to come under increasing scrutiny. We therefore need a plan to protect our industries, our reputations and our borders from the unscrupulous exploitation of companies to whom standards are irrelevant.

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BPMA & EMA DEVELOPS BETTER PUMP UNDERSTANDING The BPMA has worked with the Energy Managers Association (EMA) on the production of a ‘buyers guide’ entitled “Optimising energy consumption in pumping systems” specifically formulated for Energy Managers, Facilities Managers, Estate Managers and Procurement Teams.

It is well documented, and universally understood, that pumps and their associated systems are huge consumers of electrical energy. So with the drive for improved energy efficiency across all industry sectors, as demanded by the ‘Energy Savings Opportunity Scheme’ it is essential that this influential group of ‘non-pump experts’ gain a good understanding of the potential energy savings that are available within their respective pump systems.

The guide will ensure that the pump industry, and specifically BPMA member companies, are well represented when energy reduction strategies are identified and implemented, as part of company-wide energy audits. It was launched at the EMA’s annual event EMEX (Energy Management Exhibition) which took place on the 11th and 12th November at ExCeL, London.

Attendees to the event, included representatives from the UK’s largest organisations - those primarily governed by ESOS in terms of energy audits, and which by definition are heavy pump users – will be looking to manufacturers and suppliers of pumps and related technologies for energy reduction solutions.

This event therefore offered an ideal environment at which to launch and promote this important reference material.

Lord Redesdale, CEO of the EMA commented “The BPMA’s attendance at EMEX showed the importance of pumps in the list of energy saving devices our members can use to reduce their companies energy use. The payback on pumps is one of the quickest wins for Energy Managers, so it is somewhat surprising how often this simple measure is overlooked. The EMA, in association with the BPMA, produced this buyers guide to help Energy Managers, not only assess the savings they could make on pumps, but also which questions they should ask to make sure the system they install is the best match for their needs.”

Steve Schofield, Director and CEO of BPMA added “We were thrilled to be working with EMA on this initiative as it further demonstrates our commitment to the drive for improved energy efficiencies across all pump systems, and to ensuring that all those individuals with responsibility for energy use reduction, have a core understanding of the impact that pumps can have on a company’s overall energy consumption. This undertaking also serves to put BPMA member companies, their products, their engineering skills and their business credentials at the heart of good energy efficiency practice. In essence, if energy managers need help and guidance with their pump systems, this Buyers Guide and the wider BPMA membership will provide that support.“

STAFF CHANGES AT THE BPMA Please be advised that at the end of 2015, Jeanne Page, Assistant Director will retire. Jeanne has been with the BPMA for many years running the office in West Bromwich and dealing with the administration roles the position has demanded. She has been the backbone of the association and will be truly missed.

We are sure that you will all wish Jeanne the best in her retirement.

Trying to fill the void left by Jeanne was difficult says Steve Schofield, BPMA Director, and we have taken time to recruit the right person. I am pleased to welcome Steve Smith who has joined the BPMA as administrator. Steve’s background includes working within the Trade Associations environment which I am sure will be valuable in this new position.

Steve’s contact details are: Email : s.smith@bpma.org.uk & Phone : 0121 601 6692

ANOTHER NEW MEMBER INTO THE FOLD… We have recently welcomed Glasgow based TORISHIMA EUROPE whose parent company was founded in Japan in 1919, has been supplying centrifugal pumps to a broad range of applications, specialising in any field which is indispensable for human life. Addition to Pumps, they also offer a full range of Mechanical Seals.

LADIES & GENTLEMEN, WE ARE DELIGHTED TO INTRODUCE MR PETER REYNOLDS, MANAGING DIRECTOR OF GRUNDFOS PUMPS LTD, AS THE NEW PRESIDENT OF THE BPMA “Being appointed as President of the BPMA is a great honour that has been heightened by my having the added good fortune that my term in office coincides with the 75th Anniversary of the

BPMA.” With a story that goes back to 1941, the foundations of the BPMA can be traced 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 atthe 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 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. Which 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 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.

The role of the BPMA 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.

“I firmly believe that we can look forward to the future with confidence, as today we have a strong membership base, a firm strategy for the future and the willingness and drive to see projects through”.

BPMA PUMPING FUNDAMENTALS TRAINING COURSES With an expanding global economy and the high number of people being drawn to media or IT based industries, it is critical that UK engineering businesses develop their employees’ skills in order to maintain a strong manufacturing base.

Furthermore, it is now well accepted that pump specific training is lacking from many engineering based courses.

Being the UK’s major authority on this important product area, BPMA are able to offer a selection of traditional lecture-based courses, starting with basic pumping fundamentals and progressing to the more advanced disciplines of pump hydraulics and pump systems.

Courses are suitable for all those sectors engaged with the purchase, installation and operation of pumps and pumping systems, but are specifically aimed at engineering contractors and system integrators, as well as procurement, service and maintenance personnel within end users organisations.

Our highly regarded courses, presented by industry experts, offer: • Full ‘one-day’ modules • Excellent training facilities (with onsite catering) at our own premises • Courses held approximately every three months • Full support and training guidance • Cost effective pricing, with discounts available for BPMA members • Comprehensive course manual • Certificated by BPMA (subject to course assessment)

For more information on course content please visit http://goo.gl/RFU5tU. Venue: The National Metalforming Centre 47 Birmingham Road, West Bromwich B70 6PY (1 min from J1, M5)

SCHEDULED DATES FOR 2015/16:

Our courses are also being updated and will be renamed from 2016 2015 23 November

Module 001 Part 1 - Pumping Fundamentals

£300 + VAT*

25 November

Module 001 Part 2 - Pump Selection

£300 + VAT*

8 February

Module 001 - Pumping Fundamentals

£300 + VAT*

9 February

Module 002 - Pump Selection

£300 + VAT*

22 February

Module 003 – Pump Testing

£300 + VAT*

23 February

Module 004 – Pump Systems

£300 + VAT*

29 February

Module 005 – Hydraulic Design of Centrifugal Pumps

£300 + VAT*

6 June

Module 001 - Pumping Fundamentals

£300 + VAT*

7 June

Module 002 - Pump Selection

£300 + VAT*

22 August

Module 001 - Pumping Fundamentals

£300 + VAT*

23 August

Module 002 - Pump Selection

£300 + VAT*

21 November

Module 001 - Pumping Fundamentals

£300 + VAT*

22 November

Module 002 - Pump Selection

£300 + VAT*

2016

*£250 + VAT for BPMA Members

Dates not convenient? All courses can be arranged at your own premises. Special rates apply Contact s.smith@bpma.org.uk for booking form or for more information

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

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BPMA CERTIFIED PUMP SYSTEM AUDITOR RESIDENTIAL COURSE 25-28 APRIL 2016

Venue: Rezidor Park Inn Hotel West Bromwich, West Midlands (J1, M5)

STEVE SCHOFIELD, BPMA DIRECTOR & CHIEF EXECUTIVE, REVIEWS THE DRIVE FOR IMPROVED PUMP EFFICIENCY

T

he BPMA has always pioneered progressive initiatives which benefit industry, and has consistently put itself at the centre of the drive for improved efficiencies across UK industry, particularly those sectors synonymous with pumps and pump systems. Way back in 2005, when the EU first identified those sectors that consume large amounts of electricity and subsequently organised studies as part of the EUP Directive 2005/32/EC to determine what could be done to reduce energy consumption, the BPMA was in the thick of the activity.

The Energy Savings Opportunity Scheme (ESOS) Regulations 2014 came into force on 17 July 2014 and are a mandatory energy assessment and energy saving identification scheme for large undertakings (and their corporate groups). The scheme applies throughout the UK. ESOS Energy Audits have the potential to increase businesses profitability and competitiveness by identifying costeffective savings which, if implemented, will improve energy efficiency. The scheme is estimated to lead to £1.6bn net benefits to the UK, with the majority of these being directly felt by businesses as a result of energy savings.

ESOS is the UK Government’s approach to transposition of Article 8(4) of the EU Energy Efficiency Directive, which requires all large (non-SME) enterprises to undertake energy audits by 5 December 2015 and every 4 years thereafter.

Guidance has also been published to help potential participants in the scheme understand their obligations and on page 43 of the full ESOS guidance document you will see that the ISO/14414-Pump System Energy Assessment standard is referenced as an auditing methodology that can be accepted by “Lead Assessors” approved by the Environment Agency. Accordingly it is hoped BPMA CPSA accredited persons (who are trained according to the IS0 14414 standard) will be recommended by Lead Assessors to undertake the pumping system elements of company energy audits.

The BPMA Certified Pump System Auditor Scheme (http://www.bpma-cpsa. co.uk) has established BPMA as THE body to train and certify personnel who undertake “Pumping System Assessments” as referenced in UK Government Energy Strategy documents BPMA are now offering the opportunity to attend a four day residential course culminating in certification and eventual personal ID “Certified Pump System Auditor” status following approved audits.

Our next scheduled course will take place on 25-28 April 2016 Register now by calling 0121 601 6691 or email s.smith@bpma.org.uk Delegate fees £1,500 + VAT (BPMA Members) £1,750 + VAT non-members (incl. 3 nights accommodation (b&b) at the Rezidor Park Inn Hotel)

THE 2016 BPMA GOLF DAY WILL BE HELD AT THE WORLD CLASS Vale Resort Vale of Glamorgan on Thursday 19th May 2016 Tea, Coffee & Bacon Rolls at Reception 18 Hole Team Competition Wales National Course - Buggies Individual Prizes Prize Giving Dinner Overnight Accommodation Breakfast on Departure

Only £199 Per Player + VAT Contact s.smith@bpma.org.uk for a booking form 4

One such study named LOT 11 dealt with certain products within motor-driven systems. The outcome has been the delivery of new EU legislation covering fans, electric motors, glandless circulators and certain water pumps. The transition from the old EFF 1, 2 & 3 voluntary scheme to the new IE ratings of 1-4 is almost complete, with all motors ranging from 0.75kW to 375kW requiring a rating of IE3 (or IE2 with a VSD) as of 1st January 2017. It is believed this will be extended to 1000kW by 2020 under the new EU study Lot 30.

There are of course exceptions, with the legislation only applying to three phase motors; all submersible motors and encapsulated motors that cannot be assessed for efficiency as a stand-alone unit are excluded. Single phase motors will be introduced within the LOT 30 study.

In regard to glandless stand-alone and boiler integrated circulators, the two main technology changes designed to substantially influence energy savings are the move away from standard induction motors to permanent magnet motors and the move from standard speed technology to variable speed technology - Products Directive and legal text for Circulators can be found within commission regulation 622/2012 of 11th July 2012.

As far as water pumps are concerned, the European pump industry agreed legislation intended to remove 40% of inefficient water pumps (in accordance with a Mean Efficiency Index - MEI) from the market, the respective time lines for which being January 2013 and January 2015.

Two other study areas (LOTS) also relate to pumps and are ongoing.

LOT 28 encompasses pumps for public and private waste water (including buildings, networks and treatment facilities), and for fluids with high solids content. Lot 29 encompasses pumps for private and public swimming pools, ponds, fountains and aquariums, as well as clean water pumps larger than those regulated under LOT 11.

The BPMA, through its European Federation, Europump, has actively participated with the European Commission in the development of these LOTS and has created several applicable working groups.

The work of these Europump Working Groups has been, and will continue to be, vital in helping to influence future legislative measures and to safeguard the interests of its member companies.

These initiatives have formed the bedrock of a clearly defined energy reduction strategy policy that includes a systems based approach to the energy efficiency of pumps, along with associated Energy Audits which are required under article 8 of the Energy Efficiency Directive. Indeed BPMA Chaired the ISO Committee which has published the ISO14414 standard – the international standard for conducting a pump system audit. Furthermore, the BPMA has developed and launched its Certified Pump System Auditor scheme (CPSA) - a new qualification (based on ISO14414) designed to help improve the levels of professionalism in the sector by creating a universally recognized and respected industry qualification for individuals assessing the performance of a pumping system.

As such, the BPMA continues to play a crucial role in ensuring that the UK Pump industry remains a key driver in delivering improved energy efficiencies for UK industry.

i-ALERT2 EQUIPMENT HEALTH MONITOR The i- ALERT2 Equipment Health Monitor is a Bluetooth Smart-enabled machine health monitor that allows customers to identify potential equipment problems before they become costly failures.

ITT’s i-ALERT2 Equipment Health Monitor is an inexpensive Bluetooth Smart-enabled equipment health monitor that allows customers to identify potential problems before the machines become costly failures. It tracks vibration, temperature and run-time hours and wirelessly syncs the data with a smartphone or tablet through the i-ALERT2 mobile app.

The i-ALERT2 condition monitor combines the latest in Bluetooth low-energy and sensor technologies commonly used in the newest consumer health and fitness trackers and smart watches. The i-ALERT2 device is the first condition monitor to successfully integrate these technologies into an industrial package in a small footprint [2.24 in. (L) by 1.54 in. (W) by 1.04 in. (H)] which is half the size of a credit card. It is engineered and rated for use in a wide range of industrial environments. It is chemical resistant, rated for extreme temperatures (-40 to 183 F) and is rated to operate in environments with explosive gases, dust and fibers.

With 24/7 monitoring, a wireless range of up to 100 ft and the ability to scan multiple i-ALERT2 devices at once with a mobile device, customers will be able to quickly and safely inspect multiple pieces of equipment and be alerted of potential problems before they become critical failures.

Through the i-ALERT2 mobile app, customers can now view real-time and historical data, diagnostic information and machine records. This provides them with the data necessary to make informed decisions. Customers can now spend less time collecting data and more time solving problems.

Buy a Goulds ANSI and ISO process pump and these are supplied with i-Alert fitted as standard and a 5 year warranty - you’d have to ask yourself, why not?

For more information contact ITT Goulds Pumps, Axminster, Devon.

Tel: 01297 630473 Email: www.gouldspumps.com/Contact-Us Website: www.gouldspumps.com

HOW YOU CAN WIN & EARN WITH GRUNDFOS Grundfos Pumps are now offering you even more reasons to purchase their products with the launch of a new incentive scheme. The line-up for the Grundfos WIN & EARN scheme and their associated points value is: UPS2 15-50/60 300 points UPS2 25-80 & 32-80 300 points ALPHA2L 400 points Latest ALPHA2 600 points COMFORT (secondary circulator) 400 points The EARN element of the programme is aimed at UK pump installer company owners/managers. At registration, you are asked to enrol as an owner/ manager or an employee, you will then be able to start collecting points using the code from the pump packaging that is on relevant participating products.

Once you have reached a minimum of 1,000 points these can be translated into Amazon vouchers by visiting www.amazon.co.uk.

If you join the scheme as an employee, you can enter WIN & EARN sticker details and these will be credited to the owner/manager. Plus each code correctly logged will gain an entry into the monthly prize draws for the chance to WIN one of five iPad Air2 tablets.

So don’t wait any longer, download the Grundfos Installer Companion App or go to www.grundfos.co.uk/win to log your WIN & EARN points reward codes and start feeling rewarded today!

The path to a greener future...

Efficiency l Strength l Reliability Since January 2015, EU MEPS have stipulated that any new motors on the market ranging from 7.5 kW to 375 kW power output have to meet the IE3 efficiency standard or IE2 efficiency standard if used with an inverter drive.

WEG believe that all products should be energy efficient so we offer a complete range of W22 IE2, IE3 and IE4 low voltage motors. Our inverter drives will work with new and existing motors to help you reduce energy consumption. We have adopted the energy efficiency standard for our hazardous area motors although they do not yet fall within the scope of the regulations so our W22X motors are available to IE2, IE3 and IE4 efficiency rating.

To take your first steps on the path to a greener future visit www.weg.net LV

Watt Drive high performance gearboxes are built to withstand the toughest industrial applications meeting the demands for operation across different industries.

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

5

ALDER HEY HOSPITAL ENTERS A NEW ERA Caring for 270,000 young people and their families each year is a mammoth task that Alder Hey has been involved with since 1914.

In 2015 they have entered a new era with the opening of their much-heralded new £237m hospital.

This new hospital has been built within a park and the design, which has been partially inspired by the vision of many of the children that have been touched by Alder Hey. Environmental considerations were also important and Grundfos Pumps were delighted to play their part, not for the first time, as they have worked with Alder Hey for many years and this was one of the first sites to install energy efficient Grundfos MAGNA pumps in 2002.

By their very nature, hospitals are operationally complex sites this means selecting the correct pumps to support every aspect of their operation is vital. Grundfos assisted with the specification and supply of 70+ speed-controlled pumps and booster sets as well as pressurisation units and ancillary equipment. The system is supported by BACnet technology - an international data communication technology used in BMS worldwide.

During their 100-year history, Alder Hey have been at the forefront of medical excellence and pioneered many ground breaking medical 1sts that have put them at the forefront of medical innovation.

Dealing with unwell children and giving them the support that they need in the best environment possible is something that is at the heart of the new Alder Hey and Grundfos are proud that their pumps will be playing a supporting but crucial role.

For more information for Literature requests contact Grundfos Pumps Ltd, Leighton Buzzard, Bedfordshire.

Tel: Tel: 01525 850000 E-mail: grundfosuk@grundfos.com Web: www.grundfos.co.uk

NEW HMD KONTRO SEALLESS RANGE BROCHURE All Latest Products & Parameters Now Featured Sundyne HMD Kontro has announced a comprehensive update to their main product range brochure. This now includes all of their comprehensive range of sealless pumps including recent product introductions’ Many of the operating parameters for the existing pumps have also been updated. These details are now being integrated into their website and all other literature is being updated. In addition the recently introduced pumps are all featured including: • GSPV: Vertical • GSPX: Multi stage • GSPLF: Low flow • LMV 801S: Vertical low flow The opportunity has been taken to give the publication an updated cover design, in yellow, to differentiate with the previous version.

You can obtain an electronic copy of the brochure in the downloads section of their website. Please visit www.sundyne.com/hmdkontro.

Alternatively for a printed copy or further information, please do not hesitate to contact Vince Lee, on Tel: +44 1323 452141 Email to vince.lee@sundyne.com.

SPP PUMPS SECURES NEW FRAMEWORKS WITH UNITED UTILITIES SPP pumps, leading global manufacturer of centrifugal pumps and systems, has been awarded a multi-year, multi-product framework with United Utilities Water Limited (UU).

Won following a detailed tender process, the contract covers the design, manufacture, supply, installation & commissioning of Lower Life Cycle (LLC) Split Case Pumps, LLC vertical Turbine Pumps & SPP’s extensive end suction range. It follows on from a successful AMP5 framework for split case pumps.

Stuart Wallis, Sales Manager for SPP’s Water Division, comments: “To get this framework is a prestigious win for SPP… it will allow us to continue to strengthen our relationship with UU and its stakeholders, and build on the existing foundations laid with previous framework agreements.”

SPP products are of the highest specification, demanded now by one of the leading water companies in the world ensuring benefits such as high efficiency, durability, standardisation & delivering the best whole life cost solution for any application in which its products are used is fundamental to the way SPP does business.

Wallis continues: “We are committed to meeting the needs of our customers and partners where and when it really matters.

As well as top quality pumps and systems, we offer capital cost solutions that meet the financial requirements of each project for UU.” Matt Walker, Senior Category Buyer at United Utilities, said: “We’re pleased to continue our partnership with SPPPumps.

The team’s ability to quickly understand our requirements is what engages us to want to work with them - from proactive and early engagement, to technical support and product knowledge, we feel we can get true support fromSPP.”

For more information contact SPP Pumps, Reading, Berkshire.

Tel: 0118 932 3123, E-mail: enquiries@spppumps.com Web: www.spppumps.com

6

POLPHARMA DOUBLES PRODUCTIVITY WITH WATSON-MARLOW 620 PUMPS Polpharma, the largest manufacturer of pharmaceuticals in Poland has enhanced productivity at its manufacturing plant in Starogard Gdański thanks to peristaltic pump technology from Watson-Marlow Fluid Technology Group (WMFTG). Another 620 series process pump has recently been acquired to transfer liquids between tanks, following five years of success using an existing 600 series technology. The move has effectively doubled the productivity of the production line.

PROVEN PERFORMANCE “The decision to purchase another Watson-Marlow pump was dictated by a rational plan to increase the productivity of the plant,” explains Polpharma engineer, Damian Szymanowicz. “Put simply, we were so pleased with the performance of our existing 620U process pump that when we were looking to install another, there was no question of looking beyond another pump from WatsonMarlow.”

Watson-Marlow 620 series process pumps are ideal for working in sterile conditions.

The pumps have powerful brushless motors, while their pumphead configuration allows for gentle and virtually pulsation-free operation.

Furthermore, Watson-Marlow 620 pumps are extremely robust and offer a multitude of proven benefits for pharmaceutical and biotechnology plants the world over.

Polpharma’s use of the 620 series process pumps is coupled with Pumpsil platinum-cured silicone tubing – thus avoiding contamination between batches.

Engineered specifically for postirradiation dispensing stability and manufactured in ISO 14644-1 Class 7 cleanroom conditions under tight tolerances, Pumpsil is also post-cured for lowest extractables and features laser etched lot data.

“The pumps work seamlessly with the rest of the instrumentation located at the plant,” confirms Mr Szymanowicz.

For more information contact Watson-Marlow Fluid Technologies Group, Tel:: 01326 370370 E-mail: info@wmpg.co.uk Web: www.wmpg.co.uk

The HPK-L from KSB: Safe and Reliable KSB‘s latest generation of HPK-L hot water and heat transfer fluid pump is now available. The HPK-L pump can be operated at extremely high temperatures, without additional cooling devices and due to its robust and improved design offers excellent operating reliability.

• Wide range of variants: suitable for handling hot water, organic or synthetic heat transfer • • •

fluids.

Innovative technology: cutting-edge manufacturing methods and latest developments.

High efficiency: class leading performance due to hydraulic improvements.

Safe and reliable: HPK-L‘s design has been optiminally developed to cope with extreme thermal loads and chemicals.

Discover how the HPK-L can offer you excellent operating reliability: www.ksb.com/Industry • KSB Limited • 2 Cotton Way • Loughborough • Leicestershire • LE11 5TF • 01509 231872 • www.ksb.co.uk

Our technology. Your success.

Pumps • Valves • Service

7

PROCESS SYSTEM PROVIDES RAPID PRODUCTION OF CHICKEN VISCERA Optimising the use of food ingredients is now an essential part of the food manufacturing industry.

In the meat processing sector new and innovative processes are being employed to recover every edible part of a carcass for animal consumption.

Material previously disposed of as waste is now entering the food chain and it is sophisticated production processes and refined technologies that are making this possible.

The poultry processing industry provides a good example with the production of chicken viscera destined for use in animal food products.

Key to the process is the rapid turnaround from slaughter to chilled finished product, and under EU legislation this must be accomplished within 60 minutes.

One company that is making this a commercial reality is AxFlow, which has developed a specialised processing unit comprising an emulsifier, positive displacement (PD) pumps, centrifugal pumps heat exchangers, compressed air delivery system, holding tanks, valves and pipework.

The pumps used for the emulsifier discharge and feed processes are Waukesha Universal I Series.

This rotary piston pump employs an operating principle known as the external circumferential piston (ECP). In this design the arc-shaped rotary pistons, or rotor wings, travel in annular-shaped cylinders machined in the pump body. The resulting long sealing path reduces slippage and produces a smooth product flow without destructive pulses or pressure peaks, and without the need for valves or complex parts. Unlike progressing cavity and rotary lobe pumps, the Waukesha Universal pump is not adversely affected by varying or viscous products that may settle in the pump. Because the rotors produce a scooping action, they do not squeeze and compact the medium being pumped.

The Waukesha Universal 1 pump combines a very gentle, pulse-free pumping action with the high suction capacity necessary for allowing the thick mix to be drawn into the pump without any separation of the ingredients. The pump uses double ‘0’ ring self-lubricating sealing system for all applications, which allows high vacuum to be developed on the inlet side.

Manufactured from stainless steel and suitable for CIP cleaning, the pump’s close clearances allow the pumping of water against back pressures, whilst its simple design enables operators to completely strip it down for inspection in situ without the need to remove connecting pipework.

ABB PARTNER MKE DOUBLES FACTORY SIZE TO SERVE GROWING DRIVES’ BUSINESS ABB’s authorised value provider MKE Engineering Group has doubled the size of its factory devoted to variable-speed drives and automation solutions. This allows the company to offer more stock availability and expand its drives’ repair service.

The dedicated facility provides more space for stock holding, including ABB’s latest standard and industrial variable-speed drives.

The growing business has seen MKE’s drives systems department achieve a turnover of around £3 million a year, an increase from £750,000 of seven years ago. The increased space means MKE can hold stocks for next day delivery of all major ranges of ABB drives, with ratings up to 90 kW. “We have worked for water utilities and infrastructure companies such as Transport for London, “ says Bootes, “but can also meet the needs of a wide range of other customers.”

“This gives us information on some 3,000 ABB drives installed in customers’ plants, “ says Bootes. “It lets us see when a drive might need servicing. This means we can be proactive and approach the customer to advise of a servicing need. We are always aware of the status of the drives installed base.”

The new facility will also act as a repair centre for ABB drives up to 400 kW. “We want to expand what we do with ABB,” says Bootes, “and widening our drives’ repair services is a part of this plan.” MKE has access to the ABB installed base tool, an online database that stores information on thousands of ABB drives installed across the UK. Data includes drives’ configurations and components as well as information on customer, the drive’s application, commissioning and service reports and back-up of parameters.

For more information contact ABB Ltd, Warrington, Cheshire.

Tel: 01925 741111 E-mail: energy@gb.abb.com Web: www.abb.co.uk/energy

For further product details contact AxFlow Ltd, Ealing, London Tel: 01420 588194 Tel: 020 8579 2111 Email: info@axflow.co.uk Web: www.axflow.co.uk

9

VSD OR SOFT STARTER? CHOOSING THE RIGHT MOTOR CONTROL DEVICE TO DRIVE EFFICIENCY With environmental regulations becoming more stringent and energy bills remaining high, ensuring that motors run as efficiently and smoothly as possible has become a key concern for engineers and designers across different industrial sectors. Motor control devices such as soft starters and variable speed drives (VSD) can both offer an answer to such challenges. In this article Fábio Gonçalez, European Automation Manager at WEG, discusses how, depending on the application, soft starters and VSDs can help cut energy consumption and reduce associated costs by effectively controlling the electricity flow.

Electric motors are the largest individual source of energy use, accounting for about 45% of the world’s total electricity consumption and 70% of the industrial energy demand1. With these figures in mind, new environmental regulations have been adopted internationally. For example, in the EU, the 2005/32/EC Ecodesign Directive now stipulates that motors with a rated output of 7,5-375 kW shall not be less efficient than IE3 standards or IE2 if equipped with a VSD. To save energy and comply with current regulations, ensuring that motors – and the pumps that are driven by them – are durable and reliable is as vital as improving their energy efficiency. VSDs and ‘reduced voltage soft starters can both be used to protect expensive equipment and extend the life of the motor and coupling devices. However, choosing between a VSD and soft starter will depend on a number of factors including the type of application, mechanical system requirements and costs - both for initial installation and over the lifecycle of the system.

SOFT STARTERS

When accelerating an AC motor to full speed using a full voltage connection, a large inrush current may be required. As the torque of the AC motors is generally uncontrolled, the result could be shocking, potentially damaging the motor and its connected equipment.

By using semiconductor devices to temporarily reduce the motor terminal voltage, reduced voltage soft starters limit the initial inrush of current and reduce the mechanical shock associated with motor startup. By gradually increasing the motor terminal voltage, a soft starter produces a more regulated motor acceleration up to full speed and is also capable of providing a gradual ramp to stop, where sudden stopping may create problems in the connected equipment.

This helps protect the motor and connected equipment from damage.

Such features make soft starters ideal for applications where speed ramping and torque control are required when starting or stopping and where high inrush currents associated with starting a large motor need to be limited to avoid supply network issues or penalty charges. Soft starters are also a great fit for applications - including conveyors, belt-driven systems, gears and couplings - where gradually controlled starting is needed to avoid torque spikes and tension in the mechanical system associated with normal equipment startup.

They are also ideal for avoiding pressure surges or ‘hammering’ in piping systems when fluid changes speed too rapidly.

One of the key benefits of choosing a soft starter over a VSD is its cost. Soft starters are often the more economical choice for applications that only require speed and torque control during motor startup. Additionally, they are often preferable in applications where space is a concern, as they are typically smaller than comparable VSDs.

VSDs

A VSD - sometimes referred to as inverter - is a motor control device that protects and controls the speed of an AC induction motor. It converts constant frequency and voltage input power to adjustable frequency and voltage source to control the speed of the motor. As such, it operates during the start and stop cycle, as well as throughout the run cycle and can be used wherever complete speed control is required and, more

10

importantly, when saving energy is the ultimate goal.

Centrifugal equipment such as fans, pumps and compressors follow a general set of speed affinity laws, which define pressure change in relation to speed or flow and power change in relation to flow. Based on such laws, flow changes linearly with speed while pressure is proportional to the square of speed or flow while the power required is proportional to the cube of the speed or flow. In other words, if the motor speed drops, the power drops by the cube.

Traditionally, mechanical valves are used to control the flow while the electric motors always operate in nominal speed, meaning that a significant amount of electrical power inevitably goes to waste.

By reducing peak energy demand and power when not required, VSDs help motors singificantly increase energy efficiency, contributing to energy savings of between typically 40% and 60%. With fully adjustable speed and an ability to provide smooth motion, they are suitable for applications such as elevators and escalators in addition to driving equipment such as pumps, conveyors and fans. VSDs also play a key role in maintaining the speed of manufacturing and industrial equipment such as mixers, grinders and crushers.

Another key advantage of using VSDs is that they come with a variety of features and options to ensure ease of use and versatility to suit a wide range of applications. Some of the latest VSDs available on the market are equipped with self-diagnostics and communication devices, advanced overload protection, PLC-like functionality and software programming, digital inputs/outputs (DI/ DO), analog inputs/outputs (AI/AO) and relay outputs.

SELECTING THE CORRECT MOTOR CONTROL EQUIPMENT

While soft starters and VSDs can both play a key role in protecting the motor and connected equipment, ultimately making the right choice often depends on the user’s specific needs.

Soft starters are generally smaller and less expensive than VSDs, especially when it comes to large horsepower applications. They can also offer a more cost effective solution whenever constant acceleration and torque control is not necessary, in applications that only require current control during startup.

In contrast, a VSD can be more expensive initially but it can contribute to dramatic energy savings in the long term. In doing so, it can help users across different industries comply with current environmental regulations while providing operating cost savings over the life of the equipment for a significantly lower total cost of ownership (TCO).

Speed control is another important advantage of choosing a VSD, because it ensures consistent acceleration time throughout the entire operating range of the motor, not just during startup.

Finally, VSDs can also provide more flexible functionality than soft starters, including digital diagnostic information.

1. IEA, Energy-efficiency policy opportunities for electric motor-driven systems, 2011, http://www.iea. org/publications/ freepublications/ publication/ee_for_ electricsystems.pdf

THE EXTENDED RANGE OF MAGNETA ERP COMPLIANT CIRCULATORS FROM

SMEDEGAARD MAGNETA

ErP compliant circulators represent the latest innovation in pumping technology from Smedegaard.

Chris Barrett Managing Director of Smedegaard Pumps Limited says ‘When it comes to maintenance and refurbishment a major problem can be encountered when the pump purchased is substantially larger in physical size when compared to unit in situ. No such problem exists for the installing engineers who choose Magneta. Not only is Magneta extremely compact when compared to competitor models, it is also designed with superior advanced technology in a user friendly package benefiting the installer and consumer. The simplicity for the customer is further enhanced as all models are supplied as standard with full BMS capability and can be programmed by the use of ones finger.’

MAGNETA ADDITIONAL BENEFITS: ENERGY EFFICIENT

• Future-proofed optimised efficiencies, exceeding future energy efficiency regulations.

• Magneta models are single phase IP44 Advanced Technology – Simple to use with no gimmicks • Commissioning is straightforward with the press & turn dial.

• Integrated display and symbols indicating the operating mode.

• Dual pump operation with auto changeover (integrated interface).

• Integrated protective and manual functions.

COST-EFFICIENT

• High-efficiency technology combined with speed control • Advanced Eco Mode offer maximum savings.

• Fully integrated communication interfaces that save on both investment and commissioning costs.

VERSATILE

• Magneta covers a broad application range spanning from heating to cooling with fluid temperatures from -10°C to +110°C. • Comprehensive product range with standard pipe connections.

KSB GROUP INAUGURATED NEW FOUNDRY IN GROVETOWN (USA) The pump and valve manufacturer is investing about 75 million US dollars in its US site in Grovetown, of which 40 million US dollars are going to the new foundry.

Investments in the KSB subsidiary GIW Industries are to prime the site to meet the mining industry’s rising global demand for white cast iron pumps.

Opened in April, the new facility has been fully operational since this summer and extends to about 4650 square metres.

It houses new heat treatment and melting furnaces, sand silos and six cranes. The production building of 22 metres ceiling height is particularly suitable to make components for the large slurry pumps manufactured at the site. The new foundry’s capacity exceeds 9000 tons of castings per year, with some of them weighing up to 20 tons.

At the Grovetown and Thomson sites, GIW Industries manufactures mostly heavy-duty pumps and associated equipment for the mining industry. The centrifugal pumps are built to transport a mix of rocks and water and are used in various settings, ranging from mineral processing to waste water treatment.

For more information contact KSB Group, Germany.

Tel.: +49 6233 86 - 3702 E-Mail: christoph.pauly@ksb. com Web: www.ksb.com

INTERESTED IN BECOMING A BPMA MEMBER ?

Please contact Brian Huxley on 0121 601 6350 or e-mail: b.huxley@bpma.org. uk 12

FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves FLOTRONIC PUMPS’ NEW ‘E’ SERIES’ ACHIEVES THE EHEDG SEAL OF APPROVAL Flotronic Pumps Limited, the UK-based specialist manufacturer of air-operated double diaphragm pumps, having already secured 3-A Sanitary Standards, Inc (3-A SSI) approval for their ‘H’ series pump, have now achieved the European Hygienic Engineering & Design Group (EHEDG) accreditation for their new ‘E’ Series pump.

Flotronic’s ‘E’ Series pump has been specifically designed for the Food and Beverage industry and other processes where product contamination must be avoided. The pump’s features include Flotronic’s established and unique ‘ONE-NUT’ pump design which allows swift diaphragm access without disconnecting process pipework. The internal surfaces of the ‘E’ Series pump can be effectively ‘cleaned in place’ or, alternatively, easy dismantling can be carried out for cleaning and inspection. Cleaning is aided by the provision of polished wetted surfaces to 0.8μm Ra maximum and an electro-polished overall finish. Cleanability is also assisted by the incorporation of a support stand whereby the pump can be inverted for full draining.

“The ‘E’ series pump passed EHEDG’s tests with flying colours,” says Flotronic’s Chief Engineer, Peter Wheal, “confirming that the pump meets EHEDG standards for sanitary product transfer. Other features, including a diaphragm rupture detection system with instant pump shut-down alarm facility and BS, DIN and ISO hygienic connection options, all help to keep product contamination free and to ensure that hygienic standards are not compromised.”

“A unique feature of the Flotronic ‘E’ Series pump is that the diaphragms are reinforced as standard,” Peter continues. “The reinforcing plates add support to the diaphragms and ensure that the pumps can withstand CIP pressures in the suction line of up to 5 Bar with no diaphragm damage. Other suction pressure challenges resulting from SIP systems, bulk tanks with head pressure of more than 0.5 Bar, re-circulation and thermal expansion can all be met by the ‘E’ Series.”

Flotronic designed the ‘E’ Series for markets at home and abroad where independent hygiene accreditation is growing in importance. “While EHEDG accreditation is not necessarily a statutory requirement, our customers are increasingly seeking conformance with the high standards required,” says Flotronic’s Managing Director, Jane Waite. “Being authorised to display the EHEDG logo confirms the new ‘E’ series pump’s credibility and gives our customers peace of mind.”

For more information contact Flotronic Pumps Tel: +44 (0) 1444 881871.

E-mail: sales@flotronicpumps.co.uk / Web: www.flotronicpumps.co.uk

ATEX APPROVED, MANUAL CONTROL DOSING PUMPS Wanner International has introduced a range of Hydra-Cell, ATEX approved Dosing Performance Pumps with precise mechanical variator control, all mounted on a substantial stainless steel base plate.

These seal-less pumps are designed for use in ATEX classified environments, coupled to compatible, explosion proof motors, completely removing the need for complex and costly external VFD ATEX control.

Because Hydra-Cell pumps are true positive displacement pumps, flow rate is directly proportionate to input shaft speed and virtually independent of system discharge pressures. Very precise and repeatable, infinite adjustment of shaft speed is achieved from almost zero rpm, through a simple manual adjust hand wheel on the variator.

Flow rate is adjustable in operation and at rest and exhibits linear setting characteristics. Once set, the wheel can be locked to prevent the flow being changed, either by accident or deliberately.

Meeting or exceeding API 675 performance requirements in terms of repeatability, linearity and steady state accuracy, HydraCell Dosing Performance pumps are the low maintenance, highly efficient, low lifecycle cost option.

For more information contact Wanner International, Fleet, Hampshire Tel +44 (0)1252 816847 Email: NHerrington@wannerint.com Web: www.hydra-cell.eu

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PROCESS INDUSTRY INFORMER October - November 2015

FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves INNOVATIVE GRACO ELECTRIC PUMP PROVIDES RISK-FREE OPERATION Graco’s Husky™ 1050e electric double diaphragm pump offers dry running and stalling, as well as significant energy and cost savings over equivalent electric pumps and conventional air-operated diaphragm pumps.

Pump failures are a frustrating waste of time, energy and money. So it comes as no surprise to find that Graco, a world leader in fluid handling systems and components, has devoted considerable resources to attempt to eliminate them. In addition, Graco constantly seeks to improve the energy efficiency of pumps and create a quieter working environment for operators and nearby employees.

Does this seem like an impossible combination? Not with Graco’s new Husky™ 1050e electric double diaphragm pump, which has been designed to meet such a mix of demanding requirements.

“The Graco Husky 1050e is the only electric diaphragm pump on the market that will stall under pressure, to prevent pump failures from clogged lines or closed valves,” says Walter Leeten, Product Marketing Specialist Process at Graco. “Its energy efficient electric drive reduces energy consumption by up to five times compared to traditional air operated diaphragm pumps. In addition, the 1050e can be set to reduce pulsations, so you no longer need a pulsation dampener – which contributes to its low noise levels.”

The thinking behind developing an electric double diaphragm pump certainly makes sense. It will immediately remove the significant costs of purchasing, running and maintaining an air compressor. And of course you might need to run a pump in locations where no air is available – or will take a lot of time and logistics to get an air supply up and running. In these situations an electric pump is an excellent alternative.

HOW IT WORKS The Husky 1050e is an electric operated 1” double diaphragm pump (EODD). It works like a conventional air-operated double diaphragm pump (AODD).

However, don’t view the 1050e merely as an AODD connected to the nearest electricity supply instead of an air compressor. There’s some innovative standout technology inside.

The 1050e consists of the same fluid parts as a conventional AODD. Where it differs is that it uses an air pressurized center.

“Compare it to a bicycle wheel,” explains Leeten. “You need to load the pump with air to start it working, but after that you don’t need a constant supply of air to keep it running. In fact you only need 0.6 liters of air a day!”

When the pressure pushing on the outside of the diaphragm (fluid pressure) is equal to or greater than the center section (air) pressure, the pump will stall, removing the risk of pressure being built up. This avoids damaging the pump or the production line.

If then the air pressure in the center section increases so that it is greater than the fluid pressure, or the fluid pressure decreases so that it is less than the air pressure, the pump will start pumping again. The motor will keep running all the time.

INTERESTING ADVANTAGES OVER AODDS One of the key advantages of the Husky 1050e is that it stalls under pressure.

Historically, pneumatic diaphragm pumps stall under pressure, which makes them unique. Electric motors typically do not stall under pressure, but the 1050e does; the only electric diaphragm pump to do so. Stalling under pressure avoids the risk of damaging the pump or pipeline when it’s blocked or a valve is closed. It also negates the necessity for installing an extra pressure sensor.

The 1050e also comes into its own in applications that require low pulsation and a smooth flow. The patented air charged drive allows for the elimination or reduction of pulsation without expensive pulsation dampeners or surge tanks.

It also gives a good level of control – especially important for metering and batching. And there is no risk of contamination of products due to the absence of hydraulic backing.

Its seal-less diaphragm pump design eliminates leaking rotational seals and failures due to run-dry pump conditions. Other advantages include the lack of exhaust air, the ability to handle abrasives, and its quietness, making it ideal

PROCESS INDUSTRY INFORMER October - November 2015

for applications in close proximity to people.

SIGNIFICANT COST SAVINGS Now let’s look at the bottom line: operating costs. It’s interesting to compare the 1050e EODD 1” with a conventional 1” AODD; both operating for 24 hours at a flow rate of 95 liters per minute and a fluid pressure of 3.5 bar.

The required air for the 1050e 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 1050e of 460 EUR, compared to 2300 EUR for the conventional 1050 AODD: a 5x cost saving!

SUITABLE FOR A WIDE RANGE OF APPLICATIONS

“We see the 1050e as highly suitable for the waste water treatment industry – for applications such as the pumping of sludge and slurry – where it can replace large peristaltic pumps,” says Leeten. “In applications where saving energy is the key driving force, the 1050e is an interesting replacement for AODD pumps running in continuous duty applications. Moreover, the 1050e can handle particles up to 3.2 mm.”

If lack of air is your specific challenge, then the 1050e, with its small air requirement, is the ideal solution. For example, you may have no additional compressor capacity, or an installation where air is simply not available.

You may have a temporary lack of air due to compressor maintenance or shutdown. Or you may simply want to save the cost of a large compressor. In all these situations, the 1050e is perfect.

Another area of use is where more control is required from process pumps.

You can get more control through replacing your existing electrically driven pumps with the 1050e, and at the same time you will get improved metering accuracy.

FLEXIBLE AND EFFICIENT The 1050e is available in brushless DC, AC and AC ATEX options. The brushless 2HP DC motor, for example, offers increased control, maintenance and alarm notification, batch operation, and meets API 675 and ANSI 7.17.5. The electric 2HP AC motor offers increased efficiency, ATEX options, and runs on 110V, 220V or 480V. 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.

A final point to remember is that this highly energy efficient electric pump runs up to five times more efficiently than other air operated diaphragm pumps.

THE 1050E IN THE FIELD The 1050e was tested in a water treatment facility where it was used to pump lime slurry. In this application, one 1050e replaced two size 4 eccentric pumps. It racked up more than 24 million pumping cycles at a fluid flow rate of 68 liters per minute and a fluid pressure of 2.8 bar. With the previous eccentric pumps, hoses were having to be replaced every two to six weeks. In eight months of operation, there was no need to replace a single diaphragm of the Husky 1050e.

All in all, the Graco Husky 1050e electric double diaphragm pump looks set to have a major and long-lasting impact in industry.

For more information contact Graco BVBA, Maasmechelen, Belgium.

Tel: +32 8977 700 E-mail: miranda.houbrechts@graco.com Web: www.graco.com

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FEATURE

MANUFACTURERS SHOULD EMBRACE THE VIRTUAL WORLD Steve Leech, Business Manager - Process Control Systems, Siemens UK & Ireland, believes manufacturers should be assessing the proven advantages of virtual commissioning to develop and engineer automation technology solutions to drive productivity, cost and profitability benefits.

R

ecent headlines have seen the taxing issue of national productivity hit the front pages. The Government plans, in the words of George Osborne, to ‘crack the UK’s productivity puzzle’ as the key to future prosperity, and as a reaction to the recent challenging economic environment.

While an improving fiscal outlook and higher levels of employment are welcome steps in the right direction, nonetheless figures show that UK plc productivity has languished since the dark days of the financial crisis at the end of the last decade. The newly published Productivity Plan demonstrates a desire to focus on business investment, skills, infrastructure and innovation to drive general productivity improvements and fuel growth.

But there are already reasons for optimism when it comes to productivity progress.

Thanks in part to strategic investments made in technology, workers in the UK’s automotive, aerospace and rail manufacturing sectors now produce 50 per cent more than they did in 2009. One of the primary reasons for such progress in these industries has been the increased investment seen in the adoption of automation technology. If the process sector is to match the automotive and aerospace examples with regards to up scaling productivity levels, then the use of agile, flexible and proven automation technology solutions such as virtual commissioning and simulation tools to aid engineering projects, automation system design and, even, new plant delivery, holds the key.

Automation technology is well placed to positively impact the increasing pressures manufacturers face around meeting ever tighter project schedules and satisfying productivity and profitability objectives.

The requirement for ever shorter commissioning and start-up timescales for new production lines, plant migrations or new plant facilities, is a reality for many. This is where the added value advantages of virtual commissioning through a simulation framework can offer tangible and proven time, resource and cost benefits.

Virtual commissioning enables real-time simulation of extensive engineering projects to design, engineer and test automation projects without the risks of working within a ‘live’ environment. Consequently, automation system design testing and the delivery of higher quality code can, for example, shorten overall commissioning times, reduce project risk, eliminate human error, support operator training goals and, ultimately, allow automation projects to move from a test to live environment seamlessly and speedily.

IN ACTION Subsea 7, one of the world’s leading global contractors in seabed-to-surface engineering, construction and services to the offshore industry, recognises the value of the simulated approach in aiding efficiency; achieving faster commissioning and delivering higher engineering quality, as well as lowering its cost base and reducing project risk. The company adopted the simulated approach on the development of an automation control system for a complex winch project destined for a vessel based in Australia. With a short timescale for the winch’s control system delivery, and the clear geographical challenges of the project, the Subsea 7 team embarked on a simulated engineering approach made possible by Siemens’ SIMIT Simulation Framework. Ian Wilson from Subsea 7 says: “The ability to build and use the control system at our Aberdeen HQ meant we could proceed with the simulation project to

36

test the control system without delay.”

The impact of SIMIT on the project was profound and after just two weeks of testing within a virtual environment, the Subsea team was able to identify and resolve nearly 250 software bugs which drastically shortened the commissioning timescales typically seen in similar projects.

Ian Wilson is clear about the advantages a simulated approach can deliver. “Being able to replicate the control system in our own offices brought real benefit. We could identify and rectify issues quickly, and we estimate it has brought a 90 per cent overall reduction in the on-board commissioning timescale. This enhanced our operational efficiencies, saved costs and built up our in-house knowledge.”

THE COMPETITIVE ADVANTAGES OF A VIRTUAL COMMISSIONING APPROACH CAN BE SUMMARISED IN FOUR KEY AREAS: Faster commissioning – with engineering capable of being tested at an earlier stage, nearly all design and functional errors (as seen in the Subsea 7 example above) can be detected prior to on-site commissioning. This drastically reduces timescales by up to 50 per cent, and allows an earlier start-up than previously envisaged.

Higher engineering quality – it is also possible to extend the usual scope of testing and simulation can be performed in parallel to engineering tasks leading to higher engineering quality outcomes. The virtual approach can be a highly efficient support for the definition and clarification of specifications with operators and partners and avoids the need for costly re-engineering tasks.

Lower costs – users benefitting from a marked reduction in re-engineering incidents and commissioning will realise a significant impact on cost. Simultaneous and modular testing lead to a ‘right first time’ engineering outcome, positively impacting the project’s bottom line.

Reduced risks – virtual commissioning using non-intrusive tools such as SIMIT enables testing without the involvement of machines, equipment or personnel, thereby eliminating the inherent risks associated with on-site commissioning. Any possible malfunctions do not lead to severe consequences, and companies can avoid expensive damage to assets or injuries to individuals.

A by-product of the simulated approach is that all operator training can be carried out away from the live operating environment and essential operator training guides can be developed to aid future needs. As manufacturers seek out competitive advantage, operational efficiencies, improved levels of productivity and increased profits, the removal of project risk, shortened commissioning timescales and getting to market quicker are increasingly seen as key objectives for businesses. Adopting virtual commissioning through simulation framework tools such as SIMIT can aid the attainment of these important objectives.

With a flexible and scalable simulation framework, manufacturers have access to the easiest, quickest and most risk adverse method to automation technology project completion, whether it’s a control system, a reconfigured production line or, even, a brand new manufacturing plant.

In the battle to solve the UK’s productivity puzzle, manufacturers’ adoption of a virtual commissioning philosophy is set to play an increasingly pivotal role in delivering tangible results and overcoming the manufacturing challenges of our times.

PROCESS INDUSTRY INFORMER October - November 2015

FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves ROBUST, CLOSE-COUPLED THERMOPLASTIC PUMPS Where chemical handling or any similar fluid handling applications involve aggressive or corrosive fluids, thermoplastic pumps, as opposed to metallic options, are the ideal choice.

A good example of this is the range of ARBO thermoplastic mechanically sealed centrifugal pumps made from either polypropylene, polyethylene, PVDF and PTFE available in the UK from MICHAEL SMITH ENGINEERS. ARBO pumps are machined from solid block and a manufacturing process that involves no injection moulding or welding which eliminates the potential for stress-cracking and so ensures robust, reliable, corrosion resistant pumping. They are available in three configurations including the SealPro closed-coupled design which handles flows up to 50 m3/hr, heads to 45 metres and maximum suction pressures up to 1.5 Bar with standard seal.

They are ideal for safe and efficient transfer and circulation duty of corrosives, including liquids containing solids and also viscous liquids up to 200 cP. The pumps incorporate a single internally flushed rotating seal made from PTFE-graphite or Silicon Carbide which is mounted on the impeller so there are no wetted metallic seal components. Also, as none of the seal components touch either the sleeved pump shaft or the pump housing, this means the only wearing parts are the seal faces. An innovative internal circulation system ensures that the seal rings are always within the liquid zone and continuously flushed with the medium being pumped. This provides sufficient cooling and cleaning of the liquid surface at all times and optimises pumping efficiency.

Typical applications for ARBO thermoplastic mechanically sealed centrifugal pumps include pumping acids in anodising plants, circulating aggressive chemicals in pickling lines, tanker unloading of ferric salts in the water industry, pumping chemicals and untreated effluent in electronics manufacturing Other situations where these pumps will be appreciated include; circulating demineralised water in food industry applications, handling coolant circulation in power plants, sea water circulation in aquaria and any application where metallic pumps will either suffer from corrosion or can cause contamination.

For further information contact Michael Smith Engineers Ltd, Tel: FREEPHONE: 0800 316 7891 Email: Info@michael-smith-engineers.co.uk Web: www.michael-smith-engineers.co.uk

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FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves PUMP SYSTEM IS PERFECT FOR PASTES & HIGH VISCOSITY PRODUCTS Transferring high viscosity creams, pastes and gels which do not flow readily, such as peanut butter, shaving cream, petroleum jelly, yeast extracts and mascara, present unique challenges across many process applications in the food, cosmetic and pharmaceutical industries. In many cases operators revert to manual handling solutions due to the limitations of some pumping systems and this can result not only in wastage issues but also those of a health and safety nature.

An effective and practical solution is available from liquids handling specialists PUMP ENGINEERING who offer a CSF piston pump mounted in the centre of a follower plate which fits into a drum and seals against the inside of the drum. Two pneumatic cylinders force the plate onto the top of the product and as the pump empties the drum, the plate is drawn downwards keeping the inlet of the pump full of the product. A rubber seal on the follower plate effectively wipes the side of the drum as it travels downwards, sealing it and ensuring that very little product is wasted.

The pumps are available as quick-strip versions for easy cleaning without the need for tools. For lower viscosity liquids, a long version of the pump is available for emptying tanks, drums and IBC’s which features a special bagin-drum inlet which prevents the plastic drum lining used in some industries being drawn into the pump.

CSF piston pumps are air operated and depending on the model, will deliver flowrates up to 100 litres / minute with pressure ratios up to 20 to 1. Materials of construction are AISI 304 or 316stainless steel with Viton, nitrile or PTFE seals.

For more information contact: Pump Engineering Ltd, Tel: 01903 730900 Email: sales@pumpeng.co.uk Web: www.pumpeng.co.uk

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GRIP COUPLINGTM FOR ALL METAL PIPES MV Fluids Handling’s Straub Grip Coupling simplifies pipe- work, design and installation over traditional pipe-joining techniques. Metal pipe from 3/4in to 24in can be joined in minutes.

The Straub Coupling joins plain-end metal (black, cunifer, galv., or stainless) pipe with axial restraint and without the associated risks of ‘hot-work’, welding, or burden of expensive grooving/threading machines.

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

PROCESS INDUSTRY INFORMER October - November 2015

FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves AXFLOW DEVELOPS FEED SYSTEM FOR FOOD PROCESSING PRODUCTION LINES AxFlow has developed a bespoke feed and pump system for food processing applications. The system comprises an auger into which ingredients are fed and then forces them into the pump via a screw feed.

This provides the pump with a constant flow at a pressure no greater than 4 bar to maintain the integrity of the product.

The Waukesha pump performs exceptionally well handling delicate media, particularly where it can become viscous. However, in some applications where the nature of the media prevents a steady flow from a gravity feed system, the pump can be starved resulting in erratic flows on to the next stage of the production cycle, such as a homogeniser. The screw feed auger, which meets all hygienic requirements, removes this problem, ensuring a smooth and continuous flow According to AxFlow, its auger feed and Waukesha pump system maintains product quality and enables producers to meet production processing targets.

For more information contact Axflow Ltd, Ealing, London.

Tel: 0208 579 2111 Email: info@axflow.co.uk Web: www.axflow.co.uk

HIGHER EFFICIENCY WITH ALFA LAVAL –SAVING ENERGY & MONEY IN YOUR PROCESS Every process differs in their requirements for product handling, so selecting the right pump for your application is key to saving energy and cost. In fact, pumps account for nearly 10% of global energy consumption with the individual energy consumption of a pump varying enormously between.

SAVE UP TO 50% ENERGY Increasing pump efficiency presents huge potential for Alfa Laval SolidC, GM/GM-A, LKH-SP, LKHPF energy and cost savings. centrifugal pumps pictured top left to The optimized design of the bottom right Alfa Laval centrifugal pump range delivers greater energy efficiency than similar ranged premium pumps- offering up to 50% less energy consumption compared to competitors. 50% less energy means 50% less costs!

ACHIEVING HIGHER EFFICIENCY Alfa Laval’s range of premium centrifugal pumps are designed to operate as close to their Best Efficiency Point (BEP) as possible. The Best Efficiency point (BEP) is the point at which the pump operates at the optimum head and flow rates for a particular set of duties. The closer the duties are to the BEP the higher the efficiency of that pump.

Combined with the BEP design Alfa Laval have also readjusted their centrifugal pump impellers so that they are now designed to minimize internal recirculation ensuring a much more efficient transfer of energy whilst also reducing heating and rough handling of the product. This makes Alfa Laval the perfect choice for your pumping needs.

As Alfa Laval’s master distributer, Industrial trading solutions are able to offer competitive prices, with extended offers for larger projects and technical support for any questions you may have about the Alfa Laval pump range.

For a quotation or for further information please visit our website: www.industrialtradingsolutions.com or contact us on Tel.: 01675 465 191 or Email: sales@industrialtradingsolutions.com

XYLEM UPDATE ONLINE SELECTION TOOL Xylem has launched an enhanced version of its popular product selection tool to offer users a more intuitive and user-friendly experience, making selection of Xylem products significantly easier.

The new version of Xylect boasts a faster, more intuitive navigation function and streamlined workflow, making product selection easier than ever before.

Xylect is a comprehensive product database with advanced search functions which can help customers find and select the right product for their application.

The software brings together existing products from a host of Xylem brands, including; Flygt, Lowara, Godwin, and Goulds Water Technology, representing selection possibilities from the entire Xylem range.With the Xylect website and support for iOS and Android devices, users can search by product type, application or by specifying the required flow and head. Xylect also offers an enhanced ‘Projects’ section that allows engineers to review previous engineering projects for reference. The new Xylect is available for free at www.xylem.com, the Apple App Store and Google Play.

For more information about their products & services please visit us at www.xylem.com

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FEATURE

ENERGY EFFICIENCY –

IT’S A JOURNEY, NOT A DESTINATION

The UK Government has for many years used a carrot and stick approach to promote energy efficiency in companies and other organisations by introducing legislation and offering tax breaks or other incentives.

Here Jeremy Shinton, Product Manager – Business Solutions at Mitsubishi Electric, looks at some of the current initiatives.

B

efore the end of this year all “large enterprises” will need to be in compliance is about four times higher than necessary! with the Energy Saving Opportunities Scheme (ESOS). A business qualifies • This type of energy wastage can be addressed by reminding people to switch as a “large enterprise” essentially if it employs more than 250 people or has things off - by changing the culture within an organisation so that people become a turnover of more than 50 million euros. Further, smaller organisations are also energy conscious - and by automation. encouraged to follow the ESOS programme on a voluntary basis.

• Simple technologies like timers and presence detectors can be very effective.

Put simply, ESOS requires that you undertake an energy usage audit to account for Further, they can be integrated into building management and process control 90% of the total energy use or spend. There are large fines for non-compliance so systems that use computers and logic controllers to make relatively sophisticated it is essential that qualifying companies act quickly before the 5th December 2015 decisions about operating equipment and machinery. audit deadline. Officially it is not mandatory to follow up and implement energy • In an industrial environment, it is fairly common to see plant and machinery saving measures; the assumption is that the audit will highlight energy wastage and running yet not producing anything. However, idling machines consume energy this will encourage managers to act of their own accord to address the issues. (possibly a very considerable amount) so if they can be switched off –partially or The theory is that by keeping obligations to a minimum, organisations will be free altogether – energy can be saved. This is particularly true with pumps and fans. to develop an energy saving plan that best suits them. Reducing energy bills means 2.Electric motors businesses become more profitable and competitive; the ESOS assessment is one Something like 70 per cent of all the electricity generated in the world is used to step in the process. power electric motors, so the potential for motor related savings is enormous. There Responsibility for the ESOS programmes lies with the Environment Agency, which are several opportunities to look at: will work with other relevant government agencies and departments as necessary. • The electric motor was developed well over 100 years ago, so has had plenty Larger organisations may execute their audit using internal resources and personnel; of time to go through many refinements and become a mature technology. Initially however others may prefer to bring in outside experts to help. they were not at all energy efficient but started to become The ESOS audit must be overseen by an approved Lead so probably 50 years ago. By around 1980, they were Assessor and calculate the total energy consumption, use “Energy efficiency is now a prime very efficient and since then the increasing awareness of per production process (industrial, commercial, etc), use per consideration for machinery environmental issues has lead to regular further improvements employee, the use in each separate building and the energy designers, plant engineers and in their efficiency. We can now say that a motor more than cost of transport. Energy data collected under other schemes, 10 years old may be of suspect efficiency and should be finance directors. Fortunately there considered for swapping out. such as the Green Deal Assessments, that is less than four are many technologies that will help • Motors need to be installed and maintained properly for years old can be used as part of the ESOS audit. Further, organisations reduce their carbon maximum efficiency. They also need to be size-matched to organisations that are fully covered by ISO 50001 (Energy management systems – Requirements with guidance for use, footprint; the apparently-constant the load they are driving.

2011) are exempt from the assessment but do need to notify stream of new legislation is designed • Motors tend to have long working lives, meaning that the the Environment Agency that they are compliant with ESOS. cumulative energy cost of operation may easily exceed the to encourage their take up.”

However, after 2015 a new audit will have to be completed initial purchase cost by a factor of 100 or more. Monitoring at least every four years. It is estimated that the scheme will their efficiency will help mitigate this ongoing cost. reduce the overall national energy bill by £1.5 billion to £2 • In the past it was considered best practice to fit oversized billion pounds per year. This will make a significant contribution to the reduction motors, so that they had a bit of extra power in hand for overcoming friction, of greenhouse gases such as carbon dioxide and also improve the country’s ‘sticktion’, and blockages. However, it is now recognised that an oversized motor is constantly drawing more power than is necessary and that there are more energy competitiveness in international markets. efficient solutions for providing that bit of extra ‘umph’ when required.

• Large motors are often rewound rather than replaced. Unfortunately a rewound ECODESIGN EQUIPMENT Since 2009, some products and equipment that consume energy have had to motor may not be as energy efficient as possible, so they should be checked and meet the requirements of the Ecodesign of Energy Related Products Directive. This considered for replacement if necessary. is a framework which primarily sets minimum requirements for certain products, 3.Variable speed drives Variable speed drives, or inverters, are something including those that have a market demand of more than 200,000 units per year of a wonder product. They are used to control the across Europe. The objective of the Directive is to reduce greenhouse gas emissions speed of a motor and thus save energy. In fact, they and other adverse environmental impacts across the life-cycle of a product. This save so much energy that their purchase cost is places the emphasis on the design and development stages of a product so that usually recouped within 6-18 months, after which it is energy efficient. However, it is notable that there may also be energy costs they are saving money and saving the environment. associated with transportation, installation and maintenance.

Importantly, a VSD allows you to fit motors sized to their typical duty and can be set so that they provide OPPORTUNITIES Naturally every energy audit will be unique but there are several common themes the ‘umph’ referred that will arise in many of them. So let us look at these and draw some general to above when required. guidance principles: 1. Switch off something.

During the 1973 energy crisis, Edward Heath’s government came up with the slogan ‘Switch off something’ and that instruction is as valid today as it was 40-plus years ago. Anything that is ‘on’ is consuming energy; anything that is ‘off’ is not!

• It is often the case that things that are not switched off remain on for long periods.

For instance it is not unusual for lighting, heating, air conditioning, extract fans, etc to be left on almost permanently in commercial, industrial and business premises. Often the rooms are in use for less than eight hours a day and are not used at all during weekends and bank holidays.

So, as a first estimate, it would appear that their energy consumption

ENERGY SAVING

HEALTH & SAFETY

REDBULL MAKES SURE ALL ITS ENERGY GOES INTO THE CANS!

NEW FERRULE OPTI-GARD™ SOLO RUPTURE DISC FROM ELFAB PROVIDES HIGH PERFORMANCE PRESSURE RELIEF FOR ULTRA-LOW PRESSURE HYGIENIC APPLICATIONS

Global drinks giant RedBull has appointed ESOS (Energy Savings Opportunity Scheme) and sustainability experts Carbon Architecture to assess their UK operation and make sure they achieve energy management compliance.

“RedBull’s fellow British Soft Drink Association (BSDA) members PepsiCo, Lucozade and Ribena were already using our InMetriks.com industry benchmarking,” said Carbon Architecture’s Will Todd, “which makes achieving compliance faster, easier and more cost-effective. Adding RedBull was simple. The company also has a sizeable fleet of vehicles which represents another area where energy savings can be made.”

Carbon Architecture helps energy-intensive business and industries minimise their costs and legislative compliance by developing and implementing sustainable cost saving strategies. Its core focus is waste, energy and water efficiency solutions for the FMCG industry and works with other drinks brands including Fullers, Heineken, Adnams, Shepherd Neame and Brains Brewery.

For more information please log on to www.carbonarchitecture.co.uk

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 (inputoutput) 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, E-mail: sales@fortressinterlocks.com / Web: www.fortressinterlocks.com

PROCESS INDUSTRY INFORMER October - November 2015

Leading rupture disc manufacturer Elfab has launched Ferrule OptiGard™ SoLo, an advanced reverseacting disc designed for use in hygienic and aseptic applications.

Ferrule Opti-Gard™ SoLo enhances the existing Opti-Gard™ range, the most technically advanced rupture disc available on the market since its initial launch in 2003.

Ferrule Opti-Gard™SoLo features a 95 per cent operating ratio and three per cent tolerance, providing the highest performance characteristics available on the market for hygienic and aseptic installations.

Available in a variety of sizes, and suitable with the lowest burst pressure capability on the market, the design is non-fragmenting and capable of supporting vacuum and back pressures. The disc is for installation between triclamps and ferrules, and benefits from an uninterrupted surface finish to meet FDA approvals, making it ideal for use in CIP and SIP applications.

The unique design also includes an integral Flo-Tel™+ actuator as standard, offering the added benefit of non-invasive, ATEX- approved rupture detection through the Flo-Tel™+ system.

For more product information contact Elfab Ltd, North Shields, Tyne & Wear Tel: +44 (0)191 293 1234, E-mail: deborah.bevan@elfab.com Web: www.elfab.com

BAJOLOCK® COUPLERS FROM SMITH FLOW CONTROL PROTECT WORKERS OPERATING SYSTEMS UNDER PRESSURE To prevent accidents when opening couplings under pressure, Smith Flow Control has introduced Bajolock® patented couplers to its product portfolio.

Bajolock® couplers are ideal for use in a wide range of industries where it is common for pipes and systems to be under pressure when couplings are opened. It is often hard to determine the residual pressure in the system, and using conventional couplings can be dangerous. With Bajolock, pressure is caught and automatically equalised; any potential harmful residue material is discharged away from the operator.

Bajolock can then be uncoupled easily and safely with a simple twist. It is interchangeable with existing, similar couplers, enabling seamless integration in plant processes.

Smith Flow Control’s Bajolock coupler is designed for use in transfer systems for pressures up to 10 bar (145 psi). It is ideal for a wide range of applications including oil & gas, petrochemical, shipping, pipe, bulk, medical and the food and beverage industry, in addition to road transportation applications.

The Bajolock coupler is manufactured according to the Pressure Equipment Directive and bears the CE mark. It is constructed from high quality 316L stainless steel and incorporates market-leading gaskets.

For more information please visit the company website at www.smithflowcontrol.com Email: bajolock@smithflowcontrol.com Tel: +44 (0)1376 517901

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HEALTH & SAFETY FORTRESS INTERLOCKS GET NETWORKED tGard and amGardpro interlocks to get AS-i and PROFIsafe connectivity Industrial safety specialist Fortress Interlocks is integrating AS-interface (AS-i) and PROFIsafe (PROFIbus Safety or PROFInet Safety) connectivity into its tGard and amGardpro interlocks. The company is also developing non-contact switches and output signal switching devices which can be incorporated into its tGard and amGardpro units.

Most 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.

To overcome this scenario, Fortress has developed a number of products that utilise either AS-i industrial networking or PROFIsafe communication technology. Both have major benefits: • AS-i is an industrial networking platform used in PLC, DCS and PC-based automation systems. It is designed to connect simple field I/O devices in manufacturing or process applications using a single 2-conductor cable. As-i connectivity dramatically reduces the number of wires required, making it possible, for example, to ‘daisy chain’ to up to 62 devices to one control panel.

Fortress in now integrating AS-i and/or PROFIsafe connectivity into the following safety products and over the coming months the following will be available: • Both the tGard and amGardpro ranges will have AS-i networking • The amGardpro will also be available with PROFIsafe • A new stand-alone Non-Contact Switch with an AS-i version; this will also be integrated into the tGard and amGardpro ranges in the future • An Output Signal Switching Device will be incorporated into the tGard and amGardpro

For more information contact Fortress Interlocks Ltd, Tel: +44 (0)1902 349000, E-mail: sales@fortressinterlocks.com Web: www.fortressinterlocks.com

STREAM TRAP MONITORING SPIRAX SARCO STAPS WIRELESS HASSLE-FREE, ENERGY-SAVING STEAM TRAP MONITORING The new STAPS Wireless monitoring system from Spirax Sarco is a quick and easy way to implement continuous monitoring of entire steam trap populations, regardless of manufacturer, reducing costs and significantly improving steam system performance.

Automated monitoring systems provide continuous visibility of steam trap condition, enabling drops in performance to be identified instantly and corrected to improve energy efficiency and productivity. The problem is that installing a wired system can be time-consuming and costly, with production interrupted by the installation of power and data lines.

Spirax Sarco STAPS Wireless monitoring system eliminates these drawbacks by using the Zigbee or ISA100 wireless networking standards. A STAPS head unit is simply clamped onto the upstream side of the steam trap, avoiding the need to isolate processes or cut into pipework, for rapid installation and commissioning.

The STAPS system uses ultrasonics to continually monitor steam traps. The sound signature of each steam trap is categorised and transmitted via the wireless network to a central PC, which uses purpose-built STAPS Wireless software to determine the trap condition and calculate steam loss in actual cost terms. The technology enables steam system operators to instantly identify steam traps that are blocked or stuck open and take immediate remedial action to maintain productivity, protect end product quality and avoid unnecessary energy costs.

For more information contact Spirax Sarco - Tel: 01242 521361 E-mail: UK.Enquiries@spiraxsarco.com

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FORTRESS UNVEILING NEW SAFETY INTERLOCKS & COMMUNICATIONS MODULES AT SPS IPC DRIVES SHOW Industrial safety specialist Fortress Interlocks is unveiling new safety interlocks, communications modules and accessories at this year’s SPC IPC Drives trade show in Nuremberg, Europe’s leading exhibition for electric automation technology. The company will be in Hall 9, Booth 202 and invites anyone interested to call past the booth and speak to its industry experts.

New products on show will include: • proNET, a PROFInet/PROFIsafe communications module for Fortress’ amGardpro interlocks. This allows the features of the amGardpro to be distributed on a PROFInet network, with safety information exchanged using PROFIsafe extensions.

• amGardncs, a robust, coded, non-contact, safety proximity switch. Extremely long-lasting and requiring very little maintenance, non-contact switches are used when precise guidance of guards can be difficult. With a stainless steel IP69K housing, the amGardncs is ideal for high purity applications such as food, beverage and pharmaceutical manufacturing, or anywhere where hygiene is of paramount importance.

• amGardS40 stainless steel interlocks. Similarly to the non-contact switch, this product is designed specifically for us in high purity process environments such as food, beverage and pharmaceutical manufacturing. It also has all of the features of the amGardpro range.

All these products are part of an ongoing project by Fortress to integrate PROFIsafe and PROFInet Safety connectivity into its safety interlock ranges.

“Making our products compatible with industrial safety networks is an essential requirement for our customers,” comments Fortress’ Managing Director Rob Lewis.

“With these new product developments being unveiled at the SPC IPC Drives show, we’re letting the market know that we not only meet, but exceed, what people expect from us when it comes to industrial networking.”

For more information contact Fortress Interlocks Ltd, Tel: +44 (0)1902 349000, E-mail: sales@fortressinterlocks.com Web: www.fortressinterlocks.com

ROLLER BEARINGS BOWMET® RANGE SIGNALS STEP CHANGE IN PLAIN BEARINGS New rolled bearings range from Bowman International offers outstanding capabilities and longer life The new BowMet® range of rolled bearings, billed as the biggest advance in plain sliding bearings in more than 70 years.

BowMet® offers a higher load capacity and longer life than comparable bearings, together with outstanding heat, speed and corrosion capabilities. It is manufactured in the unique ToughMet® alloy, developed by Materion in the USA. With a static load of 820 N/mm2 and an impressive PV value of 9.6 MPa x m/s, BowMet® is ideally suited to a wide range of harsh industrial applications, including mining and quarrying, heavy construction, motorsport, offshore oil and gas, materials handling and marine. It has an outstanding ability to withstand corrosion, particularly when compared with traditional copper-based alloys.

The rolling process ensures virtually no wastage and unrivalled flexibility with no minimum quantity makes BowMet® the ideal solution for virtually any application.

Available as plain or flanged in a variety of standard wall thicknesses from 0.75mm to 3mm or above and are also available in imperial sizes. The range can be customised to include lubrication grooves, location slots, tabs, holes and pockets.

Managing Director, Paul Mitchell, said: “BowMet® is nothing short of a revolution in bearing design and capability, with the capacity to deliver increased reliability, reduced downtime, fewer warranty claims and lower maintenance costs. All this, of course, in addition to outstanding bearing properties which enable higher loads, higher speeds and combat corrosion.

The reduced wastage achieved by the rolling process generates real cost reductions with the BowMet® range. Previously, bearings made from ToughMet® had to be machined from solid bar or thick-walled tube, which could mean as much as 75% material wastage.

For more information contact Bowman International Ltd, Tel: +44 (0) 1235 462500 E-mail: sales@bowman.co.uk Web: www.bowman.co.uk

PROCESS INDUSTRY INFORMER October - November 2015

DRIVES & MOTORS

NETWORK & COMMUNICATIONS

MOUNTING FEATURES EXTEND DRIVE APPLICATIONS OPTIONS Variable-speed drives can now be used in many more applications, following the introduction of features that make mounting and installation more convenient and cost-effective.

A separately mountable cable box comes complete with its own fixings, allowing it to be mounted before installing the drive. This allows the cables to be glanded and made off without the drive obstructing the operation. The cable box can also be left in place when the drive is removed for service, keeping the cables held neatly in the wall. This prevents damage to the cables, avoids a possible trip hazard and allows the drive to be replaced more quickly.

All these features are available on the new ABB general purpose drive, ACS580, which also retains all the labour saving installation features of previous ABB drive products. Commonality of mounting means that the ACS580 can be used as a direct replacement for ABB’s earlier drives.

For more information please contact: ABB Ltd, Warrington, Cheshire Tel: 01925 741 111 E-mail: energy@gb.abb.com Web: www.abb.co.uk/energy

-1 one Z X ATE proved Ap

FAST TRACK ETHERNET SWITCHES FEATURE PRECISION TIME PROTOCOL FOR TIME-CRITICAL APPLICATIONS HARTING has expanded its range of Fast Track Ethernet switches for industrial applications with the FTS 3000-PTP range of managed switches.

The new devices feature Precision Time Protocol (PTP), allowing the creation of high-precision industrial networks in which all components of the automation process can be synchronised for time-critical applications.

The FTS 3000-PTP managed Ethernet switches support PTP in accordance with IEEE 1588v2 and can detect automation frames and accelerate them so that they always arrive at the destination in time, independent of the network load. Besides the Rapid Spanning Tree Protocol (RSTP), the switches support the Media Redundancy Protocol (MRP) for ring wiring and can be installed in various topologies. As a result, switch availability is boosted and system downtime is reduced.

The new Ethernet switches are available as a copper variant with ten RJ45 ports (Ha-VIS FTS 3100-A-PTP) or, for use with fibre-optic lines, as a version with eight RJ45 Ports and two SFP slots (Ha-VIS FTS 3082-ASFP-PTP).

Typical applications include industrial installations demanding high performance and determinism, including drives and controls, test & measurement equipment or the synchronisation of networks in wind energy systems.

For more information contact HARTING Ltd, Northampton Tel: +44 (0) 1604 827500 Email: gb@harting.com Web: www.harting.co.uk

Ex-Proof Mass Flow Meters/Controllers u Gas flow rates from 0-8 mln/min up to 220-11000 m3n/h u Pressure rating up to 700 bar u Electrical protection II 2 G Ex ib IIC T4 Gb (ATEX Zone 1) u Rugged weatherproof (IP65) housing

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

PROCESS INDUSTRY INFORMER October - November 2015

43

PROCESS MEASUREMENT & INSTRUMENTATION NEW OPTICAL SENSOR FROM ABB CUTS THE COSTS OF DISSOLVED OXYGEN MEASUREMENT Advanced digital sensor with EZLink technology offers enhanced accuracy and reliability for dissolved oxygen monitoring.

Problems associated with traditional dissolved oxygen sensing systems can now be eliminated using ABB’s new optical dissolved oxygen sensing system. Consistent, reliable and accurate, it can help operators to realise significant savings through reduced energy consumption and maintenance.

Comprised of the ADS430 sensor and multichannel transmitter, the system provides the highest levels of stability and accuracy for dissolved oxygen measurement. The ADS430 optical dissolved oxygen sensor uses Rugged Dissolved Oxygen (RDO®)* optical technology for measuring dissolved oxygen in demanding process environments.

The patented signal processing within the sensor enables it to respond to changes in process conditions up to five times faster than other optical systems, allowing improved control.

ABB’s Measurement & Analytics business unit (www.abb.com/measurement) is among the world’s leading manufacturers and suppliers of instrumentation and analyzers. With thousands of experts around the world and high-performance technology, ABB’s team is dedicated to making measurement easy for its customers.

For more information contact ABB Measurement & Analytics, Tel: 0870 600 6122 E-mail: tim.door@gb.abb.com Web: www.abb.com

NEW CALCULATOR HIGHLIGHTS POTENTIAL SAVINGS THROUGH THE WATER TECHNOLOGY LIST ABB launches web-based tool to encourage water companies to invest in the latest flow metering equipment • Water operators can save money through selecting products on the WTL list • The WTL scheme enables companies to offset 100 percent of purchase costs • Many of ABB’s electromagnetic flowmeters feature on the list • Electromagnetic flowmeters reduce operational costs and improve profitability ABB’s new ECA calculator tool (bitly.com/ABBECA-Calc) allows water operators to quickly and easily calculate how much they could save by choosing ABB’s AquaMaster, WaterMaster and AquaProbe products from the Water Technology List.

Set up over 10 years ago by Defra and the Inland Revenue in partnership with Envirowise, the Water Technology List (WTL) scheme promotes the use of water efficient technology by enabling companies to offset 100 percent of the costs associated with purchasing and installation in the first year.

As listed products within the scheme, ABB’s WaterMaster, AquaMaster and AquaProbe flowmeters are all eligible for 100 percent tax relief at the time of purchase. In many cases, this removes the purchase cost argument that has seen many water companies continuing to opt for mechanical flow meters, despite their many drawbacks compared to electromagnetic devices.

“The online calculator from ABB enables end users to see for themselves how beneficial it can be to purchase equipment from the Water Technology List,” says Alan Hunt, Product Specialist for ABB’s UK Measurement product business “Although the scheme has been around for a long time, many people are still unaware that it applies not only to the products listed but also the installation itself which can account for around 50 percent of a typical project.”

To access the calculator, please visit bitly.com/ABB-ECA-Calc.

For more information about ABB’s Water Technology List products, call 0870 600 6122 or email moreinstrumentation@gb.abb.com ref. “Water Technology Calculator”.

BRONKHORST ATEX ZONE 1 CERTIFIED MEASUREMENT & CONTROL FOR GASES Bronkhorst EX-FLOW instruments are thermal Mass Flow Meters / Controllers of rugged design and suitable for gas flow application in ATEX Zone 1 Certified, hazardous areas. The intrinsically safe measuring head is tested according to ATEX 95 Directive 94/9/EC and approved under EC-Type Examination Number: KEMA 01ATEX1172, protection II 2 G Ex ib IIC T4 Gb. The housing of the electronics compartment is also IP65 rated. Control valves can either be integrally or separately mounted, to measure and control gas flows.

Why Mass Flow? Volumetric measuring devices, like variable area meters or turbine flow meters, are unable to distinguish temperature or pressure changes. This means significant changes in ambient or process temperatures or pressures can significantly affect the concentration (by volume) and as such the quality of your process & true accuracy of the reading. Mass flow measurement for those devices would require additional sensors for these parameters and a flow computer to compensate for the variations in these process conditions. On the other hand Thermal mass flow meters are virtually insensitive to variations in temperature or pressure.

EX-FLOW Mass Flow Meters can be supplied in ranges starting from 0,16…8 mln/min up to 11000 m3n/h air-equivalent, with pressure rating between vacuum and 700 bar, while Mass Flow Controllers can be offered up to 10…500 m3n/h air-equivalent, incorporating either integrated or separate control valves.

The control valve used on EX-FLOW Mass Flow Controller is a proportional, electromagnetic control valve with fast and smooth control characteristics. Further there is a standard direct acting valve for common applications, a pilot operated valve for high flow rates and the so-called Vary-P valve with a pressure rating of 400 or 700 bar, that can cope with up to 400 bar ΔP. These valves will be equipped with explosion proof certified coils.

The control valve receives its input from the controller board and immediately responds to any deviation between the output signal from the flow sensor and the setpoint signal.

Further information about the Bronkhorst EX-FLOW - ATEX Zone 1 Certified range, please contact us at www.bronkhorst.co.uk

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PROCESS INDUSTRY INFORMER October - November 2015

PROCESS MEASUREMENT

& INSTRUMENTATION

FLEXIBLE ELECTRONIC DIFFERENTIAL PRESSURE FROM VEGA Differential Pressure is available as a standard option in all sensors in the VEGABAR 80 range. No special field electronics enclosures or transducers, it only requires a standard device with a ‘slave’ electronics module in the other, eliminating chemical seals, impulse lines and capillary systems. Any VEGABAR 80’s from the range can be used, minimising cost, complexity and stocks and you get both HP, DP and LP pressure measurements. Mix housings: ‘submersible IP68’ and standard IP66/7. Mix materials: flush ceramic and recessed metal diaphragms.

Combine sensor designs: submersible ‘hydrostatic’ transmitters with standard flanged. The standard interconnecting distance is 25m, but can extend to over 100m. Connection sizes from ½” BSP/NPT (flush) upwards. Accreditation: ATEX, SIL, FDA, EHEDGE, 3A and Marine. Communications: 4-20mA, HART, Profibus and Foundation Fieldbus.

For more information contact VEGA Controls Ltd, Tel: +44 1444 870055 E-Mail: info.uk@vega.com Web: www.vega.com/uk

OEM AUTOMATIC LTD IS PLEASED TO ANNOUNCE THE LAUNCH OF THEIR LATEST EDITION OF THE PRESSURE & FLOW CATALOGUE In the UK, we represent some of the most respected European manufacturers in Industry. These include Suco for pressure control; Tecsis with their range of pressure, temperature and force instruments; Valco for level control; Honsberg, part of the GHM group, for flow products and mPm for industrial connectors.

New products include electronic pressure switches and switches with integral connectors from Suco. The LABO range of flow and temperature sensors from Honsberg that can be custom designed to suit specific applications. From Molex the ML-XT range of multi-pin connectors in 2-4-6 and 18 pin configurations and sealed to IP68. Tecsis are launching their range of differential pressure switches and a range of differential pressure sensors are also available.

If you wish to discuss an application in person we have a team of sales engineers backed up by product managers and customer support staff who will be able to give advice on the most appropriate product or system to suit your design.

For more information contact OEM Automatic Ltd, Tel: 0116 284 9900 Web: www.oem.co.uk

WHAT TO BEAR IN MIND WHEN MEASURING PH VALUES Measuring pH values according to the potentiometric measuring method (pH-sensitive electrode and pH meter) has become an established method over years and is now a highly developed method in laboratories and the industrial sector (inline measurement).

The sensor and the meter form the measuring system and must be suited to the application to ensure reliable pH measurement in laboratories or industrial areas.

A suitable electrode must be carefully selected according to the measured medium as it is directly in contact with it. Depending on the application (laboratory or industry), further parameters such as temperature, pressure, flow velocity of the medium as well as direct environmental conditions like air humidity and temperature and transmission paths between the sensor and the meter play an important part in component selection.

PCE Instruments is a competent partner in choosing suitable solutions, regardless of whether you work in a laboratory or in an industrial environment.

For more information contact PCE Instruments UK Ltd, Southampton, Hants.

Tel: +44 ( 0 ) 2380 98703 0 Email: info@industrial-needs.com Web: www.pce-instruments.com/english

PROCESS INDUSTRY INFORMER October - November 2015

45

FEATURE

INTRODUCTION TO MAC Introduction to Machine Vision Systems are a primary consideration for any manufacturer who is looking to improve quality or automate production, but choosing systems that match your application and ownership requirements can be confusing. Knowledge of the types of systems on the market and the factors to consider when integrating vision will help implementers keep costs low and inspection robustness high.

V

ision systems can be thought of as computers with eyes that can identify, inspect and communicate critical information to eliminate costly errors, improve productivity and enhance customer satisfaction through the consistent delivery of quality products. Primarily used for online inspection, vision systems can perform complex or mundane repetitive tasks at high speed with high accuracy and high consistency. Errors or deviations in the manufacturing process are immediately detected and relayed, allowing control modifications to be made on the fly to reduce scrap and minimize expensive downtime. Vision systems are also deployed for non-inspection tasks, such as guiding robots to pick parts, place components, dispense liquids or weld seams.

Vision systems come in all shapes and sizes to suit any application need, but they all have the same core elements. Every vision system has one or more image sensors that capture pictures for analysis and all include application software and processors that execute user-defined inspection programs or recipes. Additionally, all vision systems will provide some way of communicating results to complementary equipment for control or operator monitoring. That said, it is important to know that there are significant and important differences between vision systems that make one more suitable than another for any given application. It is equally important to know and appreciate the importance of choosing the optimal sensor, lighting and optics for the job. Failure to do so may result in unexpected false rejects, or even worse, false positives.

There are many variants of vision systems on the market, but for the purpose of this paper we will classify them all into two categories – those with a single embedded sensor (also known as smart cameras) and those with one or more sensors attached (multi-camera vision systems). The decision to use one or the other is dependent not only on the number of sensors needed, but also on a number of other factors including performance, ownership cost and the environment where the system needs to operate. Smart cameras, for example, are generally designed to tolerate harsh operating environments better than multicamera systems. Similarly, multi-camera systems tend to cost less and deliver higher performance for more complex applications.

Another way to differentiate the two classes of systems is to think in terms of processing requirements.

For many applications, such as in car manufacturing, it is desirable to have multiple independent points of inspection along the assembly line. Smart cameras are a good choice as they are self-contained and can be easily programmed to perform a specific task and modified if needed without affecting other inspections on the line. In this way processing is “distributed” across a number of cameras. Similarly, other parts of the production line may be better suited to a “centralized” processing approach. For example, it is not uncommon for final inspection of some assemblies to require 16 or

46

32 sensors In this case, a multi-camera system may be better suited as it is less costly and easier for the operator to interact with.

Perhaps the most important consideration when selecting any vision system is software. The capabilities of the software must match the application, programming and runtime needs. If they don’t, you will find yourself investing more time and expense than you anticipated in trying to conform the system to your expectation. If you are new to machine vision or if your application requirements are straightforward, you should select software that is easyto-use (i.e. doesn’t require programming), includes core capabilities (i.e. pattern matching, feature finding, barcode/2D, OCR) and can interface with complementary devices using standard factory protocols. If your needs are more complex and you are comfortable with programming, you might look for a more advanced software package that offers additional flexibility and control.

In either case, make sure that the software you choose is available across vision system platforms in case you need to migrate due to changing inspection requirements.

IMPLEMENTATION FACTORS TO CONSIDER • IMAGE SENSOR RESOLUTION

Image sensors convert light collected from the part into electrical signals. These signals are digitized into an array of values called “pixels” which are processed by the vision system during the inspection. Image sensors can be integrated into the system, such as in the case of a smart camera, or into a camera that attaches to the system. The resolution (precision) of the inspection depends in part on the number of physical pixels in the sensor. A standard VGA sensor has 640 x 480 physical pixels (width x height), and each physical pixel is about 7.4 microns square. From these numbers, resolution can be estimated for your “real world” units.

Image sensors used by vision systems are highly specialized, and hence more expensive than say, a web cam. First, it is desirable to have square physical pixels. This makes measurement calculations easier and more precise.

Second, the cameras can be triggered by the vision system to take a picture based on a part-in-place signal.

Third, the cameras have sophisticated exposure and fast electronic shutters that can ‘freeze’ the motion of most parts as they move down the line. Image sensors are available in many different resolution and interfaces to suit any application need. In many cases, multiple image sensors are deployed to inspect large parts or different surfaces of the same part.

•

SENSOR LENS SELECTION

Each sensor needs a lens that gathers light reflected (or transmitted) from the part being inspected to form an

PROCESS INDUSTRY INFORMER October - November 2015

CHINE VISION SYSTEMS

We publish this White Paper by courtesy from Teledyne DALSA

image on the sensor. The proper lens allows you to see the field-of view (FOV) you want and to place the camera at a convenient working distance from the part. The working distance is approximately the distance from the front of the sensor to the part being inspected. A more exact definition takes into account the structure of the lens and the camera body.

Consider this example: If a part to be inspected is 4” wide by 2” long, you would need a FOV that is slightly larger than 4”, assuming you can position the part within this FOV. In specifying the FOV you need to also consider the camera’s “aspect ratio” - the ratio of the width to length view. The sensors used with vision systems typically have a 4:3 aspect ratio, so the example 4” x 2” part would match the sensor dimension, but a 4” x 3.5” part would require a larger FOV to be seen in its entirety.

From the FOV, working distance and the camera specifications, the focal length of the lens can be estimated. The focal length is a common way to specify lenses and is, in theory, the distance behind the lens where light rays ‘from infinity’ (parallel light rays) are brought to focus. Common focal lengths for lenses in machine vision are 9mm, 12mm, 16 mm, 25 mm, 35 mm and 55 mm. When the calculations are done, the estimated focal length will probably not exactly match any of these common values. We typically pick a focal length that is close and then adjust the working distance to get the desired FOV. Most vision suppliers have tools that will help you calculate the closest lens to match your FOV and working distance. There are other important specifications for lenses, such as the amount and type of optical distortion the lens introduces and how closely the lens can focus.

• LIGHTING SOURCE

The human eye can see well over a wide range of lighting conditions, but a machine vision system is not as capable. You must therefore carefully light the part being inspected so that the vision system can clearly ‘see’ the features you wish to inspect. Ideally, the light should be regulated and constant so that the light changes seen by the vision system are due to changes in the parts being inspected and not changes in the light source. While some vision algorithms can tolerate some variation in light, a well designed implementation will remove any uncertainty. When selecting a light source, the goal is to ‘amplify’ the elements of the part that you want to inspect and ‘attenuate’ elements that you don’t care about. Proper lighting makes inspection faster and more accurate,

whereas poor lighting is a major cause of inspection failure. Generally it is recommended to avoid using ambient light, such as overhead light, as this can vary over time. Factory lights can beat, burn out, dim or get blocked.

Similarly, if there are windows near the inspection station, outside light changes can have a negative effect on system robustness. Selecting the proper lighting requires some knowledge and experience that most suppliers can provide during application evaluation.

• PREDICTABLE PART PRESENTATION

It is important to consider how parts will be presented to the vision system for inspection. If the part is not presented in a consistent way, you will not achieve the desired result. Therefore you will need to ensure that the surface of the part you want to inspect is facing the sensor at runtime.

Next you will need to decide whether the part is to be inspected while in motion or stationary. If the part is moving, the motion will likely need to be “frozen” by turning the light on briefly or by using the high-speed electronic shutter feature of the sensor (standard on most industrial vision sensors).

In this case you will need to provide a trigger to the sensor to let it know when to take a picture. The trigger is typically generated by a photo-eye sensor that detects the front-edge of the part as it moves into the inspection area. If the part is stationary, for example indexed or positioned in front of the sensor by a robot, the sensor can be triggered to take a picture from a PLC or the robot itself.

Finally, if you are inspecting parts at very high-speed, you will likely need to optimize part positioning to reduce processing time. Keep in mind when designing your system that everything consumes processing bandwidth. So, when considering a vision system for high-speed inspection, you should try to determine which of your requirements are critical or just nice to have. Armed with knowledge, support and a reputable supplier, the cost of implementing vision solutions on the factory floor will be returned many times over through increased quality, production efficiency and scrap reduction.

Teledyne DALSA is a global leader in high performance digital imaging and semiconductor technology with headquarters in Waterloo, Ontario, Canada.

FEATURE PREVENTATIVE MAINTENANCE…

CAN YOU AFFORD NOT TOO?

By Ewart Cox - Managing Director, Assentech Sales Ltd

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BREATHER VALVES ARE NO EXCEPTION

OTHER CRITERIA CAN DETERMINE THE TIMEFRAME & FREQUENCY OF EQUIPMENT DETAILED ON YOUR MAINTENANCE PLAN & THESE INCLUDE:

Relevant Standards and Reference •EMUA Publication 231 Ed 1 – The mechanical integrity of plant containing hazardous substances.

•EEMUA Publication 159 – Users’ Guide to the Inspection, Maintenance and Repair of Above Ground Vertical Cylindrical Steel Storage Tanks.

• EEMUA Publication 217 Ed 1 – Safe and Effective Operation of Storage Tanks.

• EEMUA Publication 213 Ed 1 - Emission reduction from Oil Storage Tanks and loading operations •HSG 176 – The storage of flammable liquids in tanks.

•API 653 – Tank inspection, repair, alteration and reconstruction.

•API 2000 – Venting Atmospheric and Low-pressure Storage Tanks •Buncefield Major Incident Investigation Board http://www.hse.gov.uk/comah/ bouncefield/fuel-storage-sites.pdf .

•RR760 – Mechanical integrity management of bulk Storage Tanks.

•BS EN 14015:2004 – Site built flat bottomed atmospheric Storage Tanks ISO 28300 – Venting of atmospheric low pressure Storage Tanks.

anagement of ageing plant is never easy. Tight budgets and scarce labour resources following 7 years in recession has not made tank farm management any easier. Management of ageing plant and ever tightening legislative compliance keeps us all on our toes. It only takes an event like Buncefield or the recent Tianjin port explosion accident in Northern China to remind us how important it is to keep our employees and assets safe.

Well maintained facilities do not suffer unplanned outages or fines and the associated bad press by the Environment Agency or The Health and Safety Executive (HSE). Furthermore the quality of stored product remains at a premium, resulting in minimal production issues and product quality does not decline.

It is an unfortunate reality that most catastrophic incidents follow a number of ignored near misses.

Those who have attended one of our technical seminars will see at first-hand how 20mbarg will not burst a balloon but can lift a 6 tonne tank off its base.

Keeping your plant in tiptop shape is imperative and will ensure a safe working environment. You will also benefit from compliance, minimal downtime and maximum profitability.

One of the keys to success is maintaining the condition of the equipment and this can be achieved through the development of a Preventative Maintenance Plan.

An easy to follow program can be designed to fit any type of site by following some simple guidelines and setting up routine inspections. Failing Preventative Maintenance …. Can you afford not too? components will be identified and corrected before an incident occurs and the site operating efficiency will be maintained.

Preventative Maintenance Plans and structured Key Performance Indicators are designed to address issues of malfunctioning and underperforming equipment before an incident occurs. This strategy is a well-trodden path with high pressure relief equipment following many years of legislative development. A systematic and structured maintenance procedure of low pressure systems is less uniform between operators. The HSE are increasing focus and awareness of safety and management of ageing assets by promoting the importance of following a structured process.

The most comprehensive Preventative Plan should be developed for each piece of equipment. Once the piece of equipment has an asset number it is necessary to review its suitability for the intended service. This review can be achieved by reviewing the service manual, performance curve(s) and test certificates.

The distributor or manufacturer can assist with this process. The maintenance regime must include information on inspection intervals and the lubrication schedule. With the recommended information in hand, the plan can be tailored to fit the usage of the equipment and/or the site standards.

Construction • Quality and suitability of the original fabrication and installation • Design • Life limiting factors assumed at design stage • Design quality • Calibration • Documentation requirements • Suppliers • Obsolescence of equipment • Operation • Operating within design limits • Inspection • Visual inspection for deterioration • Modifications • Any modification or change from original scope

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A simple visual inspection is no longer accepted by the HSE. Servicing breather valves is not the most enthralling part of your maintenance routine, but if you don’t look after them they could lead to your plant being closed, a fine by the HSE or worse still, harm to your employees or loss of life.

Every company needs to ensure its valves are functioning as well as they can.

They need to be calibrated, leakage tested and certified as fully functional.

Otherwise the consequences can be very dangerous and expensive.

We recently assisted a customer reduce their annual nitrogen costs which were in excess of £250k per annum. After an expense of £15k for replacement valves and calibration, we saved the customer an estimated £90k in nitrogen loss for the year.

Breather valves lose their ability to seal over time. We often inspect valves that have had weight added to the pallet assembly to compensate for poor sealing.

This is a very dangerous correction and could result in a tank collapse. This would only be flagged by a weight test which is part of the valve calibration protocol but the subsequent HSE investigation would centre on why the weight was added, by whom and for what reason.

The conservation of vapours and minimising of water ingress are key elements in sustaining the quality of stored liquids. Storage tanks are typically large volume low pressure vessels so the provision of tight sealing and adequate vapour/air exchange is essential. An efficient breather valve safely conserves vapours up to the maximum allowable working pressure.

Servicing and maintaining valves isn’t rocket science, but it does need specialist knowledge on how breather valves work and are calibrated. For example our calculation methods are third party verified which gives customers peace of mind. Focus on the valve is part of the business process. Properly maintained breather valves can save an operator a huge amount of money and time.

When selecting your servicing provider it is important to confirm that they are fully certified to calibrate and leakage-test any breather valves on site or offsite by using specifically designed calibration equipment that has industry approval. This approach is essential to the safe and efficient running of a higher tier COMAH site.

PROCESS INDUSTRY INFORMER October - November 2015

PREVENTATIVE

MAINTENANCE

CONDITION-BASED MONITORING (CBM) IS PLAYING AN INCREASINGLY IMPORTANT ROLE IN SUPPORTING PREVENTATIVE MAINTENANCE PROGRAMMES Designed and manufactured in the UK, the IMC Group has revolutionised CBM with the new wireless Contor system.

Central to the effective running of a machine are its spindles and bearings.

Yet heavy demands on manufacturing and engineering teams mean manual checking procedures are not always a high priority and when they are missed hidden problems can arise. Additionally, not all potential problems are even detectable by a worker, whereas CBM can pick up the smallest inconsistencies.

Customers benefit from significantly reduced machine downtime and loss of production. Excessive vibration can be a symptom of problems and predictive maintenance for the bearings is enabled by monitoring the RMS vibration of the system. Spindle damage is significantly reduced thus increasing spindle life. Milling machine performance is optimised, unnecessary maintenance is eliminated and costs are reduced.

For more information log on to www.the-imcgroup.com

FLUKE OFFERS 15% DISCOUNT WITH PROCESS CALIBRATION KITS Until 31st of December 2015 or while stocks last, Fluke (UK) is offering special process industry tool packages consisting of a range of Calibration Kits or a Troubleshooting Kit at approximately 15% below the cost of the individual items if purchased separately.

The Calibration Kit consists of a Fluke 719Pro, which calibrates pressure using a built-in electric pump, and a Fluke 771 milliamp Clamp Meter, which can measure output signals without breaking the loop, used for testing PLC and control system analogue I/Os. The Troubleshooting Kit includes a Fluke 789 ProcessMeter, fitted with a Fluke ir3000 FC connector to link to the Fluke Connect™ wireless network, plus a Fluke a3004 FC 4-20mA DC Current Clamp, also part of the Fluke Connect family. The offers can be accessed from www.fluke.co.uk/ promotions The Fluke 719Pro Electric Pressure Calibrator is ideal for calibrating high accuracy transmitters, pressure switches and pressure gauges with accuracy to ±0.025%. The Fluke 789 combines a loop calibrator, a true-rms digital multimeter, a 24V loop supply and a selectable 250 Ohm Hart® resistor in a single handheld tool.

For more information contact Fluke (U.K.) Ltd, Norwich, Norfolk Tel: 0207 942 0700.

E-mail: industrial@uk.fluke.nl Web: www.fluke.co.uk

PROCESS INDUSTRY INFORMER October - November 2015

CALIBRATION YOKOGAWA’S EUROPEAN CALIBRATION LABORATORY RECEIVES ISO17025 ACCREDITATION - World’s first non-governmental laboratory to offer accredited power calibration at up to 100 kHz – Yokogawa’s European Calibration Laboratory has become the world’s first nongovernmental facility to receive full ISO17025 Accreditation for power measurements at up to 100 kHz. This is in addition to its established capability for providing high-accuracy calibration at 50 Hz, especially at very low power factors (down to 0.0001) and at high currents.

There is a growing demand to remove uncertainty in power measurements, particularly with the growing focus on renewable energy markets and the need to optimise energy efficiency while complying with international standards on power quality, especially at low power factors. In addition, the inverters used in renewable energy systems are switching at higher speeds: a scenario that introduces harmonics at higher frequencies.

There is also a demand for high-frequency power measurements on devices such as switch-mode power supplies, electronic lighting ballasts, soft starters in motor controls and frequency converters in traction applications. As a result, power calibration at 50 Hz is no longer sufficient, and accredited power calibration at up to 100 kHz is necessary to address these markets.

“The recognition offered by ISO17025 accreditation is objective proof that the knowledge of our personnel and the quality of our instruments are at a worldclass level”, says Terry Marrinan, Yokogawa’s Vice President, Test & Measurement, for Europe & Africa: “For customers working with tight tolerances, ISO 17025 accredited calibration of the measurement is vital to major critical measuring projects and provides the high level of quality assurance that our customers need.”

Obtaining this accreditation for the laboratory, based at the company’s European Headquarters in Amersfoort, Netherlands, is a key part of Yokogawa’s strategy to maintain and grow its market-leading position in the European digital power analyser market.

Yokogawa’s customers can also be totally confident that they also have easy access to accredited traceable power calibration for all their needs, avoiding time-consuming submission to national standards laboratories.

For more information contact Yokogawa Europe BV, Tel: +31 (0) 88 464 1811 E-mail: terry.marrinan@nl.yokogawa.com Web: www.tmi.yokogawa.com

QUICK, EASY AND ERROR-FREE SENSOR CALIBRATION COMPLIMENTARY POSTER FOR YOUR WORKSHOP Step-by-step pH sensor calibration for in-line Process Analytics measurement is now easier than ever.

Calibration of pH sensors with Intelligent Sensor Management (ISM®) can be done in minutes. ISM sensors store their calibration values so calibrated sensors can be easily rotated in and out of a process. This allows for valuable sensor recovery time prolonging their lifetime.

Get everything you need to know about ISM pH sensor calibration in our handy wall poster. Request your free pH sensor calibration poster at: www.mt.com/uk-pro-poster Find out more about the METTLER TOLEDO ISM digital sensor platform at www.mt.com/ism Alternatively call 0116 234 5095 or email enquire.mtuk@mt.com

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FEATURE

pH MEASUREMENT THE ACID TEST The measurement of pH has been a mainstay of water quality testing in the process industries for decades, but the technique is still prone to error and misinterpretation.

Mark Bosley, Business Support Divisional Manager at Thame based SUEZ Water Purification Systems, which is part of SUEZ Treatment Solutions’ UK offering, outlines some common pitfalls and how to avoid them.

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any process industry applications, from food and beverage manufacture to chemical and pharmaceutical production, rely on the availability of water at a known level of purity. Measuring the pH of that water can be one of the quickest ways of determining its purity. This is because many common contaminants, including dissolved air, carbon dioxide and ionic salts, have a direct effect on acidity or alkalinity.

There is, however, a catch. It’s actually quite difficult to measure pH directly, especially in industrial environments – both the measuring instruments and the sampling procedures required to use them are prone to induced errors. As a result, it’s far more common to make use of a side-effect of dissolved ions: their ability to conduct electricity.

Ions dissolved in water can have different charges, and will move at different velocities. Cations (with a positive charge) include H+, Na+ and Mg++. Anions (with a negative charge) can include OH-, Cl- and SO42-. However, the most mobile ions commonly found in water are hydrogen (H+) and hydroxyl (OH-). As a result, highly acidic or alkaline solutions will usually have the greatest conductivity.

Using a conductivity meter, it is possible to measure the flow of electricity through a fluid. The resulting reading is directly proportional to the concentration of ions in the fluid, their charge and their level of activity: the higher the reading, the greater the concentration of ions. Conductivity is measured in Microsiemens per centimetre (µS/cm). Sometimes a measurement device will actually record the reciprocal of conductivity – resistivity – measured in Megohm centimetres (MΩ.cm).

Ultrapure, or deionised, water has a natural pH of 6.998 and a conductivity of 0.055 μS/cm, or 18.2 MΩ.cm at 25°C. It is common practice to use conductivity to measure water with a high concentration of ions and resistivity to measure water containing fewer ions.

It is important to note that those numbers are given for a specific temperature.

Changes in temperature will significantly alter the conductivity of a sample. In water with the purity of typical mains supply, for example, conductivity will change by around two percent per degree Celsius. As a result, conductivity measurements are always referenced to 25ºC, to allow different samples to be compared.

However, temperature doesn’t just affect the performance of measuring equipment.

Since pH is a measure of the activity of hydrogen ions in a solution, and ions are more active at higher temperatures, the actual pH of a solution will vary according to its temperature, with a higher temperature meaning more ion activity. At 0ºC the pH of a neutral solution like pure water rises to 7.5, for example, while at 100ºC it falls to 6.2.

Commercially available hand held conductivity or resistivity meters use probes inserted into a liquid sample to measure the concentration of hydrogen ions against a reference source. Older designs typically use two separate probes, while more modern ones incorporate a single combined sensor.

Usually, the device also takes a temperature reading to allow it to calculate the actual pH value of the sample more accurately. As well as pH, the meter may be able to display other values, like resistivity, conductivity and total dissolved solids (TDS).

‘HOLDING’ HAND HELD PROBES…

The measurement of highly purified water using hand held probes can be prone to errors. The most significant cause of error arises because as soon as a sample is drawn from the system it begins to absorb impurities from a number of sources, including the sampling container itself and the surrounding air. In particular, carbon

dioxide from the air will react with the water to form carbonic acid in solution; this in turn disassociates to release conductive ions. Just a few parts per million (PPM) of CO2 dissolved in a sample of ultrapure water can reduce the pH to around 4.0.

This means that a pure water sample can’t be exposed to air without affecting the accuracy of pH measurement. The rate of sample contamination will depend on the surface area of the sample exposed and the time elapsed.

To achieve consistent measurement using hand held devices, care should be taken to ensure that instrument probes and sample containers are thoroughly cleaned before use, that the measurement is taken as soon as possible after sample collection and that consistent procedures are used to maintain the comparability of measurement between samples. It is usually best to take the measurement instrument to the source, rather than transporting the sample to the instrument.

Likewise, the probe should be fully immersed at the bottom of the sample container, with the sample allowed to overflow. Failure to ensure consistency in measurement practice can lead to changes in pH reading, and the incorrect assumption that water purification or process equipment has malfunctioned.

The problem of sample contamination can be avoided through the use of in-line measurement devices that analyse closed, flowing samples. This approach is the norm in more demanding applications, where the instrumentation is connected directly to higher level automated process control systems.

Even these kinds of sensor, however, are still exposed to the risk of contamination and to the effects of temperature changes. Fouling, scaling or chemical poisoning can rapidly affect the accuracy of sensors in process equipment and they should be recalibrated at frequent intervals to account for such effects.

Similarly, it is important that the measurement device selected is suitable for the process in question. Many devices are calibrated for samples containing relatively high levels of contamination, for example, making them unsuitable for the monitoring of ultrapure water, unless they are fitted with specialised probes.

While pH measurements will remain a mainstay of water quality analysis in process industry applications, any organisation using the technique should take care to ensure they understand the limitations of their instrumentation and measurement procedures, and that they have selected the right equipment, calibration and sampling protocols to suite the needs of their application.

THE pH SCALE

The pH scale provides a standardised method for the measurement of the acidity or alkalinity (basicity) of a solution. It was originally defined by Danish chemist Søren Sørensen, who was head of the Carlsberg laboratory’s Chemical Department at the time. pH is calculated as the negative logarithm of the activity of hydrogen ions in a solution. That activity is then affected by the concentration of hydrogen ions and their temperature. A lower pH number indicates more hydrogen ion activity and a more acidic solution. Expressed on a scale from 0 to 14, the logarithmic nature of the definition means that a single point’s difference in pH indicates a factor of ten change in basicity. pH VALUES OF COMMON MATERIALS AT 25ºC Lemon juice 2.5

Beer 4.5

Pure water 7

Household bleach 12.5

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