Process Industry Informer November 2016 by Process Industry Informer

www.processindustryinformer.com

NOV 2016 Volume 12 No.6

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

TAKING PROPEL FORCE MEASUREMENT TO NEW DEPTHS In print | Online | Mobile - The UK’s No.1 Media for the Manufacturing Process Industries

CONTENTS.

4-5 News & Events 8-10 Applications 12 Health & Safety 15 Mixing

19 BPMA News

18 Network & Communications 34-36 Process Measurement & Instrumentation 37 Process Control 38-41 Fluids & Liquids

AIR-COOLING vs WATER-COOLING

HOW TO ACHIEVE COST EFFECTIVE MEASUREMENT RESULTS

TECH START-UPS EMBRACE ROBOTICS

MONITORING THERMAL FLUID SYSTEMS

SEPARATING THE GOOD FROM THE BAD

(incl. Pumps & Valves)

43 Filling Nozzles

DIFFERENTIAL PRESSURE FLOW MEASUREMENT

43 Drives & Motors 43 I0 Link Actuation / Sensors Hub 45 Bearings 47 Products & Services Suppliers Directory

DRIVING EFFICIENCY IN PROCESS INDUSTRIES

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

TAKE IT SLOW

PROCESS INDUSTRIES & THE DIGITAL REVOLUTION

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NEWS & EVENTS HBM EXPANDS ITS HEADQUARTERS WITH A NEW PRODUCTION AND LOGISTICS CENTRE HBM – a market leader in the field of test and measurement – is pleased to announce the launch of its new dedicated production and logistics facility, which is based at its Darmstadt headquarters, in Germany. Due for completion at the end of 2017, the transparent design of the new production and logistics centre has been carefully selected to reflect the key core values of HBM; precision, innovation and reliability. To mark the opening of the new facility, a HBM time capsule was buried at a traditional foundation stone laying ceremony, which was attended by local dignitaries, HBM employees and executive leadership. Containing a HBM load cell, daily newspaper and a HBM company brochure, the capsule was lowered into the ground by the Mayor of Darmstadt, Jochen Partsch, to celebrate the launch of the building. Emphasising its commitment towards its headquarters in Darmstadt and setting the course for future growth, Karl-Heinz Pohlmann,

Vice President Supply Chain at HBM explains its reasons behind the new investment. “By creating 6,000 square meters

of extra space for the production of heavy-duty and torque sensors, we will be able to create the prerequisites for efficient logistics and modern office space with close links to production”. Situated in the ‘City of Science’, home of many scientific institutions, universities and high-technology companies, the new HBM Production and Logistics Centre in Darmstadt, which employs over 750 members of staff, is also connected to a number of major roads, which means that parts can be quickly and expediently distributed. For further information, contact HBM on Tel: +44 (0) 20 8515 6000 or via Email: info@uk.hbm.co.uk or visit Web: www.hbm.com/en/

RESEARCH BREATHES ‘NEW LIFE’ INTO LITHIUM ION BATTERY PACKS

Novel separation techniques to recover high-value metal compounds from automotive battery packs are being explored as part of a £14 million research consortium. The AMPLiFII Project (Automated Module-to- pack Pilot Line for Industrial Innovation) has received £10 million of funding from the UK’s innovation agency Innovate UK. Led by WMG at the University of Warwick, it aims to develop the next generation of traction batteries for electric and hybrid vehicles. A major focus is developing the lifecycle management of the lithium ion battery system, including its recycling, remanufacturing and/or repurposing at end of life. This includes research into second-life applications and material recovery processes as an alternative to the current energyintensive pyro-metallurgical treatment route. A variety of physical, mechanical and chemical processing methods are also being investigated. Alongside WMG and resource recovery specialist Axion Consulting - David Greenwood, Professor in Advanced Propulsion Systems at WMG comments: “Having Axion’s input has specifically changed our thinking about how to design automotive batteries Axion Consulting is part of the Axion Group that develops and operates innovative resource recovery and processing solutions for recycling waste materials. For more information, contact Axion Consulting, Bramhall, Greater Manchester Tel: 0161 426 7731 E-mail: info@axionconsulting.co.uk or visit Web: www.axionconsulting.co.uk.

NEW ESAB GROUP CHORLEY FACILITY REINFORCES CUSTOMER SERVICE ESAB Group, the global leader in welding equipment and consumables, has opened a new facility in Chorley, Lancashire to further strengthen the company’s already outstanding customer service and support its extensive range of brands. It houses a showroom and demonstration/training area, as well as a servicing/repair workshop, plus offices for customer services, administration and meetings. It also features technical support for all the brands as well as a range of demo sets, including cutting equipment. The building offers distributor and customer staff training, including City & Guilds Gas Equipment certification and gives ESAB a better base from which to serve customers throughout the UK, Ireland, France, Belgium and the Netherlands. It also provides ESAB with a second UK site, which greatly benefits customers in the North of England. As well as ESAB and Victor Technologies, the new facility is home to all the other brands under the ESAB umbrella, brands including TurboTorch, Thermal Dynamics, Tweco, Arcair and Stoody. For more information contact ESAB Publicity on Tel: 0800 3893152 or e-mail info@esab.co.uk.

LIMIT RISK AND ENHANCE BALANCE TESTING EASE WITH NEW WHITE PAPER Upgrade balance testing security and compliance with WeightLinkTM. This innovative tracking system assigns unique, scannable identifiers to each weight. Learn how quick weight identification and automated data gathering enhance balance testing by downloading our free white paper as part of METTLER TOLEDO’s 2016 e-calendar. Adjustment and testing of lab balances can be an arduous task. Difficulties are found not only the execution of procedures, but also in the possibility of misreading numbers when choosing and using weights. Because of this, operators have historically had to ask: •Was the correct weight used? •Was the serial number logged correctly? •Were the weights mixed up after their last use? •Was the calibration date and serial number accurately recorded? WeightLinkTM eliminates this extra effort—along with its inherent error potential—by assigning a unique 2D matrix code to each validated test weight. This code is easily scanned, resulting in automated transfer of balance configuration and weight-specific data. Manual transcription is eliminated completely, and if an incorrect weight is chosen, the test cannot continue. Labs regain the ability to use a single weight set across multiple balances without risk of mix-ups for enhanced process security. The new white paper, “Maximum Traceability in Balance Testing”, details the ins and outs of using WeightLinkTM to help determine if this robust technology can assist with testing in the lab. It will be of interest to anyone responsible for testing and maintenance of weighing equipment, particularly in industries where strict regulations prevail. To learn more, download “Maximum Traceability in Balance Testing” and see how organizations can reduce testing time and enhance production efforts with WeightLinkTM technology. Future installments of METTLER TOLEDO’s 2016 eCalendar will help users further refine lab processes for enhanced time savings, so keep watching for additional information. For more information contact METTLER TOLEDO AG, Im Langacher 44, 8606 Greifensee, Switzerland Tel.: +41 44 944 20 39

TECHNOTRANS VERDICT: “STUNNINGLY GOOD” ENGINEERING DESIGN SHOW

technotrans, a specialist in bespoke cooling solutions, had a “stunningly good” show according to new business development manager Stuart Packer. “We have very strong leads to follow up on in battery cooling, server cooling, inverter cooling and hydraulic cooling. There were visitors to our stand asking for temperature control solutions in medical, laser, digital screen marketing, transport, plastic injection moulding and domestic applications.” This year technotrans also acquired a 98% stake in gwk (Gesellschaft Wärme Käletechnik. This euro 45m turnover business employs 380 staff and has customers in the plastics processing industry, plastic machine manufacturers, plant engineering companies and also companies from the automotive, packaging, chemical and food industries. technotrans, which has UK offices in Colchester, has applied its temperature control know how in projects as diverse as airport security to treatment of sports injuries and trucks to measurement control devices. At the Engineering Design Show we have started talks with designers in a raft of new sectors. More information about the company and its products at www.technotrans.com

PROCESS INDUSTRY INFORMER November 2016

NEWS & EVENTS WIN A NEW DATA LOGGER! We all know that the monitoring of temperaturesensitive products is vital. So Process Industry Informer has joined UK monitoring experts The IMC Group to bring readers a new logger that combines simplicity with preprogrammed alerts – and records data for 55 days. The new IMC Biomed Xpress features a 0.5°C accuracy over the operating range of -20°C to 60°C. It’s simple to use – it’s a small, flat, waterproof recorder that uniquely plugs directly into a USB port. Fully independent operation eliminates readers and software, which makes Biomed Xpress great for monitoring exports/imports and worldwide shipments. Along with PDF file generation, Biomed Xpress includes an embedded NIST certificate of accuracy and a CSV file which displays time and temperature in 5 minute increments. To enter the competition simply send an email to tonym@ fridays-group.co.uk with subject line ‘PII Competition’ and give us your answer to this question: What is the operating range of the Biomed Xpress? And for more information on this and other IMC products go to goo.gl/zXL6f7

HANSFORD SENSORS CELEBRATES 10 YEARS AT THE FOREFRONT OF VIBRATION MONITORING EXCELLENCE Hansford Sensors, the leading UK manufacturer of industrial accelerometers, is celebrating its 10th anniversary this month. Since its formation in 2006, the Buckinghamshire based company has gone from strength to strength, establishing itself as the go-to provider of reliable and effective vibration monitoring equipment and boasting an impressive portfolio of clients worldwide. In the last two years alone Hansford Sensors’ turnover has seen an increase of 20% and the number of employees at the company has grown by 12% in the previous 12 months. This growth has been achieved through working closely with key strategic partners and expanding into new sales networks worldwide. The company opened an office in Germany last year to enable greater access to the Central European market and recently began trading directly in the American market through a new office in Texas. Chris Hansford, founder and Managing Director of Hansford Sensors would like to take this opportunity to collectively thank our distributors, partners, customers and staff for the success that Hansford Sensors has achieved in the last 10 years. To learn more about Hansford Sensors, please visit Web: www.hansfordsensors.com

BPE CELEBRATES EXPANSION WITH SECOND UK OFFICE

Pictured l to r:(back row) Paul Treloar (Business Support Manager for the Scientific and Innovation Campus at Daresbury), Simon Wheeler (Business Development Director at BPE), Noel Quigley (Technology Director at BPE), Jon McGeehan (Regional Operations Manager at BPE) (front row) Keith Plumb (BPE Consultant), Mike Brown (Managing Director of BPE), Susan Smith (Head of Laboratory and Director of ASTeC at Daresbury Laboratories)

Leading chemical and biochemical engineering design firm BPE has opened the doors to a brand-new office in Cheshire, further cementing its growth in the market. BPE, headquartered in Hampshire, celebrated the official launch of its North West office at Daresbury Innovation Centre with a networking event for manufacturers and partners. Managing director Mike Brown said: “Our track record in helping manufacturers make their processes safer and more efficient has seen our expertise called upon by an increasing number of clients across the UK. The north in particular, with its thriving manufacturing sector and specialisms in pharmaceutical and chemical production, is a hotbed for innovation and we’re delighted to be here on the ground.” BPE has been helping manufacturers make their processes safer and more efficient since 1997. It offers a full range of process engineering services, including process modelling, process safety, project management and process development/scale-up support. For more information contact BPE Design and Support Limited, Tel +44 (0)1962 717070 E-mail: enquiries@bpe-ds.com Web: www.bpe-ds.com

SYSTECH ILLINOIS LAUNCH NEWLY DESIGNED WEBSITE Systech Instruments (UK) and Illinois Instruments (USA), experts of gas analysis instruments havelaunched their redesigned website, www.systechillinois.com. The newly designed website is fully responsive on all devices – mobile, tablet and computer and showcases their extensive range, which includes: oxygen analysers and moisture analysers for the process industries; gas flushing of food and headspace gas analysers for the food and pharmaceutical industries; and oxygen permeation and water vapour permeation analysers for the packaging industries. Visitors to the website will find products and information easy to find with user-friendly advanced search functions. Resources such as product brochures, case studies and technology notes are accessible to download as pdf files or to read online and demonstration videos are available for key products. Customers and distributors will find useful support areas offering technical data and services.

For more information contact, Systech Instruments Ltd, Tel: +44 (0)1844 216838 Email: b.faulkner@systechillinois.com www.systechillinois.com

PROCESS INDUSTRY INFORMER November 2016

NEW SOLAS WEIGHING REGULATIONS COME INTO FULL FORCE

This month the new SOLAS (Safety Of Life At Sea) convention regulations come into full force requiring that exporters produce the Verified Gross Mass (VGM) of containers prior to loading them onto a vessel. The UK’s leading load cell and process weighing system manufacturer Applied Weighing International (AWI) has been working with exporters helping them prepare for the new regulations.

Rod Morgan, Sales Director, Applied Weighing International said: “It’s crucial that companies involved

in the supply chain choose the right weighing system to suit their product and packaging methods, and that the weighing equipment they use is accurate and reliable.” The new rules were imposed by the International Maritime Organisation (IMO) on 1 July 2016 however a three-month grace period has been in place to avoid supply chain disruption and port congestion. That grace period is now at an end and exporters of all goods will be expected to comply with the new regulations. Applied Weighing International manufactures all of its equipment here in the UK and its load cells carry a fiveyear warranty. Applied Weighing produces permanent and freestanding Weighing Platforms for specific purposes such as weighing pallets (U Platforms), hand push trucks, trolleys, bins and drums. These systems come with high-precision, weights &amp; measures approved, programmable Weight Controllers or indicators that monitor the weighing process, display weight data, output the data to IT systems for record purposes and print tickets for verification. Rod said: “Our platform scales come in a range of capacities, sizes and designs to suit any application however rigorous or hazardous the environment they work in. Our weight controllers and indicators are easy to use, and are able to work with trade approved applications.” The company also produces drum filling systems, high speed weighing systems, vessel and tank weighing systems, and telemetry devices. Applied Weighing is pooling its expertise with another member of the AW Group of companies, Vehicle Weighing Solutions Ltd (VWS), the UK market leader in vehicle on board weighing. Together the companies offer a one-stop weighing solution to meet every application and budget. For example, the APOLLO range of portable or fixed axle weighbridges and weigh pads, which read and store gross axle and individual wheel weights, offer a low cost and flexible solution for transport operators. If onboard weighing technology is required the VWS Load Weigh CAN system is OWL compliant and enables drivers to see the individual axle gross weight plus additional diagnostics on the display. Rod continued: “Whatever the product, method of packaging or method of transportation we have a weighing system that will suit each and every application. And in the unlikely event nothing fits the bill we will create a bespoke system for customers.” For more information about Applied Weighing International or Vehicle Weighing Solutions Ltd (VWS) Tel: 0118 946 1900 or email: awinfo@aw.co.uk

DRIVING EFFICIENCY IN PROCESS INDUSTRIES STEAM RISES ONCE AGAIN

To many, steam power reached its zenith in the 19th and 20th centuries – James Watt’s invention in 1781 of a patented steam engine set in motion the first “golden age” of steam. That epoch came to an end with the gradual processes of “dieselisation” and “electrification across industries – and it seemed like steam’s day was done. “Once they see the economic, efficiency, and environmental benefits, we’re confident more companies will look at how they can make the most of their waste steam, which they’ve been throwing away as waste heat for years”, Chris concluded. “There’s a huge amount of it out there that could be put to better use, heating homes and powering industry. It’s a real breakthrough in driving efficiency in a variety of industries and is only in its infancy – there’s still a great deal to come from steam.”

owever, that could all be about to change. A second golden age of steam beckons in the very same place that first made a breakthrough in its mainstream use: Scotland. The results could see businesses that manufacture a wide range of different products improve efficiency, cut their energy costs, and boost their sustainability credentials. In the town of East Kilbride, just outside of the country’s largest city and industrial hub of Glasgow, Heliex Power has solved a problem that baffled engineers for centuries: how to harness the power of “wet” steam. It can be surprising to learn that there’s a distinction to be made when it comes to steam – after all, it’s just vapour, and has driven turbines since the 1800s. But there’s a lot more to it than that… As a simple illustration, take a kettle. When it reaches boiling point, a small amount of almost-invisible, high temperature and pressure vapour escapes from the kettle – or “dry” steam as it’s known. This type of steam, superheated and generally more expensive to produce, has been used in turbines for years. The other kind of steam, perhaps unsurprisingly given the epithet “Wet”, on the other hand, hasn’t been used anywhere near as much. This is the type of steam you can see emanating from the kettle after it has boiled, full of water molecules that degrade machinery and make it impossible to use. “We’ve found a way around that”, said Chris Armitage, Chief Executive of Heliex Power. “We’ve developed a robust twin-screw system, our patented Steam Expander System, which will take wet steam without being eroded by water particles. It’s working in areas and conditions that were previously thought to be impossible.” The technology’s roots sit within the department of mechanical engineering at City University, London. Some of the institution’s top academics, Professors Ian Smith and Nikola Stosic, had been working on the problem for about 40 years, before coming up with the designs for the Steam Expander System. Their discovery was completely new, making the system a unique proposition for businesses looking to recover waste steam between 100°C and 200°C. “No one else has a product that can replicate what our system does”, explained Chris .“The crucial bit that makes it all happen is the screw expander, which has two rotors entwined with each other. The profile of the rotor is the important part, and the two rotors sit within a casing and are supported on bearings at each end. We expand the steam through that

A GLASS-IC EXAMPLE...

expander and, in doing so, the two rotors turn and we have an output at one end. We connect that to a generator to produce electricity.” The energy savings that could be made from using lost wet steam from industrial processes are huge. Estimates suggest that more than 40,000 gigawatt hours (GWh) of energy vanishes globally every year through waste steam. Other analyses found that up to 50% of industrial energy usage is eventually released as waste heat – enough to power 28 billion homes. As the numbers indicate, the potential is huge. Heliex estimates that the potential market for its system is in excess of £70 billion and research from a possible partner in China suggests that a million of its systems are required in that country alone. The wet steam technology transcends sectors too, with relevance to process industries ranging from chemical manufacturing and dairy processing, to areas such as waste incineration, farming and timber. “Essentially, added Chris, the technology can be used in any process that uses steam directly or uses a steam system as a heating medium. Its wide range of potential applications and the sheer amount of steam produced by all of these industries means the technology’s potential is vast”. “When we first ran numbers for market analysis, they were so huge we had trouble believing them. There are so many businesses out there that could benefit from this technology, but the majority don’t know it exists yet.” Adoption of the technology is picking up, with more than 40 units in the field, clocking up over 60,000 hours of operating time. After booking £900,000 in revenue in 2014/2015, Heliex grew sales to £2.7 million last year. The company expects to double this in 2016/2017, and do the same again during the following 12 months – which translates into a lot more of the systems in action.

Milan-based Vetrobalsamo produces more than 500,000 glass bottles every day, putting sustainability first by reducing fume emissions by 70% compared with other traditional glassworks. The company needed to produce, not only electricity for its factory, but heat energy for the districting heating grid, using energy from the process flue gasses in two furnaces. While a number of technologies were considered, a Steam Expander System was chosen as the best way of supplying both the electricity for the plant and the correct temperature of heat for the district heating scheme. The system uses steam produced by a dedicated heat recovery steam generator, working at pressure of 20 Bara °C. One of the first systems to be installed, it generates 400 kW of electricity from the glass-making plant, with the residual 4MW of free heat supplied to local residents. Thanks to high efficiency and energy-saving incentives, the complete system allows the company to save more than €1 million per year.

AND A SPECIALITY FOR CHEMICALS... One speciality chemicals company with a commitment to sustainable development is taking advantage of its waste steam, a significant amount of which is created in its manufacturing process. The business decided to investigate how it could exploit the wasted energy in its steam. With its steam raised at 18 Bara and then dropped to 3.3 Bara for its manufacturing processes, the company decided to install two Heliex systems to sit alongside the pressure reduction valve in the existing steam distribution system. This combination offers the business additional operational flexibility, while retaining the ability to generate considerable power during periods where one of the machines is under maintenance. The economic benefits have been significant, delivering savings of £122,150 per year and payback in just under three years, while 348.1 tonnes of carbon have also been saved.

PROCESS INDUSTRY INFORMER November 2016

APPLICATIONS NEW M16 DRAG MEASUREMENT SYSTEM FROM HUUB LTD USES HBM LOAD CELLS TO STAY AHEAD OF THE COMPETITION

ATRATO FLOWMETER CHOSEN FOR MAJOR PERUVIAN MINING PROJECT

As part of its continued research into demonstrating the effect of drag on different suits for world class swimmers, Huub Ltd. has developed an in water system which allows quantified gains from wetsuit use to be measured and evidenced, giving amateur and professional athletes alike the edge over other competitors. Formed in 2011, Huub Ltd – a triathlon wetsuit design and manufacturing specialist – strives to create better products through a combination of research, science and reality. With a wealth of experience gained in the field of endurance sports, spanning over four decades, Huub understand the specialist technical and scientific fields associated with triathlon, including hydrodynamics and swim stroke analysis. Winner of multiple prestigious awards, Huub have a burgeoning reputation for quality and innovative effective products, which can only be truly brought to fruition through research. And with much wetsuit promotional material literature littered with references to technology that adds performance, with no quantified evidence provided, this is where Huub dived straight in and rose to the challenge! THE CHALLENGE As swimming performance is measured to the nearest 0.01 second, with swimmers in the top 15 separated by only 0.10 seconds, athletes continue to look at factors or legal aids which could improve performance in the water and swimming suits that reduce drag are a prime example of such aids. Although it is now a well known fact that swimming suits can be effective in enhancing performance, it now appears that one specific suit does not have an equal effect on every swimmer. In response to this problem, Huub knew it had to develop a system to undertake individual testing. However, this presented a challenge for Huub, as unlike other activities on land, such as running, the swimmer does not use a fixed point to generate propulsion. MEETING THE NEED In order to address this issue, Huub took the decision to develop an advanced underwater application which could be used to measure the swimmer’s propelling force on a push-off pad. By developing a series of fixed push-off points and attaching them to an adjustable rod which is mounted 0.8 m below the water’s surface, the swimmer is able to use the system as a ladder, pushing off from each instrument push-off pad. When it comes to cell technology, it is a well known fact that too much mass between applied force and point of measurement can have a mass-spring system with low ‘Eigen’ frequency, but if you apply the load sensor at the point where forces are applied, the captured signal is of much better quality. Taking this information into consideration, Huub decided it needed a single point loadcell which only registered the applied force irrespective of the point of application and this is why it specified the PW15iA waterproof load cell from HBM, market leader in the field of test and measurement. The innovative PW15iA digital single point load cell in accuracy class C3 is made of stainless steel and is hermetically welded. Designed to achieve a degree of IP68/IP69K protection and featuring digital inputs and outputs, the new PW15iA load cell provides guaranteed protection against water and is the ideal choice for underwater sporting applications such as the M16. “As a company with an investment in testing, it was important that we choose the best equipment available for the M16 system and this is why we turned to HBM” explains Dean Jackson, Huub Ltd Founder and CEO. “In addition to delivering an exceptional product that met the demands of the task, HBM has also delivered the back up and support to match, working with us every step of the way to ensure we have the world’s greatest piece of swim testing equipment”. THE SYSTEM If the swimmer ‘swims at constant speed the average drag will equal the average propulsion. Thus the M16 system approach relies on a balance of resistive and propulsion forces. Propulsive forces of the leg action cannot be measured using this approach, so the legs are tied together with a rubber strap and supported by a pull buoy to keep the body in a horizontal position similar to that during actual swimming. The swimmer swims a series of laps on the system whereby each lap is swum at a constant speed. Each lap results in one speed drag data point. For a range of lap-speeds, drag is measured and the relation between speed and drag is calculated. The result of this being that the push-off forces from the hands from each stroke can then be subsequently measured. CONCLUSION Peak performance in swimming can often take years of training, both in competitive pool swimming and the swimming leg of the triathlon. A highly competitive sport, the difference between success and failure may only be a fraction of a second but the consequences can mean the difference between silver and gold for the athlete. With testing performed under such tough conditions, the ability to achieve accurate test results from the M16 application were a challenging prospect but thanks to HBM’s extensive experience in demanding fields such as this, it was able to provide an integrated solution which enabled Huub to achieve exceptional results which were both accurate and simple. For further information on the PW15iA and HBM’s extensive range of digital load cells, contact HBM on Tel:+44 (0) 20 8515 6000 or via email: info@uk.hbm.co.uk or visit the HBM website at www.hbm.com

Titan Enterprises reports that JLC International Inc*, its agent for North & South America, has recently shipped thirty-nine Atrato ultrasonic flowmeters to Dynaflux S.A**, an engineering company located in the Lima District of Peru. Working collaboratively on a complex project with Minas Buenaventura, Peru’s largest publicly-traded precious metals company, the team sought a flowmeter that offered excellent accuracy and repeatability at low flow rates. The Atrato line of ultrasonic flowmeters consists of four meters operating over the flow range two millilitres / minute up to twenty litres / minute. The Atrato flowmeters were selected to enable accurate and reliable dosing of expensive mining reagents in the flotation stage of a mineral extraction process. In the past, Dynaflux S.A. had used the Atrato ultrasonic flowmeter in other smaller installations with excellent results.

This positive experience led to the installation of thirty-nine units for this larger project. The rugged, clean bore construction of the Atrato ultrasonic flowmeter makes it the perfect choice for a whole range of low flow applications. Taking advantage of proprietary embedded signal processing software developed by Titan Enterprises both viscous and non-viscous liquids can be routinely measured precisely. The low flows that the Atrato flowmeter is capable of measuring vary from laminar to turbulent, and are highly immune from viscosity. With unparalleled turndown, repeatability, and linearity, the Atrato can monitor flow over a range of 250:1. Using the Atrato USB port, users can simply directly connect their laptop PC to the flowmeter and monitor the rate and total flow while also being able to alter a selection of operating parameters. For further information on the Atrato flowmeter please visit www.flowmeters.co.uk or contact Titan Enterprises on Tel: +44-1935-812790 Email: sales@flowmeters.co.uk.

PROCESS INDUSTRY INFORMER November 2016

APPLICATIONS A REFRESHING APPROACH TO PARTS SUPPLY An internationally-renowned soft drinks brand has reached a harmonious balance of production efficiency, high quality and CSR targets through a close partnership with a strategic supplier of industrial maintenance, repair and overhaul (MRO) products. Coca-Cola European Partners’ (CCEP) plant is the largest soft drinks plant by volume in Europe. In a complex the size of 15 football pitches, three of the seven manufacturing lines produce 6000 cans per minute, while its two pre-form injection lines can produce up to 450 million PET bottles per year – all adding up to 100 million cases a year. With such a vast plant to maintain and a production schedule planned down to the second, CCEP partnered with Brammer, a leading Europe-wide distributor of industrial MRO products to manage the supply of its MRO spare parts to its manufacturing operations including its Wakefield site. Working with CCEP since 2009, the partnership has since evolved and is now based on a core concept of best practice in MRO procurement – vendor managed inventory. To achieve this, Brammer implemented its Insite™ service – effectively a dedicated branch housed within the Wakefield plant, achieving cost savings of more than 11% to date. Trevor Newman, Operations Director at CCEP Wakefield, explained: “The Insite™ team has undoubtedly been successful in reducing procurement costs and ensuring we at CCEP benefit from excellent inventory availability. But where Insite™ has added the greatest value for us is through the closely collaborative relationship we share, which enables the team to get out and about around the plant, proactively identifying potential projects to improve production efficiency and reduce costs.” For further information please visit www.brammer.co.uk/insite

PROCESS INDUSTRY INFORMER November 2016

HYGIENIC LOBE PUMPS HELP TO SMOOTH THE SUN CREAM PROCESS Malibu Health Products is a private manufacturer of sun care and related products. Inoxpa SLR 2-50 sanitary lobe pumps constructed in hygienic 316L stainless steel were supplied by Michael Smith Engineers, replacing the flexible impeller pumps. These pumps are designed to handle even the most viscous fluids, such as the sun creams. Inoxpa Sanitary Lobe pumps, supplied by pumping specialists MICHAEL SMITHENGINEERS, have contributed towards improving manufacturing processes, reducing maintenance and downtime. For these products to work effectively they must be free from contamination, so manufacturing processes must be as hygienic as possible. An important stage of the process requires the transfer of sun care creams and liquids from 1000 litre vessels, which was being handled by flexible impeller pumps. However, there were issues with the pump impellers wearing rapidly due to the viscous nature of the process fluids. The resulting pump failures led to plant downtime, unplanned maintenance costs and product contamination caused by rubber particles entering process liquids from worn impellers. Inoxpa SLR Rotary Lobe pumps are an ideal solution for pumping applications which involve liquids that are highly viscous such as creams, syrups and gels, or those containing solid particles. The positive displacement, sanitary construction meets the strict requirements for processing sensitive, hygienic end-products, making them safe and suitable for use in cosmetic, pharmaceutical, food processing and fine chemical industries. The lobe rotor design features large cavities between the lobes to ensure easy handling of viscous liquids with virtually no shear onto the product. No parts can wear into the process liquid, so the risks of product contamination are eliminated. Furthermore, low operating speeds enable smooth flows, reduced wear, more efficient operation which together, contribute toward longer pump life and reduced energy savings.

For more information contact Michael Smith Engineers Ltd, Woking, Surrey. Tel: FREEPHONE: 0800 316 7891 Email: Info@michael-smith-engineers.co.uk goo.gl/Rx1r6t

APPLICATIONS CHEMICAL GIANT CHOOSES NETHERLOCKS VALVE ACTUATOR FOR SITE IN EASTERN GERMANY Power Wrench now specified as global leader’s preferred solution for mechanical valve operation A well-known German chemical company has chosen the Power Wrench from Netherlocks to manage manual valve operation at its site in eastern Germany. Previously, the company’s operators had to contend with several valve-related challenges. They spent a disproportionate amount of time operating manual valves and were faced with incidental injuries due to the laborious and uncompromising work. Valves were becoming increasingly difficult to operate over time. Product build-up inside valves impeded their operation towards the end-stop. As some valves were only rarely operated, corrosion sometimes caused them to become stuck. A few large valves needed a very high number of rotations, resulting in long operating times and high physical strain on the operators. Others were located in hard-to-reach positions, forcing operators to adopt unnatural postures, which led to back injuries and a higher chance of crushed fingers. The company decided to search for a single mechanical tool to help its operators with heavy valve operation. The appropriate tool needed to satisfy three specific requirements: •the tool had to be applicable to various process areas, including hazardous (potentially-explosive) areas; •the tool had to be driven by compressed gas cylinders; •the torque of the tool had to be controllable. After several tools had been evaluated and tested, the Power Wrench was chosen as the best option. The Power Wrench is now specified as the global leader’s preferred solution for mechanical support for heavy valve operations, and is also recommended to the company’s locations worldwide. For more information contact Netherlocks Safety Systems BV, 2408 Alphen aan den Rijn, The Netherlands Tel: +31 (0)172 427 851, Fax: +31 (0)172 491 342 E-mail: rbarendregt@netherlocks.com Web: www.netherlocks.com

DEMAG CRANE SYSTEM FOR PACKAGING BOARD MANUFACTURER • Multi-functional material handling system • Maximum crane availability for increased productivity • Application focused features to meet the manufacturing processes Terex Material handling has installed a Demag double girder overhead travelling process crane at Iggesund Paperboard (Workington) Ltd’s production facility in Cumbria. Part of the Swedish Holmen Group, Iggesund manufactures high quality folding box board products, which are used for the premium packaging and graphics markets. The crane installation was part of an investment in new and upgraded board production facilities, to increase output by 20,000 tonnes per year. The crane was required due to the increased size and weight of the rolls in the new equipment. The Iggesund production line operates 24 hours a day for 365 days per year, with a reel of board coming off the production line every 30 minutes, meaning that maximum availability and reliability of the material handling system is fundamental to the efficiency of the plant. To meet the specific requirements of Iggesund’s production processes, Demag engineers designed a complex reel handing crane, with a range of application focused features. The Demag crane is capable of travelling along the full 257 m of the paperboard production line and is operated by radio remote control or mobile pendant. Iggesund’s Projects Engineer, Michael Brew, stated: “Demag’s engineers appreciated the specific requirements of our production processes and came up with a multi-functional material handling system, designed to provide maximum operational availability. In the face of stiff competition, they have delivered the best engineered solution for our processes, with a range of innovative features, which have helped us increase efficiency and productivity.“ For more information contact Demag Cranes & Components Ltd, Tel: 01295 676100 Email: bnb-help@terex.com Web: www.demagcranes.co.uk

BABCOCK WANSON HEATERS IMPROVE EFFICIENCY IN DAIRY NUTRITION PROCESSING

Babcock Wanson has supplied two new EPC ES series Thermal Fluid Heating systems to Volac, one of Europe’s fastest growing international dairy nutrition businesses. Established in the 1970s, Volac now has four UK and two overseas production sites producing products for the human and animal nutrition markets. Its dairy processing site at Felinfach, West Wales was acquired in 1989 and since then has benefited from significant investment. More recently this has included new process heating systems, heaters and associated pipework in a purpose built housing. Volac already had a small Babcock Wanson Thermal Fluid Heater in place, used to heat air to a high temperature in order to quickly dry liquid whey and turn it into powder. The company’s positive experience of both the heater type and Babcock Wanson led them to turn to the company when the decision was made to replace a large 5MW plus heater that had been in operation for many years. The heater was burning costly heavy fuel oil and was not particularly efficient. To greatly improve energy efficiency, reduce the overall fuel bill and limit emissions, Babcock Wanson supplied Volac with two high efficiency EPC2500ES automatic coil type, multipass Thermal Fluid Heaters, which offer a high efficiency solution to a very energy intensive process. . Elgan Jones, Chief Engineer at Volac, comments on the choice of Babcock Wanson Thermal Fluid Heaters: “As we heat the air temperature to 210°C, thermal fluid systems are more suitable as they are more efficient and easier to operate. If we used steam the pressure would be very high. The Thermal Fluid System is a closed loop, plus we have swapped to running on gas with an economiser which makes for greater efficiency.” For more information, please contact Babcock Wanson on Tel: 020 8953 7111 or Email: info@babcock-wanson.co.uk or go to Web: www.babcock-wanson.co.uk

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TAKE IT SLOW Variable speed drives offer enormous advantages when applied to compressors in a variety of applications. But only if they are sized properly and specified appropriately, warns Mark Whitmore, General Manager at BOGE.

hey are called many things – variable speed drives (VSDs), inverters, adjustable speed drives, variable frequency drives, the list goes on. But, however you couch your terms, VSDs are often touted as the panacea that will inevitably boost motor efficiency and cut energy efficiency in a range of applications. This is a myth; indeed, it is entirely possible for VSDs actually to reduce system performance by introducing harmonics into the system that can cause additional heating of the motor and which, in turn, will introduce power losses. According to some estimates, a VSD run at fixed speed suffers inherent losses of around 3 to 5%. However, if they are specified well, nine times out of ten VSDs can make a huge positive difference to system performance, saving energy and cutting other operational costs by controlling the speed of motors. There is a useful analogy here that helps explain what it’s like when a fixed speed compressor is used where a VSD version would be more appropriate. Imagine you are driving an automatic car with the accelerator pedal perpetually to the floor and controlling the speed using just the brake. As well as wasting an awful lot of fuel, you would also cause a great deal of wear on the brake pads and place enormous strain on the engine. Before VSDs were invented that is effectively how motors in compressors, fans and pumps were run. While the efficiency of your car’s engine is not intrinsically improved by the presence of the accelerator, having one – and using it appropriately – enables you to boost your miles per gallon, reduce wear and tear, and experience a better ride than you would by relying on the brake alone. Why? Because an accelerator pedal enables the driver to control the speed of the car and match it to his or her precise needs at any given moment, or depending on road conditions. So VSDs align power input and energy demand to the load variances of the specific application. One application in which

their use is growing is in the control of compressors. VSDs allow air compressors to deliver precisely what is needed for the application at the right pressure while, at the same time, compensating for line losses and coping with the variability of demand. Indeed, a VSD-controlled air compressor uses an AC drive to control the speed of the unit, typically saving energy compared to a fixed-speed equivalent. Craig van Wyk, founder of South African environmental consultancy, VWG Consulting, has pointed out that the most common control philosophy employed with screw compressors is the ‘load-unload’ control scheme. He explains: “In this scheme, the compressor motor runs continuously, but may be loaded (producing air) or unloaded, depending on the discharge pressure. While an unloaded screw compressor does not produce compressed air, the problem is that it still consumes a significant amount of power – in my experience, often 30% of the power required when on load. “Running a screw compressor unloaded for extended periods of time is therefore inefficient, since energy is being consumed with no benefit in terms of compressed air production.” A VSD compressor modulates the speed of the screws, and hence the flow of air, but this only occurs when the demand for air fluctuates to levels below the capacity of the compressor. Mr van Wyk again: “The machine therefore spends most of the time producing air (it can also go off-load or even be switched off at very low air demand levels), but using less energy than would have been used with a load-unload control scheme. The flow of air and the power required are proportional to the speed of the compressor motor.” The Carbon Trust makes the point that, when more than one compressor is used on a single system, giving one compressor a variable speed drive allows the other fixed speed compressor(s) to run at optimum efficiency on base load with the VSD compressor varying its output so the compressor installation accurately matches actual demand. It says you can estimate the load on a compressor in two ways: first, by:

• timing the on-load and off-load periods – you can usually hear the change between the two states. It is not possible to determine the load with modulating control by this method so these compressors may need switching to on/ off load to determine the average load. • asking a compressed air equipment supplier or independent firm to install monitoring equipment on the system. This will measure energy consumption and variations in airflow and pressure. Compressors can be big energy users – 10 to 12% of all power generated in the UK is dedicated to the production of compressed air. Anything that can be done to reduce this energy burden is to be welcomed and – provided they are specified appropriately – VSDs can go a long way to reducing this. Single-speed compressors make sense when:

• Running at 100% capacity for fixed periods and then

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turned off when no longer required Variable speed drive compressors make sense when: • There are variable capacity demands Advantages of well-specified VSDs include:

• Less mechanical stress on the motor and therefore reduced maintenance and repair costs, and better equipment uptime • Greater control so the operator can modify the response to specific application demands and enjoy better process control, and therefore higher productivity and quality • An ability to start/stop under full system pressure without the need to unload, saving time • Big energy savings (between 5 and 35%) at less than full capacity where there are varying loads • Reduced system leakage because of the lower system pressure • Providing ‘soft starting’, thus eliminating high inrush current

VSDs IN ACTION Two real-world examples of variable speed drive (VSD) compressor installations highlight the benefits of this technology when it is applied well. First, take the example of a plastics and extrusion blow moulding company in Merseyside, which introduced VSD technology and achieved savings as a result. The existing compressed air infrastructure comprised three systems using 12 compressors with a total capacity of 975hp, or 727kW. The system was inefficient and therefore offered the company an opportunity to save energy, reduce the carbon footprint and prepare for future expansion by replacing these existing systems. The new system uses a fixed speed compressor to deliver the company’s base-load air requirements, combined with a VSD compressor that provides additional capacity to match air output precisely with demand. The two units are controlled by a master compressor control system, which senses demand patterns to deliver the required air using the most efficient combination of compressors. Following the implementation of this new system, the potential energy savings were calculated to be more than £74,000 a year, while air capacity increased by 35%. Reducing the number of compressors from 12 to two also resulted in a £7,000 reduction in annual maintenance costs. In a second example, a UK-based flooring company was able to cut its energy bills following the installation of an 11kW variable speed compressor. The unit replaced an old 18.5kW machine, one of two at the site. Just by employing a smaller variable speed compressor, the company is saving around £2,500 annually in energy costs alone. The frequency-controlled compressor automatically adjusts to the air demand while controlling the pressure perfectly. The air end operates at the necessary speed to generate as much compressed air as is required, which means expensive idling as well as load/no load cycles are eliminated.

HEALTH & SAFETY EXTRACTED KEY ADAPTOR FROM FORTRESS PREVENTS INADVERTENT MACHINERY STARTUP

To prevent the inadvertent startup of dangerous machinery, Fortress Interlocks has developed an extracted key adaptor for use with its robust amGardpro, amGardS40 (IP69K) and mGard interlock ranges. By forcing an operator to extract the safety key when operating an interlock, the adaptor ensures the key cannot be turned and left in place, inadvertently re-starting machinery. It is designed to be kept with the operator, ensuring any access points cannot be closed and re-started while working in a hazardous area. Additional safety keys can be released following the forced extraction of the initial key, allowing the protection of multiple users at the same time. The extracted key adaptor utilises the ‘CL lock’, which has over 200,000 unique combinations, meaning it works with even the largest systems. It is also available with a padlockable dust cover to be compatible with standard lockout procedures. For more information contact Fortress Interlocks Ltd, 2 Inverclyde Drive, Wolverhampton Tel: +44 (0)1902 349000, E-mail: sales@fortressinterlocks.com Web: www.fortressinterlocks.com

OCEAN OPTICS EXPANDS PRODUCT PORTFOLIO PIXEL TEQ multispectral i m a g i n g technology now available exclusively from Ocean Optics Ocean Optics, the industry leader in modular spectroscopy applications and products, has consolidated the innovative multispectral sensing and imaging offerings of PIXELTEQ into the Ocean Optics product portfolio. The move further expands Ocean Optics’ spectral imaging design and manufacturing capabilities in support of researchers, developers and OEMs across a wide range of applications including biomedical, food and agriculture, and machine vision. PIXELTEQ technology combines patented microlithography expertise with state-of-the-art coating processes. This exclusive technology enables patterning of multiple dielectric, metal and colour filter arrays directly onto imaging sensors, creating highly compact and snapshot multispectral imaging cameras and systems. PIXELTEQ solutions enhance Ocean Optics’ existing line of modular spectroscopy products by offering new options for lab, field and industrial use. Product information and support for PIXELTEQ products are available at www.pixelteq.com or by phone at +1 727.216.7140. Information about the Ocean Optics range of spectrometers, sensors, optical fibres and other accessories can be found at www.oceanoptics.com.

MARTINDALE ELECTRIC EXPANDS RANGE OF LOCK-OUTS Martindale Electric continues to lead the way in safe isolation with the addition of new professional electrical locking off devices and kits for miniature circuit breakers and fuse holders. The new lockouts, provide simple and reliable solutions to ensure circuits have been de-energised and properly isolated prior to maintenance and modifications of plant and equipment, in accordance with HSG85, the Electricity at Work Regulations. The new LOKKIT6 includes everything needed to lock off and label Red Spot or similar fuse holders as part of a safe isolation procedure. The kit includes the LOK6 universal fuse carrier lock off, a TAG4 warning tag and marker pen, plus a PAD10R padlock. The LOK6 is designed to restrict finger access to live contacts and prevent the reinsertion of a fuse whilst maintenance is in progress. It’s easily adjustable to fit fuse holders from 20A to 100A, providing a ‘’one size fits all solution’’ that’s always to hand. Martindale has also extended its range of circuit breaker locking off devices. In addition to the comprehensive LOKKIT1 which includes 7 different locking off devices suitable for use on most MCBs, fuse carriers and main switches, Martindale have introduced the extra slim-line LOK7 for those specialist applications where space is really limited and conventional locking off devices won’t fit. The new design solves the problem of locking off RCBOs with a prominent test button and applications where access to the breaker has been restricted to prevent accidental disconnection. The LOK7 can be used with the full range of Martindale padlocks and hazard warning tags for safe isolation. Locking off the circuit correctly is just one part of the procedure. Before carrying out any work on the circuit, it’s essential to verify that the circuit is definitely dead before proceeding. This requires a dedicated voltage indicator and a proving unit. To simplify the whole safe isolation process, Martindale Electric has released a safe isolation video and VIPDLOK kits which include everything needed to implement an effective procedure, stay safe and ensure compliance with the Electricity at Work Regulations. For more information, please contact Martindale Electric on Tel: 01923 441717 Or visit www.martindale-electric.co.uk

SHINING A LIGHT ON EMERGING PATHOGENS atg UV Technology, the UK’s leading manufacturer of ultraviolet water disinfection systems, has developed a range of UV disinfection units to meet the needs of the food and beverage industry. Waterborne micro-organisms are responsible for adverse effects on flavour, colour, odour and shelf life of products and, of course, potential health risks to consumers. A number of emerging pathogens, like Cryptosporidium and Giardia are showing increased resistance to chlorine disinfection. As a result, the food and beverage industry is tightening its already stringent microbiological safety and quality standards for process water, product water and sugar solutions. UV irradiation has a long history in pharmaceutical and drinking water disinfection where it has been proven that 254nm UVC light, at the correct and consistent dosage inactivates the whole range of spoilage microorganisms – viruses, bacteria, moulds and protozoans – even chemically resistant ones including thermophilic bacteria which are resistant to pasteurisation. UV systems from atg UV Technology are entirely chemical-free, low maintenance and cost-effective and can be used in a range of process applications, from CIP rinsing to liquid sugar. Unlike alternative methods of disinfection, UV leaves no contaminating toxins or residues and there is no change to the chemical composition, colour, taste, odour or pH of the fluid being treated. The success of UV disinfection depends on ensuring that the applied dose is always sufficient to inactivate the target microorganisms. atg’s UV systems closely match the US EPA guidelines for equipment validation – the standard generally adopted for UV disinfection systems. And with continuous UV intensity monitoring as standard, you can be totally confidant that the UV dose is always being delivered. For further information contact atg UV Technology, Wigan, Lancs. Tel: +44 (0)1942 216161 or visit www.atguv.com for chemical-free disinfection systems.

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PROCESS INDUSTRIES & THE DIGITAL REVOLUTION The digitalisation of industry is helping change and shape the way things are being produced and consumed. The so-called fourth industrial revolution – Industry 4.0 – will help manufacturers enhance and improve productivity and enable flexible manufacturing where intelligence is shared both locally and internationally. With the process sector currently considered to be behind more progressive industries such as aerospace and automotive in the adoption of digital technology solutions, the sector needs to make a significant leap forward to unlock its true potential. Siemens brought together a number of specially invited participants – including representatives from industry trade bodies, government agencies, technology system integrators and process industry companies - to debate three key issues: technology, innovation and collaboration. They are some of the primary catalysts that will help shape the ‘digital process of the future’ and contribute to improvements in UK productivity performance. TECHNOLOGY The automotive sector was cited as a clear example where digital technology adoption is leading the way and against which process industries are lagging behind. Legacy technology is commonplace and the process sector is a long way from achieving the 7 to 8% productivity improvements witnessed each year in the automotive sector. Such performance excellence by vehicle manufacturers has been built on yearly programmes of continuous improvement addressing both cost and the supply chain value issues. The business potential inherent in digitisation is based on far better connectivity, data communication and intelligence. However, participants cited the practical difficulties of ‘getting communications working’ between disparate sites or locations and failure to address this is often a cultural issue. For others, difficulty in technology adoption came down to cost and having to adapt what is in place. A call for better access to smaller-scale trial systems to allow companies to innovate and test as part of attempts to commercialise ideas and production would be welcomed. The topic of non-physical production runs that use technology to model and test was cited as a potential way forward. An example of a pharma company in the USA using digital technology to simulate and carry out multiple experiments at the laboratory stage and share outcomes and learnings through a highly connected structure, is allowing its modelling to take place at a fraction of the cost of a physical lab. Such an approach relies upon the intelligent use of data, and there was general agreement that cyber security issues and vastly differing company culture approaches to the uptake of data continue to hold many back in this area. Making the case at board level for digital technology investment remains an ongoing challenge for many, despite the advantages it can deliver in terms of supporting innovation and productivity enhancements. It was also argued that supporting the uptake of digital technologies would require new and enhanced employee skill sets. Traditionally skilled process engineers need to build engineering skills now for a future digital environment, while operations departments will also need support to optimise their understanding of digital technologies that increasingly include industrial software, communications, cloud computing, intelligent sensors, simulation and data management. While an older generation of workers may require more urgent support in this area, the role of apprentices and young people offers hope. The increasing number of apprentices (thanks to Government support) and better enabled graduate entrants will

bring fresh blood into the industry that is more conversant with a digitised industrial environment. The case for shaping digital solutions is also highly dependent upon the user seeing the end benefit for themselves. Technology providers and system integrators have to help them on this journey of discovery and unearth and pin down project deliverables as proof points to assist end users in building the case for wide scale investment in digital technology adoption.

INNOVATION With UK gross research and development today standing at 1.72% of GDP versus an average of 2.06% across the EU - Germany’s level is 6% - innovation remains a key topic when it comes to improving UK manufacturing competitiveness. New technology innovation centres such as the High Value Manufacturing Catapults are making innovation more accessible to manufacturers, but some barriers remain. These include funding obstacles that can enable, for example, small scale modelling to take place before committing to significant levels of expenditure. The biotech sector was cited as

IN SUMMARY, THE KEY ASKS FROM ATTENDEES COVERED A NUMBER OF AREAS: •

• • • • • •

A call for better engagement across process industries and the need for a respected leadership figure who could inspire and help deliver a strategy to fully embrace the potential of digital technology solutions, without relying upon government to do so Lobby government to support and develop a cohesive Industrial Strategy Gain better transparency of what we already have from a process industry capability and use this to support and optimise our supply chains A focus on the digital skills needed by both an ageing workforce and new recruits to realise a true digital future Work to develop a clear argument articulating how digitisation can deliver value and commercial worth in the minds of end users Encourage government to devise and implement a cohesive industrial strategy and ensure it remains committed to its delivery Build a better brand image representing the true value and impact of the work of process industries in the minds of the consumer.

an industry looking to innovate but is hampered by the number of competing companies targeting the same funding channels. It was felt that Government needs to get fully behind a push for innovation and unlock the funding streams to allow small and medium-sized businesses to go to the next innovation stage. The issues of intellectual property and commercial sensitivity constraints are holding companies back from using the centres designed to support them from an innovation perspective. They are wary of sharing valuable information in a more collaborative setting and are therefore reluctant to engage. Leadership is required to see beyond the immediate constraints and develop a vision that places the value of innovation at the heart of the sector. Some positive examples were provided where organic links between local process companies and academia were producing good innovation practice, but agreement was clear that the need for strong political will and a robust industrial strategy to drive shared innovation is required to overcome some of the commercial barriers currently in place. The potential of digital technologies to deliver personalised medicines for the pharma sector, or a batch size of one at mass production prices, are ambitious goals that sound on the surface to be of value. However, some questioned the real value of a highly customised product or a batch size of one on a commercial basis.

COLLABORATION Manufacturing companies in a new digital world need to move much faster to adopt and develop technologies, requiring stronger collaboration between research and development and innovation networks through to commercial manufacturing. Trade bodies and higher education institutions were cited as strong examples where collaboration can thrive, while the example in the commercial world of a specialist biotech company now working with other specialist businesses to offer a more holistic market solution, also illuminated what is feasible on a collaborative basis notwithstanding commercial sensitivities. It was felt that huge efficiency gains would be possible through a more collaborative philosophy, for instance across the supply chain. With process industry products often hidden from general view (in pipes, or part of a larger manufacturing process), the reputational status and image of process industries was also raised. A call to promote the contribution the process sector makes to the everyday lives of the population would be helpful in many ways including proving momentum for the recruitment of new blood and fresh skills in the sector. Perhaps a more unified face to the sector and the joining together of currently disparate representative bodies that embrace chemicals, pharmaceutical’s and life sciences, could be a step in the right direction?

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MIXING LESS HANDLING, LESS CLEANING WITH FLEXIBLE VACUUM MIXING DISPERSION SYSTEM The ability to disperse and mix under vacuum is becoming commonplace as it’s often essential for performance and quality purposes to prepare products under closed conditions and that do not contain entrained air bubbles. A new Vacuum Dispersion and Mixing System which offers users’ outstanding flexibility, is now available from laboratory instrumentation specialists FULLBROOK SYSTEMS. The range of Dispermat CHS Vacuum Systems, manufactured by VMA-GETZMANN GmbH, is ideal for small batches and sample production where vacuum is required. Unlike other vacuum dispersers the DISPERMAT CHS vacuum system offers users exceptional versatility because it’s designed to accept single wall pails, buckets, non-standard and most importantly even users own containers. This means that materials can be processed without the need for dedicated vacuum containers, significantly reducing the time associated with handling and cleaning. Suitable containers can be secured in the vacuum system quickly and easily in just a few simple steps. Users place the container on the mobile system trolley then a top-mounted fixing ring is screwed into place which securely holds the container in place. The vacuum cylinder is then placed over the container whilst the assembled vacuum system is positioned underneath the powerful Dispermat AE pilot plant vacuum dissolver, ready for the dispersion process to begin. The dissolver disc is height adjustable even with the cover in place which allows the blade to be positioned at the perfect height to ensure that addition of powders can be made to the batch under optimum conditions. This allows for the ideal dispersion conditions to be achieved which are typically indicated by a slow, rolling product flow (“doughnut effect”). The complete process and the product under vacuum are able to be observed by the operator through a large viewing glass in the vacuum cover. To enhance viewing a powerful LED lamp can be added if required as an option. A vacuum can be pulled on the product at any stage, either during dispersion or at the end of the process. An optional wall scraper is available so that high-viscosity and thixotropic products can be dispersed easily. The high torque scraper system motor is mounted on the top of the vacuum cover and can be adjusted using the control panel. The solid scraper arm within the vacuum container effectively removes any product residue which is sticking on the container wall and folds it back into the dispersion process. For temperature sensitive applications, an optional PT100 probe enables operators to control temperature as required. At the end of the dispersion process the container is simply released and removed, the finished de-aerated and dispersed product is held in its own container, so no transfer to another container, which often adds air back in, or cleaning is required. The CHS system is then ready to accept the next batch. The Dispermat CHS30 (pictured) accepts 30 litre containers but is also available for container volumes up to 60 litres and also for other specific container sizes if required. An explosion-proof ATEX certified version is also available. Dispermat CHS vacuum dispersion and mixing systems are ideal for smaller batch applications across a wide range of industry sectors, such as; paints, varnishes, pigments, additives, printing inks, powder coatings, chemicals, plastics, or wherever efficient, flexible vacuum dispersion is required. Further details available from: Fullbrook Systems Ltd, Hemel Hempstead. Tel: +44 (0) 1442 876777 Email: sales@fullbrook.com Web: www.fullbrooksytems.com

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DIFFERENTIAL PRESSURE FLOW MEASUREMENT

A GUIDE TO MAKING THE RIGHT CHOICE

Although it is over 100 years since the first DP devices were used, they still form the largest installed base of all flow measurement loops, especially in the process and chemical, oil and gas sectors. Steve Gorvett, product manager for DP flow and temperature for ABB Measurement & Analytics in the UK, outlines the main options on offer and explains how developments in technology are steadily broadening the appeal of the meters into other sectors.

he origins of differential pressure measurement can be traced back to 1738, when Italian mathematician Daniel Bernoulli determined that the total energy (kinetic + pressure + potential) within a flowing fluid is constant. Some 60 years later, another Italian - Giovanni Battista Venturi - determined that a fluid flowing into a restriction gains kinetic energy or velocity at the expense of pressure and that some of the pressure is recovered when the fluid leaves the restriction. More than 270 years after Bernoulli developed his theory, flowmeters based on the differential pressure measurement principle continue to account for the majority of the global flowmeter market. In 2007, a survey carried out by flowresearch. com estimated that the global market for differential pressure devices is actually growing by around 6% per year, with a total value of over $1bn.

DIFFERENTIAL PRESSURE FLOWMETERS EXPLAINED To achieve a differential pressure measurement requires two key items of equipment. Firstly, a primary element is needed which creates a pressure drop. Essentially, this element creates a restriction or reduction in the flowline which causes a difference between the upstream and downstream pressures. This restriction can vary in shape, according to the type of element being used and the type of medium being measured. More about the different elements available is included later in this article. The difference in pressure is measured by a differential pressure transmitter, which can then be used to calculate the flow. Recent developments in transmitter technology have transformed the possibilities for differential pressure measurement. With the arrival of multivariable transmitters, for example, users can now measure not just differential pressure, but also static pressure and temperature, all within a single unit, giving them additional data that can be used to further enhance their process. A crucial factor in selecting differential pressure flowmeters is the issue of pressure drop. Although creating a local drop in pressure is an integral part of the measurement principle it is important to ensure that any permanent loss of pressure is minimised in order to maximise the energy of the flowstream. Certain types of differential pressure flowmeters are better than others at maximising this

recovery. For example, venturi flowmeters, with their much larger pressure recovery section, offer a much lower pressure drop than orifice plate flowmeters. One of the biggest benefits of differential pressure flowmeters is their inherent versatility. They can be used to measure the flow of gases, steam and liquid, giving them a wider field of applications than any other type of flow meter. This versatility, and the relative simplicity of the differential pressure principle, has led to DP flowmeters enjoying the largest market in terms of both sales and installed base. In particular, they are in widespread use throughout the oil and gas industry and are continuing to be installed apace as the demand for energy drives the construction of new oil and gas exploration facilities. Though the oil and gas market continues to represent a core area, new applications in new sectors are also being opened up by recent developments in differential pressure flowmeter technology.

CHOOSING THE RIGHT TYPE OF DIFFERENTIAL PRESSURE FLOWMETER Choosing the best type of flowmeter for any application requires careful consideration of a range of factors. Where differential pressure flowmeters are concerned, there are a range of sensors each of which have their own advantages and drawbacks for certain types of applications. The main types of differential pressure flowmeters are: • Orifice plate flowmeters • Pitot tubes • Venturi tubes • Flow nozzles • Wedge elements

ORIFICE PLATE FLOWMETERS Orifice plate flowmeters are the most commonly used of all DP devices. Their durability and lower purchase cost compared with other meter types mean they are widely used throughout industry. They are ideal for a wide range of high temperature, low velocity applications measuring clean, dirty or corrosive liquids, including viscous liquids, as well as vapours and gases. Orifice plate flowmeters typically comprise of flat metal disks with a precision hole drilled in the centre, the size and profile

of which depends on the application. The disks themselves are often held in place by a carrier assembly f i t t e d into the pipeline. Various types of orifice plate flowmeters are available, including concentric, eccentric and segmental, each with their own set of advantages for particular applications. One key drawback with conventional orifice plate flowmeters stems from the number of separate components required for an installation. A typical orifice plate flowmeter installation consists of the orifice plate, orifice flanges, an isolation valve, valve manifold, the DP transmitter, interconnecting tubing and couplings. When connected together, all of these present potential leak points which can affect the accuracy and reliability of the flowmeter, as well as leading to fugitive emissions of the liquid or gas being measured. They can also suffer from a slow speed of response, due to issues such as long or blocked impulse lines, or impaired signals due to condensation in gas system impulse lines or gas bubbles in liquid lines. These problems have been overcome with recent advances in orifice plate flowmeter technology. ABB’s OriMaster flowmeter, for example, features a single piece design combining all the major components needed for an orifice plate installation. This eliminates the need for users to source and install a separate manifold, transmitter and impulse piping, typically cutting the cost of installation and commissioning by up to 50%. The all-in- one design also solves the previous problems associated with impulse lines, leading to enhanced accuracy and a faster speed of response.

PITOT TUBES As a low cost, easily installable flowmeter with a low pressure drop, pitot tubes present the ideal solution for measurement of clean liquids, gases or steam. Although less accurate than orifice plate flowmeters, they can be readily installed in most locations,

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including square or rectangular pipe ducts. Pitot tubes measure flow by sensing the difference between the impact pressure of the flow and the static pressure. There are two main types of pitot tubes. Single port pitot tubes measure impact pressure, with the tube inserted into the flowstream with its sensing port facing the direction of flow. A second tube is then inserted to measure static pressure. The flowrate measured is proportional to the difference between the impact pressure and the static pressure. These devices are limited by their ability to only measure at the actual point of impact. In contrast, averaging pitot tubes feature multiple impact-sensing ports along their length, positioned at equal, calculated points, and include both an outer and inner impact tube. The inner tube provides secondary averaging of the various sensor holes, making averaging pitot tubes ideal for coping with the non-uniform flow profile conditions inherent in the short pipe runs found in most applications.

VENTURI FLOWMETERS As one of the oldest types of flowmeter, venturi tube flowmeters represent the workhorse of the flow measurement world for measurement of clean liquids and gases. Despite their maturity, they continue to enjoy market domination in the oil and gas industries in particular, where their solid performance, low pressure drop, reliability and durability make them ideal for the arduous demands characteristic of oil and gas applications. The general design of a venturi tube is simple. It consists of a parallel inlet section of the same diameter as the pipe, followed by a coned reduction (typically 21° included angle) and a parallel throat section. The outlet is also conical, but with a shallower angle (typically 15°) than the inlet. The outlet cone either finishes at the same diameter as the pipe (referred to as a classical venture – the most common design) or at a diameter smaller than that of the pipe (a truncated or short venturi). The high (i.e. upstream) pressure tapping is located just before the inlet cone and the low (downstream) pressure tapping is at the centre of the throat section. In recent years, the use of venturi meters has been extended into the field of sub-sea measurement and processing, where their attributes make them particularly suitable for the hostile environments found in such applications. They can also be designed for the high process and ambient pressures routinely found in sub-sea applications and are suitable for the multi- phase fluids found in production (oil + gas + water + sand). It is also relatively easy to integrate specialist sub-sea DP transmitters, cabling systems and manifolds with the Venturi assemblies.

WEDGE FLOWMETERS Featuring a v-shaped flow restriction, these types of flowmeter are particularly well-suited to measuring more demanding types of fluids, such as those with a high solids content, high viscosity or high levels of erosive/abrasive particles. They are also ideal for measuring air flows.

ACHIEVING OPTIMUM PERFORMANCE Choosing the appropriate DP flowmeter sensor is just one aspect. To optimise the installation, it’s important to consider a range of other factors as well. These include transmitter turndown. Traditionally, older transmitter technologies have measured to an accuracy of ±0.2% of the calibrated span. With advances in transmitter technology, this has now improved base accuracy to ±0.025% of the calibrated span. Another consideration is the minimisation of leak paths, both for improved health and safety and enhanced process efficiency. The answer here is to select a DP primary, such as the wedge, that can be fitted with remote diaphragm seals. Alternatively, users can opt for an all-welded design Featuring integrated welded manifolds, these types of devices reduce the leak paths associated with traditional manifolds. With the introduction of second generation multivariable pressure transmitters, it is possible to measure mass flow from any DP primary device. This technology can be applied retrospectively, making it ideal for existing installations where enhanced performance through measurement of mass flow is required.

AT A GLANCE The below table provides a quick guide to the various types of differential pressure flowmeters available and the types of applications where each can be applied:

FLOW NOZZLES Flow nozzles are essentially flow tubes with a smooth entry and sharp exit. Flow nozzle type flowmeters are most commonly used for high velocity flow measurement of non-viscous liquids or gases in applications where there is a risk of erosion or cavitation that would damage an orifice plate. Typical examples include flow testing on steam raising plant. With no sharp edge that could degrade over time and affect performance, flow nozzles offer excellent long-term accuracy. They also offer a relatively low pressure loss.

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SUMMARY The above information provides a basic guide to the various types of differential pressure flowmeters available and their general suitability for particular types of application. With decades of experience in the design and manufacture of a full range of flowmeter technologies for both industrial and utilities applications, ABB is well placed to advise you on the best solution for your requirements.

NETWORK & COMMUNICATIONS SWITCH-ON TO THE “SMART FACTORY” WITH HARTING’S HAN-MODULAR® SWITCH US4 HARTING today reaffirmed the recent UK launch of its Han-Modular ® Switch US4 connector as a strategic part of its Industry 4.0 portfolio. This connector is designed to save control cabinet space, reduce wiring and improve distributed networking, specifically in support of Industry 4.0 modernisation programmes. HARTING is one of the leaders in Industry 4.0 and enables technologies support the next generation of industrial production and factory automation. Howard Forryan, Product Market Specialist at HARTING Ltd, said; “One of the key Industry 4.0 principles is the ‘Smart Factory’ which is focused on enhanced interoperability and flexibility, cell modularisation, miniaturisation and increased decentralisation. However, many established manufacturers face barriers of physical space. This clever connector design helps save space by integrating multiple components and connections into a single unit.” To achieve this, HARTING has integrated a very compact but fully functioning ‘store and forwarding’ 4-port Ethernet active switch device into its market leading Han- Modular ® I/O mixed connector design concept. This means that network devices can be deployed closer to the field while reducing the effort of retrofitting when integrating new Ethernet modules. As a result, system integrators and production machinery OEMs can achieve simpler networking of typical cabinet control systems (including I/O´s, PLCs HMIs etc.), easier extension of an existing IP based image processing vision system and more straightforward distributed cabling for interlinked production cells. The Han-Modular ® Switch US4 module makes it possible to network 4 EtherNet/I or PROFINET nodes with transmission speeds of up to 1000 Mbit/s. Integrated LEDs provide quick and easy power and network diagnostics for individual ports, displaying both the presence of the Ethernet connection as well as ongoing data exchange and the associated speed. The module automatically detects the send/receive lines of connected devices, and automatically finds the correct setting for the lines (Auto MDI/MDIX function). In connection with the 10Base-T and 100Base-Tx interfaces, the module autonomously corrects polarity errors in wire pairs and reverses the polarity of data signals (Auto Polarity). It also allows two connected Ethernet nodes to AutoNegotiation and configure the maximum data transfer rate – up to 1000 Mbit/s incrementally – as well as the type of transmission, i.e. half-duplex or full duplex. Other features of the Han-Modular ® Switch US4 include: the option for prioritisation of data packets (Quality of Service function); integrated reverse polarity and overvoltage protection; high data throughput (Jumbo Frame Support), and power supply adapter (10-30V DC). Commenting on HARTING’s approach to introducing Industry 4.0, Howard Forryan concluded; “HARTING has provided another very effective option to support Industry 4.0. This connector supports the trend of integrating more intelligent hardware at the field connectivity level of machine modules within the production process. It does this by routing data through a Han-Modular ® Switch US4 module and combining it with the other Industry 4.0 main lifelines of power and signal in a single, compact, space-saving Han-Modular ® housing.” For more information contact HARTING Ltd, Northampton, Northamptonshire . Tel: +44 (0) 1604 827500 | Email: gb@harting.com |Web: www.harting.co.uk/han-modular

PROCESS INDUSTRY INFORMER November 2016

NEWS

NOVEMBER 2016

WE CELEBRATED OUR 75TH ANNIVERSARY IN SPECTACULAR STYLE...

his magical Dinner Dance, held on the evening of 6th October at the splendid Heythrop Park Resort in Oxfordshire, on the outskirts of the picturesque Cotswolds, was attended by 150 staff from the BPMA and member companies and their partners. Sponsored by Grundfos, Wilo and WEG, and supported by some of the leading companies associated with this important industry sector. The evening started with a Champagne Reception in the Grand Hall of the old Manor House, accompanied by live music. This was followed by the sumptuous Anniversary Dinner in the Enstone Suite after which there was cabaret from a group of brilliant previous members of the cast of Les Miserable. The evening continued late into the night with dancing to the excellent ‘The Swinging Little Big Band’ and the usual conversations and banter that always follows such a wonderful event.... BPMA Director and CEO, Steve Schofield, commented, “ We were delighted to acknowledge the past endeavours of the Association with a wonderful night of celebration and to herald the next 75 years of BPMA service to the industry. He added, “The evening was a joy to host and on behalf of the BPMA and all those in attendance, I would again thank our three sponsors for their kind and generous support. BPMA staff members have been overwhelmed by the reaction to the dinner, which without exception, and against the backdrop of ‘Brexit uncertainty’, has been extremely complementary.” Here is just a small sample of the feedback and comments: Peter Reynolds, BPMA President and Grundfos Managing Director -“The 75th Anniversary event wasa fantastic success and it was great to see so many people who are associated with the industry – both past and present – in attendance. It was a particular honour for me, as the current President of the BPMA, to be involved and we at Grundfos were pleased to play our role and help sponsor and support such an auspicious occasion.” Russell McCabe, Sales Manager, WEG UK - “On behalf of WEG and its guests, can I just say how much we enjoyed Thursday evening – superb hospitality and entertainment in a wonderful setting. We were honoured to be part of the BPMA’s 75th Anniversary celebrations.” Richard Harden, Managing Director, Wilo UK - “As a long-standing member of the BPMA, we were one of the first to support the idea of a celebration dinner to acknowledge its 75th year, and we were proud to have been involved. The venue, hospitality,

entertainment and overall organisation was excellent, all contributing to a truly great evening – and a fitting tribute to the BPMA.” David Hawley, Motors Generators Business Unit Manager, ABB -

“We were really pleased to be able to support the BPMA 75th Anniversary celebration by bringing along some of our key clients for what was a superb evening. Our colleagues and guests had a great time, catching up with many current and old contacts from within the pump industry. The whole evening, reception, dinner and particularly entertainment meant it was a really memorable evening.” Dale Croker, Managing Director, KSB Limited - “On behalf of KSB Limited and all our staff members who attended the Anniversary Dinner, a big thank you to the organisers and the sponsors for a superb evening which was thoroughly enjoyed by all of us. Great venue, great food, great entertainment and equally great company; what more could one ask for? The prestigious event was a fitting celebration of the BPMA’s milestone and one which KSB is proud to have been associated with. The hard work and valuable impact the BPMA continue to provide in the pump industry deserves to be celebrated in such a fashion. We’re looking forward to the next milestone!” David Rozee, Managing Director, Triark Pumps - “We had a great night at the BPMA 75th Anniversary Dinner and it was an honour and privilege for us to be dancing the night away (while doing business) with some of the industry’s top brass. Joining the BPMA this past year has already proved itself to be a positive move for us and we wish the BPMA every success while they move ever closer to their 100th year” Julijana Ristov, Business Manager, Siemens - “Thank you for organising such a wonderful event last week. It was our pleasure to support the BPMA and celebrate, together with our customers, suppliers and colleagues its milestone 75th Anniversary. We thoroughly enjoyed the evening – the food, entertainment and overall organisation were exceptional, making it a great networking event.” Alex Onslow, Technical Director, Flowserve SiHi - “A great night with great food &amp; entertainment, great company and a great achievement by the BPMA in reaching its 75th Anniversary. Having been around for three-quarters of a century helping engineers within our industry maximise their endeavours, let’s make sure they continue to do so for the next 75 years.”

CERTIFIED PUMP SYSTEM AUDITOR (4 DAY COURSE) NEXT DATE: 6 – 9 FEBRUARY 2017 Pumps consume 20% of global motive power – Pumping System improvements can deliver up to 40% reduction in energy costs. How can you achieve this? • SAVE MONEY • SAVE ENERGY GET CPSA TRAINED! CPSA (Certified Pump System Auditor Scheme) – the pump industry special professional qualification developed by BPMA and referenced in recent government energy strategy documents Designed to equip individuals with the skills needed to conduct a Pumping System Audit in accordance with the ISO 14414 Pump System Energy Assessment Standard Please note: The Energy Efficiency Directive mandates energy audits for large companies from December 2015*

Cost per delegate for this course . £1,750 Plus Vat for Non-BPMA Members . £1,500 Plus Vat for BPMA Members Price includes 3 nights accommodation (B & B) at The Rezidor Park Inn, West Bromwich Courses to be held at:- The Rezidor Park INN, West Bromwich B70 9RS For a Booking form contact Steve Smith on s.smith:bpma.org.uk

FREE SAFECHECK FROM CRONER FOR BPMA MEMBERS Croner, BPMA’s partner and supplier of employment law and health &amp; safety advisory support, are offering a free SafeCheck for the first 10 BPMA members to respond to this offer As a business owner there are a number of responsibilities and legal obligationthat you have to meet. A SafeCheck review can provide you with the peace of mind that you are compliant when it comes to keeping your employees safe in the workplace. Normally charged at £295 + vat, The SafeCheck Review provides organisations with a professional and independent evaluation of health and safety compliance. The SafeCheck Consultant carries out a tour of the premises reviewing work activities and safety arrangements providing pragmatic advice, at the time of the visit. The consultant then produces a comprehensive evaluation report, containing details of recommended solutions, in the form of a userfriendly Action Plan, which is presented and explained at a second appointment. To secure your free of charge SafeCheck, please contact s.smith@bpma.org.uk, giving your: • contact name, • company name, • nature of business, • site address for SafeCheck to be carried out, • telephone number • email address. Croner will then be in touch directly to make arrangements for a mutually convenient time for the SafeCheck to be carried out. Remember: This offer is available to the first 10 Respondents only

2017 PUMP INDUSTRY AWARDS - CALL FOR NOMINATIONS For the past sixteen years, the BPMA’s Pump Industry Awards Programme has been recognising the best performing companies, products and people for their achievements and positive contributions. In 2017, the BPMA will proudly lead the call again in championing those who strive for business, professional and engineering excellence. Eight awards are up for grabs at the 2017 event. • Technical Innovation of the Year – Products Projects • Environmental Contribution of the Year • Manufacturer of the Year • Distributor of the Year • Supplier of the Year • Engineer of the Year • Lifetime Achievement Award To make a nomination, visit www.pumpindustryawards.com The prestigious Awards Dinner and Presentation Ceremony will take place on Thursday 23rd March 2017, at the fantastic Crowne Plaza Hotel, Heythrop Park, Oxfordshire. Dating back to 1710 this quintessential English country estate seamlessly combines elegance with style, and is set in 440 acres of stunning Oxfordshire Countryside. Located just 12 miles from Oxford, its central location ensures easy access from all over the UK. Peter Reynolds, BPMA President, commented, “The competitive nature of the pump industry, and the constant search for greater operational performance and improved efficiencies across its myriad customer base, requires that all those operating within this important sector be at the top of their game. This awards programme allows the pump industry to come together in recognition of that drive for engineering excellence.” A full complement of Sponsors has once again been secured for this important industry event, with each one contributing to the overall success of the Awards Programme and Presentation Dinner. They include ABB, John Crane, Flowserve SIHI, KSB, Process Industry Informer, Siemens, SPP Pumps, Tomlinson Hall, WEG Electric Motors and World Pumps. As a new sponsor this year, Julijana Ristov, Business Manager at Siemens, commented, “Having attended the event in 2016, we were impressed with the event and the opportunity it provided to network with senior figures from across the pump industry. Siemens prides itself on providing manufacturing enterprises with the equipment required to increase productivity, efficiency and flexibility, and as such we are delighted to be sponsoring the award category, and play our part in recognising the business and engineering acumen of pump manufacturing companies.” Entries are sought for any company, product, application or individual within the pump industry that is worthy of recognition and reward. Nominations and entries are not restricted to BPMA membership, and you can put forward entries for yourself and your own company, or you can nominate others that you know of or work with. The Call for Nominations’ process is now open, with the ‘Online Entry’ Forms being available for completion until 5.00pm on Monday 5th December, providing ample time in which to submit an entry. So if you want industry-wide recognition for a job well done, be it for technical innovation or application know- how, for environmental consideration or distribution and supply, please make a note of this key date. FOR MORE INFORMATION, PLEASE VISIT THE WEBSITE - HTTP://PUMPINDUSTRYAWARDS.COM.

ECONOMIC VIEWPOINT – GLOBAL & UK (NOVEMBER 2016) FROM OXFORD ECONOMICS – THE LEADER IN GLOBAL FORECASTING AND QUANTITATIVE ANALYSIS Our world GDP growth forecasts are unchanged this month at 2.2% for 2016, which would be the lowest since 2009, and 2.6% in 2017. Short-term activity indicators have been mixed. The global PMI rose to an eight-month high in September, but growth remains subdued compared with its long-term average. In addition, other high-frequency data such as the Citigroup economic surprise indices have been trending down since August. Indicators of international trade continue to show signs of weakness: the volume of world trade fell 1.1% on the year in July and was flat in the seven months to July. That said, the latest data for some countries show a pick-up in trade volumes in August, particularly in Asia. This has been to the benefit of China, where data suggest a slight improvement in the outlook. We now expect GDP growth to average 6.6% this year, a slight upward revision. But meeting the overly ambitious targets for GDP growth will remain reliant on continued fiscal and monetary easing to shore up domestic demand. The recent shift in monetary policy in Japan means that we now see yields on 10-year Japanese bonds capped at 0% until 2020. Despite this policy shift, the yen is likely to stay relatively close to current strong levels for the rest of this year, and forecast to weaken to only 110 by mid-2018. The relatively strong yen further clouds the outlook for exports and overall growth. We maintain our cautious view for the US, expecting 1.5% growth in GDP this year, followed by a modest rebound to 2.0% in 2017 (down from 2.3% previously). This is primarily down to weaker momentum in the private sector, particularly consumption and investment. But uncertainty is also playing a role, given the extremely different policies from the two main presidential candidates, uncertainties about which policies will be implemented, and the risk of a ‘trial-and-error’ presidency under Mr. Trump. Activity in the UK continues to surprise to the upside, therefore supporting our above-consensus call on UK growth (1.9% this year and 1.2% in 2017). But sterling is bearing the brunt of the adjustment, falling to new lows against most major currencies. This has led us to revise our end-year GBP forecasts to 1.25 to the US$ and 1.12 to the euro (from 1.28 and 1.19 last month). Though the economic data has held up better than the Bank of England had expected, the minutes of the September policy meeting suggested that this had not altered its bigger-picture view of the economy post-referendum. As such, the majority of members still expect to vote for another rate cut before the end of the year.

LATEST APPRENTICESHIP LEVY NEWS

BPMA GOLF DAY 2017 The 2017 BPMA Golf Day will be held at the Heythrop Park Resort Oxfordshire on Thursday 25th May 2017

The way apprenticeships are funded is changing. The apprenticeship levy is a new tax on businesses that will be introduced to help support the government’s target of 3 million apprenticeships by 2020. The levy will be paid at a rate of 0.5% by employers with a pay bill of more than £3 million per year Following extensive consultation with employers and training providers, the Government have published on 25 October 2016 the final funding policy that will take effect from May 2017 when the new Apprenticeship Levy is introduced. Details of the new register of apprenticeship training providers have also been announced. The following adjustments have been made to the funding policy since the Governments proposals were announced in August which will help ensure that the reforms benefit more employers, providers and apprentices. THE KEY FEATURES ANNOUNCED WERE: •Higher funding for STEM apprenticeship frameworks and higher pricing of apprenticeship standards to support improved quality, and greater flexibility to train those with prior qualifications; •Longer period of time for employers to spend funds in their digital account, now with 24 months before they expire, an increase from the original proposal of just 18 months; •A commitment to introducing the ability for employers to transfer digital funds to other employers in their supply chains, sector or to Apprenticeship Training Agencies in 2018; •90% contribution from government to the cost of training for employers that will not pay the levy; •100% contribution from government to the cost of training for small employers that will not pay the levy and who take on apprentices who are 16 to 18 years old; •£1,000 each from government to employers and training providers when they take on 16 to 18-yearolds; •Help for training providers to adapt to the new, simpler funding model through an additional cash payment equal to 20% of the funding band maximum where they train 16 to 18-year-olds on frameworks; and •A simplified version of the current system of support for people from disadvantaged areas to ensure the opportunity to undertake an apprenticeship is open to everyone, no matter where in England they live, their background or family circumstances. BPMA WILL BE HOLDING A WORKSHOP ON TUESDAY 29TH NOVEMBER TO CONSIDER ALL OF THE FOREGOING. IF YOU WOULD LIKE TO ATTEND, PLEASE CONTACT STEVE SMITH ON 0121 601 6691 OR EMAIL. S.SMITH@BPMA.ORG.UK

GOLF AT HEYTHROP PARK Open 365 days of the year the Bainbridge Course at Heythrop Park was redesigned in 2009 by Tom MacKenzie the golf course architect responsible for many Open Championship venues. The 7088 yard par 72 course weaves throughout the 440 acre Heythrop estate and provides the perfect challenge for all golfers. The 18 hole course meanders over ridges and through valleys that are studded with ancient woodland, lakes and streams. The course is quintessentially English and has several signature holes notably the 6th hole where the green nestles beside a fishing lake, the 14th which sweeps leftwards around an ancient woodland and the closing hole which is straight as a die and has the impressive mansion house as its backdrop. Located 12 miles north of Oxford just outside Chipping Norton in the Cotswolds, Heythrop Park is within a 90 minute drive time of London and the Midlands, making it very accessible indeed. BPMA GOLF DAY ITINERARY Tea, Coffee & Bacon Rolls at Registration 18 Hole Texas Scramble Team Competition with Buggies Individual Prizes Prize Giving Dinner, Overnight Accommodation BREAKFAST ON DEPARTURE 18 Hole Texas Scramble Team Competition with Buggies Individual Prizes Prize Giving Dinner, Overnight Accommodation Only £199.00 + VAT Per Player 18 Hole Team Competition – Bainbridge Course Buggies Individual Prizes Prize Giving Dinner O v e r n i g h t Accommodation Breakfast on day of Departure Only £199 Per Player + VAT Interested in entering a team; Contact: Steve Smith E-mail: s.smith@bpma.

org.uk

BPMA OFFERS FURTHER ELECTRICAL COMPETENCY TRAINING 7-9 MARCH 2017 – WEST BROMWICH This three-day ‘City & Guilds’ course is specifically designed to assist non-electrical employees to prepare themselves for cross trade working, and to help companies comply with the requirements of current legislation regarding the use of such people for minor electrical tasks. Course Objectives After completing the course, students should be able to: • Recognise safe working practices (related to electricity in the workplace) • Work within the requirements of current electrical legislation (relating to topics covered) • Understand the fundamental principles of electrical energy • Perform routine electrical tasks at a basic level • Perform safe isolation of electrical circuits • Enhance their workplace skills • Relate to electrical circuit diagrams Who should attend? The course is primarily aimed at mechanical or un-skilled tradespersons that are preparing themselves for work upon electrical systems. The course may be of great benefit to companies that intend to employ non-electrical personnel to perform routine electrical duties, such as, lamp replacement or portable appliance testing etc. Topics Covered • Health and Safety legislation (related to electricity in the workplace) • Basic electrical principles • Electrical power and units of measurement • Safe isolation of electrical circuits • Electrical test instrumentation • Conventional circuit layout • Basic first aid (related to electrical hazards) • Electrical diagrams • Cable and wiring system Costing just £495.00+ VAT per person, which includes lunch, refreshments and City & Guilds certificate, this three day course will be held on 7th, 8th & 9th March at the National Metalforming Centre in West Bromwich. With just 12 places available, early booking is advisable. For further information and a Booking Form, please contact Steve Smith at the BPMAon 0121 601 6691 or by email at s.smith@bpma.org.uk.

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

HOW MUCH WILL YOUR P When it comes to specifying pumping equipment, many companies, particularly those under increasing pressure to cut costs, could actually be making decisions that will cost them more in the long run. In this article, Steve Schofield, Director and Chief Executive of the British Pump Manufacturer’s Association (BPMA),explains how lifecycle costing can help to reveal the true cost of a pump.

The need to cut costs wherever possible is an increasingly familiar requirement for engineers charged with ensuring the continued smooth operation of plant on a limited budget. When it comes to pumping systems, although choosing the lowest cost option may seem like the best short term solution to achieving cost savings, it will almost always result in additional costs being incurred that could have been avoided by spending a little more time and money during the specification and design stage. According to statistics from the US Department of Energy’s Office of Industrial Technologies, pumping systems can account for between 25 and 50% of the total energy consumed by certain industrial processes. Add to this the need for ongoing service, repairs and maintenance throughout a typical service life of 20 years and pumps quickly begin to represent a substantial area of expense. The expectations of some pump users can be unrealistic when it comes to the cost of pump ownership, in many cases they focus too much on initial outlay, opting for the least cost alternative, which is not always actually the best solution for the application.

SO WHAT IS THE ANSWER? The BPMA and many of its members are keen to emphasise the importance of life cycle costing (LCC) as a vital part of any pump purchasing and ownership strategy. Life cycle costing takes into account many factors, all of which impact on the total cost of owning and operating a pump, which includes much more than just the initial outlay. A pump’s life cycle cost encompasses the total overall costs that accumulate throughout the life of a pump, from installation, energy consumption, operation, maintenance and down time, even environmental and through to the final decommissioning and disposal of the pump. By carrying out an analysis of the costs that are likely to be incurred throughout the operational life of the pump, it is possible to objectively compare all the potential options at the outset. Lifecycle costing can be useful not only for selecting new equipment but also for justifying the upgrade of existing systems. Throughout the lifetime of a pumping system, it is unlikely that the same operating conditions will continue to prevail. Factors such as the addition of new equipment upstream of the pump or changes in production techniques can all cause variations in pump duty away from the pumps ‘Best Efficiency Point’ (BEP). This is the point where pump capacity and head pressure combine to provide the maximum efficiency performance from the pump. If the pump is incorrectly sized and is operating too far from the BEP, wear and tear can occur which can shorten its operational life. An oversized pump, for example, will not only be inefficient,

but will also cost more to maintain because operating too far to the left of its performance curve puts an extra strain on pump bearings and seals. On the other hand, a pump which is undersized for the duty may end up running too quickly, which may potentially ruin the product being pumped and also prematurely wear out parts of the pump. Also its efficiency will be affected, resulting in excessive energy consumption. Although a pump should be sized to an application, achieving this is not always straightforward. Involvement of third parties and the need to meet possible changing future requirements can all affect the sizing of a pump. Over design on parameters is very commonplace. If every party involved in specifying a pump adds on even a small percentage to their sizing estimate, the end result can be a highly inefficient pump. The extra cost, both in terms of running and maintaining the pump can be very high over the life of the plant. One survey of 4,000 installations showed that water pumps typically operate with a shortfall in efficiency of between 12.5 and 20 per cent because they are incorrectly specified. The situation is worse for pumps that handle more unusual or complex media, such as chemicals or pharmaceuticals. To help with changes in duty and assist with energy reduction many pump manufacturers are now promoting the use of Variable Speed Driven pump systems, frequency drive being the most prominent system used. By using VSD’s you in effect combine electrical and mechanical principles. The addition of the latest controls or ancillary equipment can often help boost efficiency and enable pumps to meet changes in demand at a fraction of the cost of building a new system from scratch. In some cases, simply upgrading a pumping system can result in energy savings of up to 50%.

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

PUMPING SYSTEMS £72.00 EUROPUMP – A GUIDE TO LCC ANALYSIS FOR PUMPING SYSTEMS £83.00 EUROPUMP – A GUIDE TO SUCCESSFUL APPLICATIONS FOR VARIABLE SPEED PUMPING £72.00 EUROPUMP – AMAZING DISCOUNTS! (ABOVE 3 PUBLICATIONS) £150.00 FOR FURTHER INFORMATION, PLEASE ALSO VISIT: WWW.BPMA.ORG.UK/PUBLICATIONS Looking at the possible energy savings in the entire pumping system the BPMA in 2010 created the CPSA scheme (Certified Pump System Auditor). This is a new industry specific professional qualification developed by an established and highly regarded body within the industry. The objective of the scheme is to help improve the levels of professionalism in the sector by creating a universally recognised and respected industry ‘standard’ for individuals assessing the performance of a pumping system. THE CPSA SCHEME TRAINING INCLUDES: • Pump System Requirements &amp; Analysis considerations • ISO 14414 Pump System Energy Assessment Standard Requirements • Pump System Optimisation methods • For further information please visit our CPSA website

HOW TO GET IT RIGHT – SOME TOP TIPS FROM THE EXPERTS The following are just some of the key factors that should be considered when specifying a pump, which could help ensure it delivers optimum performance and economy throughout its service life.

1. WHAT SORT OF PUMP DO YOU NEED? There are many different types of pump available, each of which is suited to particular applications. The two most popular types are Centrifugal pumps and Positive Displacement pumps. Centrifugal pumps are generally suited to fast flowing or low viscosity liquid applications where the pressure is relatively constant. They perform most efficiently and cost effectively when operating at or near their Best Efficiency Point (BEP). Positive Displacement pumps, on the other hand, are particularly ideal for high viscosity applications, as they are better able to maintain a constant rate of flow. It may also be necessary to consider what type of material the pump is manufactured from. Hygienic processes in the

PUMP REALLY COST YOU? pharmaceutical or food and beverage industries, for example, are subject to the strict requirements of the Food and Drug Administration (FDA), which call for equipment to be manufactured from 316L stainless steel. Information on selection and which pump is best suited /used on different applications can also be found within the BPMA buyers guide available on the BPMA website.

2. IS THERE SUFFICIENT PRESSURE FOR THE PUMP TO WORK EFFECTIVELY? The efficiency and operation of centrifugal pumps in particular can be affected by the Net Positive Suction Head (NPSH) available. Basically, this is the amount of pressure that is required to prevent the liquid being pumped from vaporising inside the pump.If the liquid vaporises, bubbles can be formed which will be carried into the pump. When these bubbles encounter zones of higher pressure in the pump, they will collapse violently, resulting in a phenomenon known as cavitation which can severely damage the pump. When designing a pump system, it is essential to ensure that the available pressure on the pump inlet is greater than the pressure required within the pump to avoid the occurrence of cavitation.

3. IS THE PUMP POSITIONED IN THE CORRECT PLACE? Where a pump is positioned within a pipeline can also greatly affect its performance.

As well as determining the amount of pressure available, the positioning of a pump can also affect the quality of the product being pumped. Too much or too little distance in the pipeline before the pump, for example, can lead to friction losses which can affect the flow rate of the substance being pumped, which in turn can affect the efficiency of the pump. The presence of pipe fittings, such as elbow joints, filters or other in-line equipment, can also affect the flow rate of a substance to the pump.

4. DON’T JUST PURCHASE ON COST ALONE When it comes to selecting a pump, cheapest is by no means best. Be particularly careful where reductions in the purchase price have been achieved by cuts in supplier back-up and expertise. Ultimately, the most cost-effective installation will be the one where the supplier can offer good technical back-up, an established track record and a reputation for high-reliability products based on sound research and development.

5. ALWAYS TAKE THE PUMP MANUFACTURERS’ ADVICE! It’s surprising how many customers don’t take advantage of the expertise available from the pump manufacturer when it comes to ways of getting the best performance from their pumps. After all, nobody knows more about how to get the best out a pump than the company that built it.

GRUNDFOS TAKE CENTER STAGE

FOUNDRY MATTERS WITH GRUNDFOS

Having easy access to useful information is something that is important to us all but isn’t always that attainable. At Grundfos, we have been providing an increasingly sophisticated audience with various on- and off-line product selection support tools since 1984. These tools have evolved by speaking to customers and looking at best-in- class options from multiple disciplines. The latest on this evolutionary ladder is the Grundfos Product Center. Today this Product Center allows you to begin your search journey from a number of starting points. For example, you can choose to search by family, pump design or application area. Alternatively, you may want to start your search by viewing the replacement options for an older Grundfos or a competitor model. Another way to start your search is by application and to find your choice based on head, flow and application type. Certain pump choices need to be dictated by the liquid type to be pumped, so this is yet another point you can start from. So whether you need to select a pump by size, application, replacement or liquid, by making the Grundfos Product Center a favourite will be central to helping you to make the right choice. Find out more at www.grundfos.co.uk

Every day at the Grundfos foundry 25 tons of aluminium go through a process of being melted down so that this material can reinvent itself as a range of new pump components. This is all part of Grundfos’ sustainable ambitions where caring for resources takes on a practical meaning at Grundfos’ own foundry. This aluminium itself comes from a range of sources including car and bicycle components, cans as well from pump process offshoots before it is melted and becomes part of the next generation of sustainable Grundfos pumps. So successful is this project that every year some 13.5 million new units are cast by the 100 employees within the department, becoming almost 50 different pump components that includes stator housing, electronics parts, flanges and tops for terminal boxes. The current die cast plant in Denmark is in itself unusual, as its chimney makes use of an electrostatic filter that efficiently purifies the smoke. The filter is the only one in the world that is used within a die cast plant situation. Not only that, but Grundfos have reduced the energy usage in the foundry by 50 per cent since 1992. It is easy to talk about sustainability. However, some companies like Grundfos can actively demonstrate this by showing how thinking outside the box can have a positive impact, on many levels. For More information contact GRUNDFOS Pumps Ltd. Leighton Buzzard, Bedfordshire. Tel:(+44) 1525 85 00 00 E-mail: grundfosuk@grundfos.com Web: www.grundfos.co.uk

AXFLOW INTRODUCES THE WILDEN HS430S PUMP AxFlow has announced that it has added the latest Wilden AODD pump, the aluminium HS430S to its product range. Ideally suited for applications that require high head pressures such as viscous and solid-laden slurries, the HS430S high pressure aluminum pump comes equipped with the revolutionary FIT wetted path that minimises the number of fasteners and allows for single socket reassembly for faster, easier maintenance. The new pump also provides superior flow rates, is easy to maintain and increases plant profitability beyond any other 1-1/2” (38 mm) high pressure aluminum AODD pump on the market. The HS430S FIT high pressure aluminum pump has been designed for superior fluid containment, and is a direct replacement for existing 1-1/2” (38 mm) high pressure aluminum pumps and does not require any repiping for applications. This high pressure pump features a “Simplex” design – which means that one liquid chamber is used to pump fluid while the other is used as a pressure amplification chamber. With a 2:1 pressure ratio, this pump generates 17.2 bar and does not require costly external boosters or amplifiers to achieve this discharge pressure. FIT high pressure aluminum pumps are fitted with the extremely energy-efficient Pro-Flo® SHIFT Air Distribution System (ADS). This innovative ADS provides up to 60% reduction in air consumption compared to competitive AODD pump technologies. For more information contact AxFlow Ltd, Ealing, London Tel: 020 8832 1872 | Email: info@axflow.co.uk |Web: www.axflow.co.uk

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

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

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

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

+44 (0)1323 452141 vince.lee@sundyne.com www.sundyne.com/hmdkontro 7

TURN ANY ANDROID OR WINDOWS DEVICE INTO A POWERFUL CONDITION MONITORING DATA COLLECTOR

HEAVY DUTY CHOPPER PUMPS FOR INDUSTRIAL PROCESS APPLICATIONS

AVT Reliability ® are pleased to announce further developments to Machine Sentry ® its revolutionary condition monitoring system. The Machine Sentry ® mobile software can now be installed on any Android smartphone or tablet device completely eliminating the need for an expensive custom made data collection device. AVT Reliability ® offer a range of both tablet and other handheld devices, including the waterproof CAT ® S60 smartphone which incorporates both a visual and a FLIR ® infrared camera at a cost that is comparable to consumer smartphones. Machine Sentry ® integrates all condition monitoring techniques and watchkeeping data into a Condition Based Maintenance (CBM) solution to provide effective maintenance planning and reporting. Machine Sentry ® is simple to use, and includes automatic fault diagnosis assistant that helps identify potential issues with rotating equipment. The use of readily available hardware coupled with the unique Bluetooth™ enabled tri-axis vibration sensor (Pat. Pending) significantly reducing the cost of the equipment required for data collection. The integrated fault diagnosis assistant, automatically detects rotating equipment problems (broadly equivalent to a level II vibration analyst) simplifies data analysis. The algorithms used in the Fault Diagnosis Assistant have been developed by AVT Reliability’s own team of vibration experts using thousands of hours of vibration data coupled with extensive field experience Machine Sentry® combined with access to AVT’s team of condition monitoring experts eliminates the requirements and costs associated with hiring highly qualified condition monitoring engineers and technicians making it the ideal solution to any condition monitoring program. For more information visit: www.machinesentry.com, or alternatively call: 0161 486 3737.

With T-T’s 57 years’ experience they have vast knowledge on the challenging fluid handling problems in the process industry. T-T’s range of heavy duty chopper pumps have been designed to tackle the tough industrial processes. The ETO, ETV and PTS range of heavy duty chopper pumps have a double chopping anti-clogging performance. The first chopping system consists of two chrome steel blades secured on the body inlet, acting in contrast to a spiral conveyor made from high grade cast iron and fitted to the motor shaft. The second chopping system consists of a shear cutting plate in special high grade cast iron, the cutting edges of the high grade impeller maximise the cutting action against the cutting plate. With a maximum speed of 2900 rpm, this is the only chopping system that operates at over 170 cuts per second! Each pump in the range is ideal for particularly heavy applications that require a preliminary chopping of the solid material suspended in the liquid being pumped. The PTS range is a submersible heavy duty chopper pump. The ETO is an electric horizontal version which is mounted on a frame and coupled with a standard starter electric motor by a flexible coupling, and the ETV is a vertical option of the chopper pump range. The ETO, ETV and PTS range of heavy duty chopper pumps are available in a Nitec anti-corrosive coating for protection against aggressive liquids, making them the ideal choice for industrial applications. For more information visit Web: www.ttpumps.com or call our technical team on Tel: 01630 647200.

Motors | Automation | Energy | Transmission & Distribution | Coatings

We’re ready for January, are you? Energy efficient motors and drives for all applications available now. From January 2017, in compliance with the EU Directive, all new electric motors with a rated output of 0.75 kW to 375 KW sold should not be less than IE3 efficient, or meet the IE2 efficiency level if equipped with a variable speed drive, this extends the scope of the directive from the previous 7.5 kW lower limit. At WEG, we have a wide range of IE2, IE3 and IE4 energy efficient motors and variable speed drives available in stock and ready for delivery.

www.weg.net

AN INTELLIGENT SOLUTION TO PUMP SPECIFICATION by Chris Harvey, Business Development Manager at Xylem The changing nature of communities and our lifestyle choices cause havoc for wastewater pumping stations. Chris Harvey, an expert in wastewater pump selection at Xylem, outlines the problems and offers some solutions. The water and wastewater industries face continuing pressure to reduce their impact on the environment through both energy and carbon reductions as well as protecting it from flooding and spillages. However much of what they do, is governed by the specific nature of the wastewater flowing into them. Our disposable society is a major culprit in this, with many consumers throwing items such as cleaning wipes, cotton buds and even clothing down the toilet. This unnecessary action is wreaking havoc on our wastewater systems and as a result, the focus of pumping station teams has turned to resolving the impact of non-biological solids, as opposed to system hydraulics. In fact, one of the key problems, is that wastewater is often discharged into old gravity sewer systems - positioned upstream of a pump station. Never designed for high material loads, the resulting effect is blockages. With this in mind, there has been growing acceptance within the market that pump blockages were simply a natural consequence of pumping wastewater. This needn’t be the case.

FACTORS TO CONSIDER

For the delivery of an effective pumping system, it is crucial that it is

reassessed at various intervals during its working life. Over time, pumping station needs will change with new housing or commercial developments increasing the inflow and with it, potentially the characteristics of the water and solids may alter too. Pump selection therefore has always depended on some basic key criteria, such as the required forward flow; how high and how far the liquid needs to be pumped, the internal diameter of the pipe (or rising main as it is often referred to) that the liquid travels through and, not forgetting any undulations in the rising main. What should be taken into consideration, but can be difficult to ascertain, is the internal condition of the rising main. As a consequence of the impact of liquid on the walls of the pipe, it can result in friction loss within the system - the more liquid that is pushed through, the more disproportionate the amount of friction it generates. So a relatively small increment in flow, in long rising mains, can require a significant increase in required pump pressure. However, the more pressure the pump has to generate to pass a given flow, the more power it consumes. Over-time the internal walls of pipework can become rough; caused by abrasions, corrosion, and/or fat build up, which in turn effectively reduces the pipe diameter. Any increase in roughness, or reduction in the effective pipe diameter, will increase the friction loss / resistance that is being generated at a given flow. With fixed performance pumps, this can result in a reduction of forward flow capability. Delivering the right solutions to waste water pumping stations is unquestionably easier when the historical and current performance data is available, but to make specification even trickier, this is not always the case. In fact, having access to performance data, can in fact lead to systems being oversized, also resulting in increased power consumption. In short, wastewater pump selection has multiple variants, many imponderables and elements of risk.

stocking emergency spares a truly herculean prospect. One of the biggest problems is having access to the right data. In an emergency situation, having a pump in the ground often takes priority over having the right pump to optimise longevity, efficiency and performance. While the reasoning behind this may be sound, the approach does lead to a number of potential issues. Firstly, in the case where a pump is fitted based on availability rather than correct selection, it will not be delivering optimum pump performance and is therefore at risk of premature failure. At the point of replacement, there is a tendency to replace equipment like-for-like, beginning a constant cycle of having the wrong pump for the application. Secondly, the reactively selected pump may not meet the performance requirements, resulting in the pump having to be taken out and the impeller changed, at an increased cost and risk, further down the line. That’s not even considering the impact on power consumption the greater risk of clogging – further increasing operational costs. The good news is that the next generation of pumps have arrived, and they are capable of being much more flexible in operation, equipped with intelligent integrated control systems that can automatically deliver optimal wastewater pumping performance. Flygt’s new Concertor pump, has built-in capabilities to adapt to different duty points, which means that instead of replacing the pump or impeller, the pump will adjust its performance to cope which changing conditions over time. This a world away from the traditional pumps in place today. Having the potential to automatically adjust performance in-line with operational conditions, is enormous. The development will mean that there is no need for large stocks of back-up inventory because one pump size can be used in multiple applications. What’s more, high energy consumption can be solved by automatic self-optimisation, which has the potential to result in up to 70 per cent improvements in energy savings along with increased product reliability and longevity.

WHAT CAN BE DONE TO REDUCE THESE RISKS AND THE HIGHER OPERATING COSTS?

When combined with self-cleaning clog-free impellers and blockage detection/pump cleaning protocols that reduce the need for vacuum cleaning, call-outs can be reduced by up to 80 per cent. Over the entire serviceable life of a pump, these factors offer a significant reduction to whole life cost and risks. Planned maintenance can now be resourced effectively thanks to a reduction in stoppage time. Modern life is impacting the operational efficiency and risks of wastewater pumps which, in turn, is making pump specification during new build and replacement projects, increasingly challenging. The answer however may lie in a new generation of intelligent wastewater pumps that can alter their performance in line with the changing demands of each application.

In the UK water industry there are currently around 36,000 waste water pumping stations. Take a look through the asset base of any water company, and you will see different pump manufacturers and models, each with specific flow and head characteristics. This makes

GREATER OPERATIONAL EFFICIENCIES

WEG’S NEW AUTOMATION RANGE LEADS THE WAY TO EFFICIENCY AND RELIABILITY AT SPS IPC DRIVES 2016 WEG, a leading global manufacturer of motor and drive technology announce its latest automation technology which that includes new soft starters, medium-voltage variable speed drives (VSDs) and compact circuit breakers that are designed to deliver increased uptime and efficiency to a wide range of industrial and commercial applications. “WEG is committed to increasing the reliability and efficiency of electric motor-driven systems (EMDS) and we have developed our automation range to support a larger section of the European market across industrial and commercial applications,” says Johannes Schwenger, Head of Product Management Low and Medium Voltage Drive Systems Europe at WEG. “Over

the last few years we have been investing in our automation offering to better support our customers, and we are proud that WEG has grown into a global provider of drive technology with a full-spectrum automation portfolio.” WEG’s new SSW900 compact soft starters are high-performance top-end devices with integrated PLCs that provide fully programmable algorithms for regulating induction motors. They feature an integrated bypass contactor for longer service life, optimal space utilisation and lower heat dissipation in the switchgear cabinet. The new MVW3000 VSDs have been designed to meet a growing demand for medium-voltage devices in Europe. They are built with multilevel technology and cascaded H bridges (CHB) to enable users to achieve medium-voltage levels simply by using standard cost-effective low-voltage components (diodes, IGBTs and plastic film capacitors). WEG is also expanding its DWB series of compact molded case circuit breakers (MCCBs) with three additional case sizes for output currents from 800 A to 1,600 A. The circuit breakers provide flexible, cost-effective and reliable protection for power distribution systems as well as for motors and generators in commercial and industrial applications, particularly in panel building. For more information on WEG’s energy efficient drive solutions visit www.weg.net/uk

STRUCTURED APPROACHES TO ENERGY MANAGEMENT THROW SPOTLIGHT ON ENERGY SAVING POTENTIAL OF SINE TM PUMPS The leading manufacturer of Sine TM pumps is encouraging food and beverage manufacturers to review their existing pump technology as part of a structured approach to energy management. Watson-Marlow Fluid Technology Group, which manufactures MasoSine sinusoidal pump technology, believes companies should embrace energy management standards such as ISO50001 as an opportunity to assess the potential for savings at a plant level. This includes a complete review of existing pump technology, specifically in high-viscosity applications. For example, a switch to MasoSine technology in such scenarios, will deliver up to 50% power saving in comparison to lobe or circumferential piston pumps. ISO 50001 The path to effective energy management for a growing number of companies is via ISO 50001. This international standard outlines energy management practices that are considered to be the world’s best. Energy management experts from more than 60 countries developed the standard to help companies save energy, cut costs and meet environmental requirements. ISO 50001 shows plants how to take a structured approach toward measuring and monitoring energy use. For those that have chosen to go down the ISO 50001 route, this stage will highlight the need to look in detail at energy-intensive plant and equipment, including pump technology. ESSENTIAL ANALYSIS The requirement for such a detailed analysis is echoed by data from the BPMA (British Pump Manufacturers’ Association), which states that pumps account for around 10% of the world’s electricity consumption, while two- thirds of pumps use up to 60% more power than necessary. Furthermore, energy represents 95% of a pump’s lifecycle cost, so the opportunities for savings are substantial. Florian Walter, MasoSine product manager believes the greatest savings opportunities exist for food and beverage plants faced with processing viscous substances, from mayonnaise to meat. “There are some obviouseasy-wins to enable significant and immediate gains. Among these is upgrading to more energy-efficient pump systems,” he comments. SAVINGS FOR HIGH-VISCOSITY APPLICATIONS With this in mind, a growing trend is the adoption of sinusoidal pump technology. Mr Walter continues, “Opting for Sine pumps not only ensures energy efficiency, especially when processing high viscosity substances, but offers particularly gentle pumping.” There are a number of key benefits associated with using Sine pump technology with respect to added value and cost reduction, particularly regarding energy consumption. For instance, Sine pump technology typically requires up to 50% less power than lobe or circumferential piston pumps. Moreover, the size of the savings increase in line with viscosity: the higher the viscosity, the more the savings. So how is this achieved? Well, the rotor design of Sine pumps enables a very large range of viscosities (from 1 cP to 8 million cP) to be handled without modification to the pump and with minimal effect on power requirements, hence the significant energy savings. For more information contact Watson-Marlow Fluid Technologies Group, Falmouth, Cornwall. Tel: 01326 370370 E-mail: info@wmfg.co.uk Web: www.wmfg.com

CLIVE FELLOWS TO RETIRE AFTER 40 YEARS WITH M BARNWELL SERVICES After more than 40 years with M Barnwell Services, the UK’s leading stockist and distributor of fluid sealing products, Clive Fellows has announced his retirement as Sales Director. Throughout his successful career, Clive has been instrumental in growing the company through acquisitions, alliances, key account development and expansion of International Sales into over 60 countries. Clive Fellows commented: “I have thoroughly enjoyed my time working at M Barnwell Services. It’s been a real privilege to work with everybody and I have met some great friends. I am extremely proud of where the company now stands as a leading International supplier of fluid sealing products. I will be looking forward to a relaxing retirement spending it with my family.” Michael Barnwell, M Barnwell Services MD, said: “Ever the professional and a true gentleman, I, on behalf of everyone at M Barnwell Services wish Clive, his wife Sue and his family every happiness in this well-earned new phase of their

lives well. He will be missed by us all.”

SIGNIFICANT ACCREDITATIONS AWARDED TO TWO FLOTRONIC PUMPS Flotronic Pumps’ recently developed ‘E’ Series Pump has been accredited by the European Hygienic Engineering & Design Group (EHEDG) - a consortium of equipment manufacturers, food industries, research institutes and public health authorities promoting hygiene during the processing and packing of food products. Engineered for the food, beverage, dairy and pharmaceutical industries and tested to exacting performance standards by EHEDG, Flotronic’s ‘E’ series pump features polished wetted surfaces to 0.8μm Ra or better and an electro-polished overall finish, making this pump the ideal choice for any environment or process where avoidance of product contamination is paramount. Flotronic’s ‘H’ Series 3-A Pump has also been designed for conditions demanding rigorous hygiene standards. The ‘H’ Series has been accredited by 3-A Sanitary Standards Inc, the US-based independent not-for-profit corporation dedicated to advancing hygienic equipment design for the food, beverage and pharmaceutical industries. 3-A SSI accreditation confirms that ‘H’ series parts and raw materials are of the highest quality with their provenance duly certified.

For more information contact Flotronic Pumps Ltd, Bolney, West Sussex Tel: 01444 881 871 E-mail: sales@flotronicpumps.co.uk Web: www.flotronicpumps.co.uk

ENERGY EFFICIENT PUMPING & GENTLE HANDLING OF SENSITIVE PROCESS FLUIDS CUTTING ENERGY USE WHILE SAFEGUARDING PRODUCT QUALITY PROVEN PERFORMANCE AND RELIABILITY

Alfa Laval SRU rotary lobe pumps are carefully engineered to provide reliable performance, troublefree operation and superior energy efficiency for demanding applications in the dairy, food, beverage, personal care and pharmaceutical industries. It is an excellent choice for duties that require contamination-free pumps to meet high standards of hygiene, low-shear and low-pulsation operation. This pump handles both Cleaning-in- Place and Sterilization-in- place, and can be supplied with thorough documentation to support rigorous validation requirements. Consistency with minimal risk of contamination Alfa Laval SRU rotary lobe pumps are designed with features that maximize performance and minimize the risk of contamination. These include a defined compression front cover sealing, rotor nut retention design, drainable pump head and ultra-clean surface finishes. Understanding of flow patterns is vital to ensure high efficiency fluid transfer with low pulsation, low shear and low noise characteristics. Alfa Laval employs Computational Fluid Dynamics (CFD) to establish exact geometry f o r the rotors and rotor case. Robust construction – low maintenance To deliver reliable operation and low maintenance the SRU features a robust gearbox construction with heavy-duty shafts, torque locking assemblies and taper roller bearings throughout. Certification, specification and standards Alfa Laval SRU rotary lobe pumps comply with EHEDG, 3-A, 3.1 and FDA hygienic standards and have ATEX approval for use in explosive environments.

For more information visit www.alfalaval.com

HOW TO ACHIEVE COST EFFECTIVE

MEASUREMENT RESULTS Bernd Knoll, International Product Manager at HBM, explains how to determine the real cost of ownership and looks at the different cost drivers which should be taken into consideration when upgrading or buying new test and measurement equipment.

hen selecting your test and measurement equipment, it’s important to consider the purchase price of products. However, what appears to be a bargain at face value could quickly prove to be an expensive acquisition which could result in considerable

subsequent costs. Understanding the true cost of ownership is always difficult for test and measurement equipment as it is often hard to take variables into account, for example, let’s assume you want to buy a new multi-channel measurement system which will be used over a 7 year period and that the purchase price of this instrument is £8,000. Although this sounds like a very competitive price, would this be the final cost of your equipment? Of course not! There will be an accumulation of associated costs, which more often than not are not specified on the invoice or in the quote. Firstly, there is the time and effort involved in specifying the measurement task and its requirements for the test and measurement equipment – an essential prerequisite to designing, building, verifying and ultimately using a test system that will meet the application required. Not to mention all the coordination and research involved, which could easily amount to a week’s worth of work. Based on an average working week of 40 hours and an average hourly rate of £60, the resulting costs of this alone could be in the region of an extra £2,400. And let’s not forget about implementation and training. This too could easily total 60 hours and considering the hypothetical hourly rate, could easily amount to another £3,600. Operating costs are also another factor which needs to be taken into consideration. For example, configuration, adapting and evaluation over a service life of seven years, the expenses accrued could amount to £10,000, so as you can see, compared to the moderately low purchase price of £8,000, there is now an estimated cost pool of nearly of £24,000! Obviously this calculation is based on hypothetical figures but irrespective of the final calculations, one thing is clear: the total cost of purchasing and operating test equipment far exceeds the purchase price. This is what is known as “Total Cost of Ownership” (TCO). More than just an economic theory, when taking the decision to invest, measurement technology companies worldwide are now increasingly shifting their focus from the simple cost of purchasing equipment, to the total cost which will arise during the use of this equipment.

CUTTING COSTS DOESN’T MEAN CUTTING CORNERS When it comes to purchasing new equipment, it’s safe to say that the purchasing cost will determine the decision to buy. Different quotes will be compared and the supplier offering the lowest

quote will be awarded the contract, so no great savings can be achieved here. However, as we’ve seen, the purchasing price does no represent the biggest proportion of the TCO. This is where we need to take the implementation and operating costs into consideration, as these are the factors which offer far greater cost saving potential.

KEY FACTORS TO BE CONSIDERED WHEN SELECTING EQUIPMENT As is the case in most manufacturing industries, the world of measurement data acquisition is experiencing radical changes with market trends and new technology gearing towards smaller, more compact and flexible equipment and in line with this shift, the range of measurement technology systems is also becoming broader. On one hand this can be seen as an advantage, but on the other hand it could be argued that this advance has increased the possibility of specifying a system that is not optimally tailored to the task in hand. And this is where additional costs for purchasing, start up, set up times and use can be generated. Leading on from this, usability is also a key issue. Despite the advance into more complex and diverse equipment, it is important that operation is kept as simple as possible, to avoid expensive operating errors and therefore the recording of incorrect test results. Another important issue here with regards to implementing user friendly equipment is the number of individuals who might be working with the measuring system. There could be a considerable amount of employees, some of which may not be experts, so with this in mind, it is important to ensure that personnel can learn how to use equipment quickly and effectively, which can often be achieved through drawing upon well known operating concepts. So, from this we can see that two of the main key factors are; the consultancy and preparation involved in specifying test equipment, and also its usability function.

TESTING TIMES When selecting your test equipment it is also important to investigate possible maintenance concepts as the consequence of unplanned corrective maintenance events, such as equipment failure, can be catastrophically high. As there are obvious difficulties in quantifying and predicting the outcome of such events, it is often very difficult to account for such eventualities in the TCO, so with this in mind it is important to consider using corresponding service concepts when purchasing new test and measurement products, for example such as those offered by HBM. Other invaluable matching service offerings for regular, preventive or requirements-orientated maintenance and services also includes remote or on site support, practical technology

PROCESS INDUSTRY INFORMER November 2016

trainings and project management, all of which could potentially save you valuable time and money.

CONCLUSION As with most purchasing decisions, when selecting equipment, the purchase price is often viewed as the single most important cost element in the equation, whilst other variables, such as operating costs, maintenance etc, are not taken into account. TCO mythology helps to bridge this gap by providing a model to calculate cost of key ownership factors over the entire life of the equipment. When developing a TCO strategy, one of the most critical elements is to understand that TCO is not simply about the purchase price. This is just one small element; equally important are the elements that go into the ‘maintain’ variables. All too often, procurement groups rarely take this into account and base most of their decisions on simply the purchase price and getting the largest discount possible, largely ignoring the costs involved for extra support, maintenance and operating etc, which could prove to be a very expensive option!. TCO methodology is an important part of the equation as it helps to bridge the gap by providing a model to calculate cost of key ownership factors over the entire life- span of the equipment. Not only is it important to assist equipment owners to make informed decisions on the actual purchase but perhaps most importantly, it can clearly demonstrate how variables can drastically change the overall cost of ownership for test and measurement, across the life cycle of the product. As technologies become less of a differentiator between competitors, understanding the true cost of ownership has become more critical than ever to the success of a business.

MONITORING THERMAL FLUID SYSTEMS An estimated 3,000 companies within the UK’s process industries operate thermal fluid systems to transfer heat around their manufacturing plants. ATEX and DSEAR legislation stipulate that these firms must proactively monitor and manage the condition of their systems in order to protect employees from the risk of fire or explosion. In this feature, Richard Franklin, managing director of UK Thermal Fluid Solutions (TFS), offers some tips to Process Industry Informer readers on how best to monitor the condition of their thermal fluid systems. He stresses the way in which the implementation of a continuous risk assessment and management programme can help firms to save money as well as lives. 1.REGULARLY MONITOR THE CONDITION OF THERMAL FLUID The heat transfer media used in thermal fluid systems are typically mineral or synthetic oils. A system’s operating temperature is invariably higher than the “closed cup flash point” of the media the minimum temperature at which, in the presence of a source of ignition, such as light switches, pump failure or sparks, the fluid’s vapours will ignite. Where heat transfer systems operate under high pressure, any leaks from the pipework at points such as flanged joints, valves and connection points, can create mists or sprays, which result in the creation of an explosive atmosphere outside the system. Most thermal fluids operate above their flash points, and the systems that contain them must therefore be treated on a risk assessment basis. Whether inside or outside heat transfer systems, on ignition, volatile atmospheres result in fires and explosions, and European ATEX (Atmosphère Explosible) legislation - implemented in the UK via DSEAR (Dangerous Substances and Explosive Atmospheres Regulations) – stipulates requirements for the protection of workers against such incidents arising from the presence of hazardous substances in the workplace. PUWER (Provision and Use of Work Equipment Regulations) stipulates that all installations, including thermal fluid systems, are operated correctly and properly maintained. While most companies are aware that heat transfer systems operating above the flash point of the fluid must be maintained according to DSEAR, many do not appreciate that organic thermal fluids based on mineral oils will degrade over time. Degradation can cause a fluid’s flash point to decrease, as “light” materials with lower flash point than the heat transfer fluid itself are generated, reducing the flash point of the fluid overall, so that fluids that were not flammable at the operating temperature at installation, eventually become flammable. DSEAR demands that the risks inherent in the use of flammable fluids are assessed and eliminated or reduced. Regular fluid sampling and analysis is required to indicate when unacceptably

“Sampling station” - Regular fluid sampling and analysis is required to indicate when unacceptably low flash points are reached.

low flash points are reached. If necessary, oil must be replaced or conditioned so that a safe flash point is restored. The formation of explosive atmospheres outside the thermal fluid system following a leak can be reduced via the fitting of sprayprotected safe rings. The importance of adherence to DSEAR cannot be overstated. Although thermal oil fires and explosions are not common, they do occur with avoidable regularity. Over a ten year period clients of insurer FM Global experienced 54 fires and explosions caused by thermal oil. In February, 2010, the thermal oil boiler at a wood processing plant in Northern Europe exploded, killing three people.

3. RECONDITION RATHER THAN REPLACE THERMAL FLUID Historically, the only available option for firms whose thermal fluids required flash point restoration was total replacement, but some suppliers are now able to recondition customers’ existing oils in order to maintain the appropriate flash points.

2.USE LONG-LASTING THERMAL FLUIDS Employing a thermal fluid with a high flash point combined with chemical stability, prolongs the period for which it may be safely used, making it highly cost-efficient. Such fluids enable companies to operate their systems safely and efficiently at high temperatures long-term, reducing the frequency with which the oil needs to be reconditioned or replaced in order to ensure that vital parameters such as minimum flash points are always maintained.

HTfluidfit rigs remove volatile organic compounds from the oil, returning it to a safe condition.

The first to offer this service, which offers a quick, cost-effective, environmentally sustainable alternative to total fluid replacement, HTfluidfit rigs remove volatile organic compounds (VOCs) from the oil, returning it to a safe condition, extending fluid life by a factor of at least 10, saving customers up to 70% of their thermal fluid costs.

4.EMPLOY A LONG-TERM RISK MANAGEMENT STRATEGY

New oil - TFS’ new oil in comparison with standard high performance oil, when aged in the company’s standard laboratory test.

Following six months of testing at our Derbyshire headquarters, this summer the firm launched Magma Ultima and its food grade sister, Thermaltrans FGS, two semi-synthetic heat transfer fluids with the market’s highest ever flash point of over 2600. The chemical composition of these highly refined oils ensures a considerable level of stability allowing the fluids to resist for longer the process of degradation and consequent flash point reduction. The fluids’ exceptional stability means that they may safely be used in systems operating at a bulk (highest average) temperature of up to 3000C and film (container boundary) temperature of up to 3250C.

Only a continuous risk assessment and management approach to thermal fluid system condition monitoring will ensure a system’s safe and efficient operation and ATEX, DSEAR and PUWER compliance at all times. While the development of bespoke, comprehensive, continuous improvement plans enable companies to meet DSEAR standards, the explosion protection documents that form part of our plans also enable clients to prove their safety credentials to insurers and so reduce their premiums. Our experience within the process industries is across a range of sectors, including food, wood panel, petrochemicals and fine chemicals to achieve and maintain legislative compliance for 20 years, minimising and managing their risk, such as Premier Foods, Dow Chemical Company and Pfizer. As well as the supply of oils and HTFluidfit, together with other providers, we offer individual services include fluid testing, analysis and advice; water removal; drainage and refill as well as a comprehensive, continuous risk management service, ensuring the safe and efficient operation of customers’ thermal fluid systems and legislative compliance, via the creation of bespoke improvement plans.

PROCESS INDUSTRY INFORMER November 2016

PROCESS MEASUREMENT & INSTRUMENTATION IT’S ALL IN THE PRICE! A new Bluetooth radar level sensor for the water sector The new VEGAPULS WL S 61 contactless radar sensor is an ideal solution for applications in the water and sewage sectors. Its very competitive price combines with globallyproven success and comprehensive features to deliver a compelling radar based level sensor. Radar technology offers numerous advantages when compared with ultrasonic level sensors; radar is independent of weather influence: strong sun, wind, surface turbulence, condensation, fog or rain. In addition, no compensation is needed for signal transmission time due to air temperature fluctuations. Water radar sensors are ideal for level control and flow measurement in water treatment plants. The excellent focusing enables their use in sewage pumping stations, rainwater overflow basins, digesters, sludge tanks, open channel flow measurement and for open water level gauging too. As a compact, loop powered sensor with an accuracy of +/- 5 mm and range up to 8m along with its flexible mounting options, this means it can easily be installed into new or existing applications and connection to level controllers, telemetry or SCADA systems is straightforward too. The latest development stems from many years of experience of applications worldwide in the water and environmental sectors, providing ease of set up, ultimate performance reliability and protection of the environment. It joins the VEGA radar portfolio with another water radar device: VEGAPULS WL 61, which has been available for several years and now has a very large installed and working base of over 40,000 units world-wide. Previously, cost was perceived as an issue with radar technology, but this new variant VEGAPULS WL S 61 offers a price more favourable than comparable to short range ultrasonic systems. It has a fully featured specification, performance and design optimized for use in the water-supply and sewage sectors. The housings are a robust IP 68 (2 bar), this high degree of protection also makes it suitable for applications where the sensor may be temporarily submerged, the technology is wear and maintenance-free. It complies with the latest Level Probing Radar standard (LPR): approved for open-air use without restrictions or special attachments. Another entirely new feature is Bluetooth wireless operation from a free App via IOS or Android smartphone or tablet and/or PC with free to download PACTware when combined with a VEGA Bluetooth USB adapter; this option makes commissioning and diagnosis even simpler. Excellent value and resistance to weather conditions, make VEGAPULS WL S 61 the ideal level sensor for water-supply and sewage applications. For more information please go to: www.vega.com type WLs61 in the search bar or contact VEGA Controls Ltd, BURGESS HILL, WEST SUSSEX. Tel: +44 1444 870055 Fax: +44 1444 870080 E-mail: info.uk@vega.com Web: www.vega.com/uk

SENSOREX LAUNCHES NEW LABORATORY pH SENSOR FAMILY FOR EVERY APPLICATION Basic, Advanced and Research-Grade sensors available with a range of customised options Sensorex’s new line of laboratory pH sensors offer a range of options to maximise measurement accuracy and sensor lifetime. The Basic, Advanced, and ResearchGrade pH sensors allow end users to choose just what fits their application needs– eliminating overspending on overly sophisticated sensors, or on frequent sensor replacement in challenging environments. All Sensorex pH sensors offer accurate and reliable measurements across full pH ranges (0-14), compatible with all pH meters accepting a BNC connector. Sensorex’s Basic pH1000 sensor is durable and easy to use, ideal for swimming pool, aquarium, or hydroponics measurement, as well as science class experiments. Designed to withstand regular wear and tear, with a durable polycarbonate body and built-in protection for the pH glass measuring surface, the pH1000 provides reliable, stable readings in temperatures of up to 60°C. The Advanced family is more versatile for more difficult sample types in environmental, wastewater and food production applications. The standard and specialty Advanced models offer extended sensor life and measurement accuracy in temperatures of up to 80°C. The sensors feature chemically-resistant Ultem® bodies, double junction references, and booted meter connections for durability. This family includes the pH2000 extended life laboratory sensor for unpredictable samples prone to contaminants. The pH2100 flat tip electrode is ideal for viscous samples, slurries, and soft surfaces such as agar plates and skin. The family’s pH2200 spear tip sensor is specially designed to pierce semi-solids like food and soil. The pH3000 Research-Grade sensor is Sensorex’s most sensitive lab electrode, best for low ionic samples, including drinking water, biomedical and pharmaceutical applications. It is specially designed to respond quickly and accurately to rapid temperature changes, up to 100°C, with accuracy down to 0.04 pH. To help users choose the best sensor for their applications, Sensorex has launched an interactive sensor selection tool. For more information, and to access the selection tool, visit www.Sensorex.com, email info@sensorex.com or phone +1 714-8954344.

KATRONIC TECHNOLOGIES LTD ARE PLEASED TO INTRODUCE THE LATEST FLOWMETER TO JOIN THEIR HIGHLY ADVANCED KATflow PRODUCT PORTFOLIO The new KATflow 210 has been launched in response to demand from customers for a rugged measurement device, with a high IP rating and a long battery life. This new flowmeter is ideally suited to use in the water, leak detection and environmental markets as it is intended for use in harsh environmental conditions and in areas where long –term measurements are required without access to a power supply. The KATflow210 has been designed around a Peli ProtectorTM housing which is a brand synonymous with robust, watertight case manufacture. All connections to the instrument electronics are done on the outside of the case, meaning that once programmed, the flowmeter can be closed, locked and left to measure. In order to provide the ideal combination of weight, power and durability, extensive research was done to find the best possible battery configuration and chemistry. Numerous options were considered with the final realisation being that the only practical solution to meet all of the instrument’s requirements was to commission the production of a custom-made battery pack. As a result, the KATflow 210 can be fitted with between one and three internal batteries offering up to 37.2 Ah of capacity. There have also been further innovations to how the device makes use of this large capacity. The flowmeter is programmed with three different operating modes which allow the user to vary the measurement frequency or send the meter into hibernation. This in turn creates flexibility in the way in which the flowmeter can be implemented. The operator can have measurements which are updating every second for a duration of weeks, or potentially data taken over a period, presently estimated at nine months. In support of the new KATflow 210 design, the already reliable Katronic transducers have been further enhanced. The new K1N sensors maintain the standard stainless head and conduit but now have additional sealing and a larger diameter IP 68 connector fitted in order to provide the optimum in water proofing and strength. As well as having a large internal datalogger, the KATflow 210 can offer users remote data access through wireless data transmission. The instrument also has up to five different wired output or input options including 4-20 mA, pulse and MODbus outputs. Due to its rugged and robust construction, the new KATflow 210 is proving to be a welcome addition to the portable flowmeter market. The design will appeal to service and commissioning engineers and anyone working in an area where the tools need to suit the job and not the other way around.

Further more information contact Katronic Technologies Ltd, Coventry, West Midlands. Tel: +44 (0)2476 714 111 | Fax: +44 (0)2476 715 446 E-mail; mail@katronic.co.uk | Web: www.katronic.com

PROCESS INDUSTRY INFORMER November 2016

PROCESS MEASUREMENT

& INSTRUMENTATION

ACCURATE PRESSURE CONTROL IMPROVES VACUUM COATINGS RESULTS Alicat’s MCE-Series and MCV-Series direct replacements for common industry mass flow controllers Alicat Scientific’s mass flow controllers ensure the optimal coating environment in vacuum chambers, maintaining product integrity in coating and sputtering processes. The MCE-Series and MCV-Series may be used to replace legacy and discontinued MKS instruments. Made to fit the same space as common industry mass flow controllers, both series are easy to integrate into existing systems. In use, they offer fast, accurate flow control for process uniformity and quality. The Alicat MCE and MCV accurately control gas flow rates as low as 0-0.5 sccm full scale or as high as 0-20 slpm full scale with control response times of 50 to 100 milliseconds. Fast response times can greatly improve vacuum coating end products and help eliminate target poisoning. The integrated pneumatic shut-off valve is normally closed, affording positive shut-off of 1 x 10-9 atm-sccm/sec Helium max. The MCE can be used as a replacement of the legacy Type MKS 1179A Mass-Flo®, while the MCV replaces the discontinued Type MKS 2179A Mass-Flo®. The Alicat mass flow controllers operate on universal 12-30 VDC supply, and Alicat will match any pre-existing pin out on 9-pin or 15-pin D-sub connectors, for easy replacement. The units can be mounted in any orientation, even upside-down, without recalibration, further simplifying installations. Pre-programmed with calibrations for 98 gases, the MCE and MCV measure mass flow, volumetric flow, absolute pressure and temperature, with full temperature and pressure compensation. Units may be programmed directly through the instrument keypad or remotely via RS-232 (RS-485 also available).The MCE and MCV use patented laminar flow differential pressure (DP) technology found in many Alicat Scientific flow instruments, are supplied with NIST traceable certification, and carry the CE mark. To learn more about Alicat’s mass flow meters, visit www.alicat.com, or contact Alicat Europe via email at: europe@alicat.com or phone at: 01223 472804. * Type MKS 1179A Mass-Flo® and Type MKS 2179A Mass-Flo® are registered trademarks of MKS, Instruments, Inc. No affiliation, endorsement or sponsorship is stated or implied.

MODULAR IN-LINE FLOW METER FOR COMPRESSED AIR & GASES -Suitable for Various Pipe Diameters The compact EE741 in-line flow meter from E+E Elektronik measures accurately the consumption of compressed air and technical gases. Thanks to the modular design, one and the same transmitter can be used for three different pipe diameters (DN15, DN20, DN25). To do so, the transmitter is simply combined with the appropriate gauge mounting block. The thermal hot-film anemometer measurement principle stands for best long-term stability and short response time. Easy installation and low maintenance make the EE741 ideal for cost-effective consumption measurement of compressed air and technical gases such as nitrogen, oxygen, helium, CO2 or argon. The flow meter can accurately monitor standard volume flow, mass flow, standard flow, temperature as well as the consumption of air or gas. The EE741 employs the well proven E+E thin-film sensor, which operates on the thermal anemometer principle and stands out by excellent long-term stability and short response time. One particularly useful feature of the EE741 is the integrated consumption meter which enables cost-effective consumption monitoring without an additional datalogger. The EE741 flow meter can be easily integrated in any measurement and monitoring chain. It features a scalable analogue output (4-20 mA / 0-20 mA), two switch outputs and a pulse output. A Modbus RTU or M-Bus (Meter-Bus) interface makes the device future-proof and ready for Industry 4.0. For further information visit here E+E Elektronik GmbH. Tel. +43 7235 6050 | E-mail: pr@epluse.at | Web: www.epluse.com

PROCESS INDUSTRY INFORMER November 2016

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

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

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

4000 SLPM MFC

mass flow controllers mass flow meters pressure controllers

http://alicat.com

PROCESS MEASUREMENT & INSTRUMENTATION FROM SUBSEA AND MINING UP TO AEROSPACE

As the UK agent for ESI Technology OEM Automatic can offer standard pressure sensors and specialised pressure sensors through bespoke solutions for specific applications. A unique feature to ESI Technology is Silicone-on-Sapphire (SOS) technology which gives superior performance to older construction methods of sensors meaning capabilities and applications are vast. Not only can we provide products and solutions but we can also offer a recalibration and repair service to extend the life of the sensors further whilst keeping costs down. •USB pressure sensor to analyse and record direct to your PC •Differential measurement from 0...5mBar up to 0...200Bar •ATEX & IECEx certification (Zones 0 & 20 and Group I M1) •Very low pressure applications down to 0...50mBar •-1...4000 bar measuring ranges available •High temperature versions up to 250°C OEM Automatic Ltd Whiteacres, Whetstone, LE8 6ZG www.oem.co.uk

CUSTOMISED TANK MONITORING SOLUTIONS

CALORIMETRIC CREATION

Monitoring conditions in fuel and coolant tanks usually involves many instruments and ports which can cause many issues especially for service. Val.Co can offer fully customised level monitoring solutions according to your specifications incorporating many requirements into one and reducing the need for numerous ports in tanks and separate instruments. •Level switch and sensor combined •Temperature switch or sensor •Incorporated fill and return system with integrated air vent •Digital level display on head with battery backup for quick level indication check via button •Options for applications where there is severe liquid movement •Materials including brass, stainless steel, PVDF, PVC, polypropylene •Various process connections and electrical connector options OEM Automatic Ltd Whiteacres, Whetstone, LE8 6ZG www.oem.co.uk

Your specialist for pressure monitoring

Introducing the latest generation of Calorimetric sensing/ switching; LABO. A small robust product engineered within a 12mm housing the LABO is available as a flow switch/sensor, temperature switch/ sensor or level switch. It can also be used to monitor or switch the flow of nonaggressive gases. • Switch (push/pull, programmable) • 4...20mA • 0...10V • Frequency output OEM Automatic Ltd Whiteacres, Whetstone, Leics LE8 6ZG www.oem.co.uk

Mechanical pressure switches

Intelligent

Changeover (SPDT)

Basic (NO or NC)

Electronic pressure switches

With a comprehensive range of mechanical and electronic pressure switches complemented with a full range of pressure sensors, OEM Automatic, as the UK agent for Suco, can cover all your critical to basic applications including: l Automotive

l Mobile hydraulics

l Agricultural

l Off highway

l Medical

l Rail

Premium

information@uk.oem.se

Performance

High performance

Performance

Pressure sensors

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www.oem.co.uk

High performance

0116 284 9900

PROCESS INDUSTRY INFORMER November 2016

PROCESS CONTROL PROMAPP LAUNCHES PROCESS VARIANT MANAGEMENT SOFTWARE IN UK - New Tool Helps Companies Control Process Variations Promapp Solutions – an industry leading provider of cloud-based process management software – is changing the way companies with multiple locations or multiple products manage processes with the launch of its new Process Variant Management (PVM) software. “Managing process variations has always been a huge problem,” says Promapp CEO Ivan Seselj. “It is unnecessarily complex, costly, and inconsistent, particularly for companies which are multi-nationals, have numerous locations, or offer multiple core products or services.” The Promapp PVM Module addresses all of these issues by recognising standard processes and either managing or eliminating process variations. Unlike competing products, the Promapp PVM Module enables the standardisation of processes across the entire company, while simply incorporating process variations to meet the requirements of a specific corporate location, product, or customer if necessary. It also enables companies to customise activities and manage service delivery for key customers. This is particularly useful for internal or external shared service providers. “Simplifying the management of process variations allows companies to save both time and money, while enabling them to control and improve customised services and activities,” Seselj explains. BPM experts who previewed the Promapp PVM Module agree. IDC market analyst Joseph Hsiao notes, “Managing process variations is a big issue for multi-national enterprises who need to enable a certain level of localisation. Most companies are challenged with business process mapping – standardising business processes and creating a single source of truth. That is what Promapp does really well.” Steve Stanton of FCB Partners concurs, adding, “Ninety percent of the organizations I know have failed at standardisation. The fact that Promapp can identify and calculate the cost of process variants is very powerful.” Promapp clients who have been given pre-launch access to PVM are also impressed. Neal Ross, Director, IT & Services, Konica Minolta u With On Board PID Electronics ensures control of virtually any Business Solutions Australia explains, “We have an APAC regional pump technology imperative to standardise business processes. The initial program to u Independent of Fluid Properties standardise our core processes on our ERP platform was successful from an u On Board CORI-FILL firmware eliminates need for a Batch Controller IT perspective, however the impact of u Alarm Functionality to protect both the Process & Pump different business process requirements at a local level caused real problems u Self Learning with Fast Response and Stable Control for business users, service levels and costs.” “We are establishing an APAC region Innovation - Experience - Responsibility Centre of Excellence which includes process management and governance,” he added, “Promapp’s Process Variant Management Module allows local owners to manage their variations, while allowing the Centre of Excellence visibility and governance of all regional processes.” For more information about the Promapp Process Variant Management Module or other Promapp products, Bronkhorst (UK) Ltd - T 01223 833222 visit www.promapp.com.

Coriolis Flow Control

Precise Direct Mass Flow Control of Pump systems gives proven COST savings

I www.bronkhorst.co.uk - E sales@bronkhorst.co.uk

PROCESS INDUSTRY INFORMER November 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves PRECISE FLOW CONTROL FOR CRYOGENIC APPLICATIONS When precise, reliable flow control is required in challenging ultra-low temperature applications, such as cryogenic or other similar situations, Badger Meter control valves are an ideal choice. Available from liquids handling specialists PUMP ENGINEERING, the extensive Badger range includes models such as the Series 9000, an ANSI Class 300 globe style valve with bolted bonnet and post-guided inner valve. They are also available as specially configured options, for example Orion Control Valves which have extended bonnets for optimum protection against extreme temperatures. These valves are available in 1”, 1½” and 2” pipe sizes with body, bonnet and inner-valve in 316 S/S as standard, or in Alloy C as an option. The standard valve body, configured as a flangeless / NPT version, enables installation using NPT fittings or can be clamped between matching companion flanges. They are also available with conventional flanges in either the same nominal size as the valve body, or oversized flanges can be adapted to smaller bodies. Each valve is available with several inner-valve sizes, the largest having an integral seat for maximum Cv, while reduced Cv inner-valves will fit a threaded body with replaceable seat rings. The field-proven packing / bonnet design provides high performance in the most demanding environments along with quick, easy maintenance when required. Optional double packing in either PTFE or REK is available for fugitive emission control. To meet the demands of the most extreme applications and environments, Badger Valves can be specified with a range of options. For example, Stellite inner-valves, Teflon PFA soft seating, graphite packing, double packing, extended bonnets up to 18” and bonnets fitted with cooling fins. Also, to meet specific application requirements a wide range of accessories are available including; positioners, i/P positioners, transducers, gauges, filter regulators, solenoids, limit switches and position transmitters are also available. The high performance, multi-spring, diaphragm design 9050 actuator is field reversible from air-to-open to air-to-close without the need for additional components. The yoke and actuator housings are constructed from carbon steel and are coated with epoxy for corrosion resistance. Badger Meter Series 9000 valves and their associated actuators are ideal for control of liquids and vapours across a wide range of industrial applications where the demands are for compact, yet rugged and highly reliable control valves. Further details and product literature is available from: Pump Engineering Ltd, el: 01903 730900 E-mail: sales@pumpeng.co.uk | Web: www.badgermeteruk.com

GRIP COUPLINGTM FOR ALL METAL PIPES

WASHDOWN CLEAN UP... The CSF Steam Water Mixer is perfect for cleaning and washing down process machinery or storage vessels. ● Delivers water to a maximum temp of 95˚C

and volumes up to 10,000 litres/hour.

● Simple to install, safe to operate. ● Running costs minimised, because all the

heat energy in the steam is transferred to the water.

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

AB15-911

Safe, simple cleaning with CSF water mixer

MV Fluids Handling’s Straub Grip Coupling simplifies pipework, 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 setting-up, 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, Tel: 0118 9503707 E-mail: straub@mvfh.co.uk Web: www.straub.co.uk

PROCESS INDUSTRY INFORMER November 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves HIGH HORSEPOWER QUINTUPLEX DIAPHRAGM PUMPS LAUNCHED

INTELLIGENT HIGH PRESSURE COOLANT PUMP GENERATES COST SAVINGS

Wanner International has launched a new range of Hydra-Cell. Seal-less, high horsepower, quintuplex diaphragm pumps that it claims eliminates the expense associated with seals and packing, leakage, external lubrication, and emissions. Achieving flow rates of up to 595 lpm and pressures up to 241 bar, the pumps have low NPSH requirements, allowing for operation with a vacuum condition on the suction - positive suction pressure is not necessary. Hydra-Cell Q155 Series pumps can operate with a closed or blocked suction line and run dry indefinitely without damage, eliminating downtime and repair costs. The unique diaphragm design is said to handle solids up to 800 microns along with the minute abrasive particles that cause wear in gear, screw or plunger pumps while the compact design and double-ended shaft provide a variety of installation options. Having five diaphragms in a single pump head guarantees virtually pulseless flow and tests have shown that these pumps are able to handle shear sensitive liquids better than rotary positive displacement pumps. There are some five pumps in the Hydra-Cell Q155 range to ensure your pressure and flow rate requirements are covered in the most economical way. For more information contact: Wanner International, Fleet, Hants. Tel +44 (0)1252 816847 Email: NHerrington@wannerint.com Web: www.hydra-cell.eu

Wanner International has introduced the Hydra-Cell Intelligent High Pressure Coolant Pump that it claims can save machine tool operators up to 70% of their pump energy costs. In through-tool coolant systems, each cutting tool requires a different coolant flow in order to achieve its optimum pre-set pressure. Conventional high pressure coolant pumps tend to be sized to meet the requirements of the largest cutting tool and continue to produce that fixed flow rate whatever the tool size in question. For smaller tools or during tool change intervals, these pumps merely bypass all or excess cutting fluid back to the sump, wasting energy. This wasted energy is dissipated as heat, warming the coolant itself, necessitating and the use of chillers in many instances. The Hydra-Cell Intelligent Pump succeeds by delivering the right amount of coolant for each tool in the carouselâ&#x20AC;Ś automatically. No energy wasting coolant bypass is necessary. Further savings to can also be made in terms of chiller costs and chiller energy consumption. Installation is simple, requiring no complex valve assemblies or pressure feed-back loops; merely a power source and simple M-code on / off instructions. Seal-less by design and run-dry protected, Hydra-Cell Intelligent Pumps handle abrasive fines and particles with ease, removing the need for fine filtration. They are equally efficient in pumping neat oils and water-mix fluids and excel when pumping the non-lubricating grinding fluids that cause damage to pumps with dynamic seals and tight internal tolerances. For more information contact: Wanner International, Fleet, Hants. Tel +44 (0)1252 816847 Email: NHerrington@wannerint.com | Web: www.hydra-cell.eu

PROCESS INDUSTRY INFORMER November 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves AUMA’S ACTUATOR LEAKAGE TESTER FOR LONG-TERM PEACE OF MIND Every single AUMA electric valve actuator is fully pressure tested and guaranteed IP68 when delivered to site, as part of the bespoke assembly process. AUMA’s PV1691 portable leakage tester, available in the UK via AUMA’s in-house service team and many of their ACE service partners, helps users to check air and water-tightness of AUMA actuators after electrical installation, retrofits or repair work. Environmental ingress into an actuator usually results from an external issue, such as cable glands being wrongly installed or of the wrong type. Even if water does get in, AUMA’s double seal makes sure that it can’t reach the electronic heart of the device, but the leakage tester makes it easy to check that the electrical connection is properly sealed and that O rings in the housing joints are intact and correctly seated. AUMA’s leakage tester consists of a compact device that is attached to one of the housing openings on the actuator. An integral pump pressurises the housing, after which the clear LCD display shows the pressure loss over a predefined time period, with a pass/fail result based on a choice of pre-programmed test routines. Battery powered for use throughout a plant, the leakage tester is supplied in a compact, robust carrying case that also includes an adaptor, leak detection spray and charger. For more information contact Auma Actuators Ltd, Clevedon, Tel: +44 (0) 1275 871141 Email: mail@auma.co.uk Web www.auma.com

HOW TO IMPROVE A DOSING OR METERING PUMP…

ENGINEERED FOR ENGINEERS

By James Walton, Sales Manager of Bronkhorst

Many of our customers want to combine flow meters with pumps and as a result we frequently get asked the same questions again and again… If we have a dosing/metering pump why do we need to have a Mass Flow Meter? Traditionally, and in most cases we see, dosing/ metering pumps are believed to be accurate because the theory is that a known pump head displacement will move a known volume over a known time giving a known delivered volume. Very often this will be OK, though it will never achieve a high level of accuracy with deviations of 10-15% being normal. Inaccuracies like this are caused by many changing process conditions: 1. Temperature 2. Pressure shifting 3. AiR entrapment 4. Wear of components These factors can each be the cause of an inaccuracy in the expected volume of displacement from a pump head movement, if you then multiple each of those factors you can realise quite large errors that create both inaccuracy and inconsistency. Please refer to our earlier blog ‘High Accuracy’. WHAT CAN BE DONE TO MANAGE THESE PROCESS CONDITIONS? Add a flow meter between the pump and the process. You can then take information from the flow meter to adjust the speed of the pump. Traditionally this would be managed with an output, analogue 4….20mA or similar, signal from the flow meter into a separate PID controller that compares the real flow signal to the desired flow. The electronic controller can then adjust the speed of the pump to achieve the desired dose/flow. Using that solution will mitigate the issues in the original solution, however it introduces more: 1. Slow flow signal due to filtering 2. Slow pump response due to extra control relay 3. Increased complexity with extra components 4. Time to achieve stable flow can be long Now we need to discuss the next possible solution, using a direct Mass Flow measurement device with built in PID control that can drive a pump to achieve the desired dose or flow. With this solution you do not need to include the pump in the control system, just give a set-point demand to the Mass Flow Meter and it will drive the pump to achieve the desired dose/flow. This solution will give you several advantages. 1. Direct mass flow control of the dose/flow 2. Accurate delivery mitigating normal pump issues 3. Alarm functionality of low dose/flow 4. Preventative maintenance based on pump performance over time 5. Consistent dose/flow measurement based on actual not assumed numbers. These advantages can be utilised in many different industries: Anywhere that liquid is dispensed into a container that will require QC, and commonly the QC test is carried out on a small percentage of the vials to ensure general compliance. If you use a Mass Flow Meter to control the dose you can achieve 100% QC checking of your product with reduced human input. If you need to dose additives, performance chemicals or mix liquids then the ability to control the flow of the additive and know what that flow is can be a huge advantage to the outcome of the application. If you enjoyed the blog I would ask you to investigate out Youtube channel and website, both linked below. goo.gl/C3WQwh goo.gl/mCf5Zd

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

PROCESS INDUSTRY INFORMER November 2016

FLUIDS & LIQUIDS HANDLING incl. Pumps & Valves HANDLING HEAT WITH HIGH TEMPERATURE REPAIR COMPOUND NCH EUROPE INTRODUCES MEGA FIX-IT HT Water, energy and maintenance solutions provider, NCH Europe, has launched Mega Fix-IT HT, a high temperature repair compound. The product is ideal for fast, in situ repairs of industrial plant pipework and equipment in high temperature environments, helping companies reduce downtime and increasingprofitability. Mega Fix-IT HT uses a unique formula with ingredients similar to those found in the latest high tech aerospace adhesives. As a result, the new repair compound offers high strength repairs at temperatures up to 260° Celsius. Easy to carry and use, the product cures hard enough for engineers to machine or drill the surface. Up to four times stronger than competitor compounds, Mega Fix-IT HT also retains some flexibility, allowing parts to expand and contract under high temperatures. “One of the biggest problems plant engineers face is making quick repairs to stop plant downtime,” explained Peter Crossen, VP of the Maintenance and Partsmaster Innovation Platform at NCH Europe. “This is why we’ve developed Mega Fix-IT HT, a repair compound that has an initial cure time of just 60 minutes and after eight hours has similar properties to that of steel. “While most epoxies weaken above 150°C, Mega Fix-IT HT toughens and retains high levels of bond strength up to its maximum temperature of 260°C.” Unlike other high temperature repair compounds that contain titanium, which can become lumpy when mixing, Mega Fix-IT HT uses a unique titanium-free formula, which makes it easier to mix with increased toughness at high temperatures. After the success of its other high performance stick repair compounds, Mega Fix-IT HT completes NCH Europe range of repair epoxies designed to cover almost every industrial application. To find out more about improving plant maintenance and repair applications, contact NCH Europe on +44 (0) 1902 510200 today.

PROCESS INDUSTRY INFORMER November 2016

AIR-COOLING vs WATER-COOLING A guide to choosing cooling systems for industrial applications During summer every year, something very unexpected occurs in the UK; we glimpse a fleeting moment of sunshine. During this, there is often a debate about what the best way is to cool down from the seemingly unbearable heat, with some people choosing the humble fan and others opting for a dip in the pool. A similar debate often occurs when businesses look for ways to keep their machinery cool. Here, Steve Hughes, managing director of power quality specialist REO UK, explores how businesses can choose between air-cooling and water-cooling systems for industrial applications.

ost of us can appreciate that industrial equipment gets hot during use, damaging components and hindering functionality. This is particularly true of electrical equipment where, in addition to the typical operational temperature, there is also the heat generated by electrical currents on the network. Being acutely aware of this, it is commonplace for plant managers and original equipment manufacturers (OEMs) to install cooling systems into equipment. However, cooling electrical infrastructure and industrial equipment isn’t as simple and straightforward as just turning on a fan. In fact, even something seemingly unrelated like the location of the device is vital in ensuring that the system is cooled effectively and safely. Considering these factors, engineers can choose the right cooling system for their equipment. There are two main ways of regulating device temperature, aircooling and water- cooling. Air-cooling is the most commonly used and, as the name suggests, uses fan technology to circulate air around the device. Water-cooling, on the other hand, uses liquid coolants to transfer heat out of equipment and is often met with apprehension by plant managers. However, both have their place within industrial environments if used correctly.

AIR-COOLING CONSIDERATIONS While the humble fan is what many people initially think of when asked about cooling, it is not without its limitations. For example, the inclusion of a fan often means that theenclosure of a device needs to be bulkier to accommodate it, which can cause problems with integrating devices into certain industrial

setups. This is especially true with electrical power controllers, as many are integrated into transformer cabinets. In instances such as this, the bulkier design of products featuring fans may cause problems and engineers may require the sleeker design of a water-cooled power controller. Yet air-cooling does offer benefits to businesses. The reason that these systems have proven so popular is because they are relatively inexpensive and typically require less maintenance beyond the replacement of filters. So long as engineers are vigilant, fan- based systems will not encounter too many operational difficulties. Fans are also independent in use, able to provide effective heat transfer in more remote applications. Liquid cooling requires a series of tubes for the coolant to flow through, taking away the heated fluid to another part of the plant for use in another process. This may sound efficient but some applications are unable to facilitate such a system, making the uncomplicated design of fans desirable. In addition to this, there is an element of peace-of-mind with air-cooling. One of the biggest concerns plant managers have with alternative systems such as liquid coolants is their safety and stability. Many electrical engineers have reservations about using water-based systems in close proximity to electrical equipment.

LIQUID COOLANTS AND WATER-COOLING Initial safety concerns aside, water-cooling boasts a range of benefits for industrial applications that go beyond those offered by traditional air-based systems. In fact, these systems are able to deliver on the areas where fans often fall short. Water-based systems operate on a very simple principle of heat exchange: pipes containing a liquid coolant circulate around an enclosure and out of the device to keep components cool. The excess heat generated during use is thermally conducted by the water in the pipes. This heated water is then transferred out of the device and into other industrial processes, such as plant heating. The development of cooling technology in recent years means that it now poses no risk of causing an electrical fire. This is due to the self-contained housing that these systems include as standard, which ensures that no water can reach

critical components in the unlikely event of a coolant leakage. Despite this added safety measure, the system remains compact so that it can be easily fitted into equipment without increasing the product footprint. This solves the problem faced by air-cooling and means that water cooling can now be used in environments where space is limited. The biggest selling point for water-cooling is its increased energy efficiency. Not only are fans are limited by their reliance on ambient temperatures to cool down overheating components — after all, air conducts less heat than water — in order to provide sufficient cooling, multiple fans might be necessary. This increases the energy consumption of the cooling system. Conversely, water has a high heat conductivity so systems only require a single pump to effectively cool infrastructure. This coolant can also be stored in the pipes at a temperature below a plant’s ambient level for an even faster cooling. Engineers looking to specify liquid cooling need to consider the fact that, although it will have a higher return on investment, the initial setup of liquid cooled systems is more complex and more costly than air-cooled systems.

HOW DO YOU CHOOSE? The first step to selecting the right cooling system is by identifying where the device will be used and what the typical operating challenges will be. For example, businesses in the electroplating sector will find that a lot of the copper sulphate particulates produced during plant production can get into the enclosure vents of air-based systems an corrode core components and wiring. In these situations liquid-cooled alternatives might be preferential. Likewise, high voltage electrical infrastructure generates more heat than a standard electronic device. To this end, electrical OEMs such as REO UK can work with electrical engineers to determine the best solution for particular electrical requirements. Take for example our REOTRON MDW 700 power controller which is designed for use with industrial transformers and is available in both air and water-cooled versions. For transformers expected to operate at more than 50A, it is advisable that businesses opt for either additional fans for the air-cooled model or opt for the water-cooled REOTRON MDW 700 WK model to eliminate the risk of overheating. The final step to choosing the right cooling system is to determine how regularly it will realistically be maintained. Fan filters need replacing frequently to avoid a build-up of contaminants that can lead to overheating, so using these systems in difficult-to- reach or less frequently maintained applications is not recommended. Just as choosing between standing in front of a fan and standing in the ocean on a warm day can be a difficult decision, so too is selecting the right cooling system for industrial applications. By considering the factors that affect equipment performance further down the line, engineers can ensure they make the right choice every time.

PROCESS INDUSTRY INFORMER November 2016

DRIVES & MOTORS

FILLING NOZZLES BESPOKE NON-DRIP HYGIENIC STAINLESS STEEL FILLING NOZZLES

ABB INTRODUCES DODGE® QUANTIS® GEARMOTORS THAT DELIVER INCREASED PERFORMANCE

Working in collaboration with key engineers from a leading UK Pharmaceutical Manufacturer, Axium Process has developed a new Hygienic Filling Nozzle design that has helped eliminate potential cross contamination or lost product with associated down time caused by standard filling nozzles dripping excess material onto bottles during

liquid filling processes. The nozzle, which is manufactured from 316L stainless steel, underwent a series of rigorous trials across a number of applications and following successful completion has now been installed as standard on the majority of filling machines across the Manufacturer’s site. Axium Process, is one of the UK’s leading hygienic stainless steel fabricators and specialises in delivering bespoke high end machined and fabricated components such as sampling devices, filters, tanks, vessels and manifolds. The company’s Procedures and Welders are Notified Body approved to ASME IX, BS EN ISO 9606-1 and BS EN 15614-1, which combined with the company’s stringent production, inspection and validation procedures, enables it to fully meet almost any level of requirement, including full traceability dossiers as specified by companies operating in the pharmaceutical, food, beverage and chemical industries. For further information please contact: Axium Process Ltd, Tel: +44 (0) 1792 883 882 Email: info@axiumprocess.com | Web: www.axiumprocess.com

ABB introduces the Dodge Quantis gearmotor featuring IEC rated motors that have NEMA Design B torque characteristics offering up to 50 percent more starting and overload torque versus competitive

products. This means more torque is available when cold or fully loaded starting is required, ensuring equipment gets moving. For shaft-mounted applications, Quantis gearmotors feature a patented twin-tapered bushing system that provides easy installation and removal of the reducer from the shaft, saving time and maintenance. Quantis gearmotors are available for the European market in three styles: inline (ILH), right angle (RHB) or offset parallel (MSM). With ratings from 0.18 kW to 7.5 kW, up to 14,000 Nm output torque, and ratios up to 350:1, the new Quantis gearmotor is ideal for pumping, material handling, conveying and mixing applications found in a variety of industries. For more information contact ABB Limited, Warrington, Cheshire Tel: 01925 741111, Email: energy@gb.abb.com | Web: www.abb.co.uk/energy

PROCESS INDUSTRY INFORMER November 2016

I0 LINK ACTUATION

/SENSOR HUBS

MORE EFFICIENCY & FLEXIBILITY

IO-Link sensor/actuator hub with expansion port IO-Link actuator/sensor hubs from Balluff feature eight ports for 16 in-/outputs. They allow for example signals from up to 16 switching sensors to be collected from a distance of up to 20 m so that they can be made available to the machine controller via IO-Link and an IO-Link master using a simple 3-conductor cable. Brand new in the market are versions with an expansion port. Here Slot 7 can be reconfigured as an expansion port by means of a simple parameter entry. A complete valve plug or an additional sensor hub can be connected to it. For the user this means a significant gain in flexibility and efficiency. Now it is possible not only to cost-effectively process additional in- and outputs, but also expand the range to a circle of another 20 m. Thanks to plug-and-play and the use of unshielded standard cables, the system can be started up in no time at all. For more information contact Balluff Ltd, Cheadle, Cheshire. Tel: +44 (0) 161 282 4726 E-mail: jayne.hawkesworth@balluff.com.uk Web: www.balluff.co.uk

TECH START-UPS EMBRACE ROBOTICS According to the International Federation of Robotics (IFR), robots sales are at an all-time high. By 2018, the IFR estimates that 2.3 million industrial robots will be in operation across the globe. Jonathan Lee Recruitment has seen a 35% increase in demand for skilled people to apply automation and robotics to their fledgling high-tech businesses. In this article, Richard Heaton, automation specialist at Jonathan Lee Recruitment, explores why tech start-ups are embracing robotics and automation as they look to compete on the world stage post-Brexit and the options they have to get the right team in place to achieve the best solution.

here is much talk of the threat that robots pose to our workforce. Only last month market research company Forrester predicted robot will eliminate 6% of all jobs in the US with their impact particularly felt in the fields of customer service and transportation. However, despite doom and gloom prediction, the outlook for manufacturing is one of opportunity rather than threat. Manufacturing has for the large part, already had to reinvent itself in order to compete, often on a global stage. The move to lean and more efficient and effective Japanese manufacturing methodologies first penetrated automotive then the wider industrial base and most factories now are dominated by machines and automation delivering consistent and quality products. The new digital wave is dominated by data, the headlines by high profile projects such as driverless cars and drones. Meanwhile adoption of 3D printing, once seen as niche, is now part of a mix of innovative new technologies destined to be the catalyst of exciting change. For many in industry, the Brexit vote has crystallised the need to harness new digital technologies wherever they have the potential to increase competitiveness by minimising waste and cost and increasing efficiency. It is in this space where many tech start-ups are emerging. They tend to follow two possible routes: either developing and creating disruptive technologies of their own, or looking for ways to partner with big business to enhance and transform older legacy technologies to help them embrace Industry 4.0. They are looking for problems to solve and are working with manufacturers to deliver practical solutions. A recent story in the Daily Mail was headlined Move over Gordon Ramsay, robot chefs are coming: Intelligent machines are now helping make PIZZA and told the story of how a start-up in California was using robots to put pizzas together to order and will soon be used to cook and box the pizzas too. The point of the story is that robots are being used to eliminate the boring, repetitive and dangerous jobs. In recruitment, we have always focused on the role of the skilled engineer and while that job is highly unlikely to be replaced by a robot, engineers will increasingly need to understand the role that digital and data will play and digital pioneers will need to understand the constraints and properties of materials in a whole range of different environments. Essentially they will

need each other; each will act as an enabler to the other.

DIGITAL TECHNOLOGY IS MOVING APACE... The Tech Britain 2016 report highlighted that digital technology sector is growing at a faster rate than any other industry. The sector represents 38.5% of science and high tech industries, 35.9% of aerospace and defence, 32.4% of electronics equipment and instruments, and 20.1% of electronic parts and components businesses. According to the World Economic Forum, for every job lost through automation in the UK almost three new ones will be created. In the same way that the typing pool was replaced by computers that depend on IT support staff, programmers and analysts, robotics and automation also need a dedicated team, indeed a whole industry to service them. Premier Foods has introduced 47 robots in a ÂŁ20m investment to pack Mr Kipling Cakes, remote controlled robots were used to clean up the Fukushima nuclear plant and the University of California introduced robotic pharmacists which have so far zero errors dispensing 350,000 doses. Vine picking robots are being introduced in France to help with cutting, pruning and harvesting and the mining sector is turning to robots to reach remote and treacherous areas. But for each of these working robots, there is a team that has designed it, taught it how to operate and established maintenance protocols. As far as tech start-ups are concerned they are looking for scalable ways to quickly bring new products to market. Robotics and automation make sense for businesses that will increasingly rely on data-driven opportunities. For example, the Internet of Things is making it possible for unprecedented levels of personalisation in products. The potential to make products to specific requirements helps to reduce inventory and waste, which, for fledging businesses faced with a cash flow challenge, can be enormously beneficial. If you think about how quickly our phones and TVs become obsolete then this gives a flavour of how dynamic changes in manufacturing can be. Many manufacturers now nurture relationships with universities to cultivate the skills that will ensure positive business transformation as part of their future planning. Tech spin-outs from universities often work closely with manufacturers to realise their ideas and designs and achieve the commercial potential they could never have achieved alone.

In turn, it is a great way for manufacturers to tap into expertise that they cannot find within their own workforce, or indeed the market as a whole and explore the potential of the latest advances in artificial intelligence, machine learning, robotics and 3D printing and how these may give them competitive advantage in the future. We have also seen rapid advances in remote monitoring, including the use of drones to collect visual data, transforming maintenance roles in aviation and the utilities sector. The symbiotic nature of digital technologies, their ability to talk to each other and connect businesses and their customers in ways never dreamed of unleashes a wide range of ways for tech start-ups to add value. Behind every new invention that hits the headlines there is a startling and exciting array of new components that are needed, from sensors to batteries to wireless, radar and data and energy storage. The list of supporting technologies being developed and the speed with which they will come to market, makes the application of automation in their delivery almost inevitable.

ROBOTS INEVITABLY â&#x20AC;&#x201C; BUT THE VALUE OF ENGINEERS IS PARAMOUNT... The array of robotic technologies being applied to industry, transport, medicine, defence and communications alone, is vast and the challenge to find the right mix of people to deliver them is one that is sparking a revolution of its own. At the recent Paris Motor Show, we saw rival car companies announcing collaborative technology projects to rival the threat of autonomous vehicles posed by Google and Apple. Some, particularly those with limited research and development budgets are looking for innovation from suppliers. Commentators are also predicting a shift from these start-ups operating in a purely automotive space in the race for leading edge software solutions. Against this backdrop, the mix of skills required by engineers is diverse, from mechanical, through electronic and into software. Add to that the need for leadership, team working and problem-solving skills and the continued value of the engineer in this latest industrial revolution should not be underestimated. Creativity, relationship building and nurturing talent will be key and these are attributes I doubt a robot will ever be able to achieve in my lifetime.

PROCESS INDUSTRY INFORMER November 2016

BEARINGS H3G BEARING GREASE FROM NSK IS 100% FOOD DERIVED NSK has developed the world’s first grease lubricant that is 100% derived from food grade ingredients. The development represents a breakthrough for any plants where machinery, production equipment or devices come into contact with foods, pharmaceuticals or cosmetics. Furthermore, the new H3G grease is ideal for any application that is suited to the lubricant’s additional strengths of water resistance and low torque. Typical applications range from food machinery such as shakers, fillers, centrifugal separators, bottling machines and conveyors, through to pharmaceutical, cosmetics and medical process devices, including pumps. Importantly, the environmentally friendly grease conforms to the highest international standards for safety regarding products that may come into accidental contact with food. The new NSK eco-friendly grease, which is petroleum-free, exceeds the standards of lubricants currently used widely in such applications. These are generally based on rapeseed oil and other vegetable oils that contain many non-food ingredients. Such greases can also have performance limitations, with lower oxidative stability, resulting in lubricity and durability issues. In contrast, NSK’s grease is made entirely from food-based ingredients including the base oil, thickening agent and additives. For instance, foodgrade vegetable oil is used for its excellent heat tolerance as a base oil, while the thickening agent contains food additives with a fine 3D network for good base oil retention. The lubricant is also formulated with food additives that further enhance the durability of the base oil, delivering a grease that offers enhanced oxidative stability and one-third lower friction loss (torque) than existing comparable products. Further advantages are less leakage and longer service live, even where there is exposure to water. From an environmental perspective, the grease is naturally biodegradable and produces no toxic waste, making it both non-polluting and fully sustainable. For more information contact NSK UK L td, Nottingham. Tel: +44 1636 605123 E-mail: measham-h@nsk.com Web: www.nsk.com

PROCESS INDUSTRY INFORMER November 2016

SEPARATING THE GOOD FROM THE BAD:

PRIORITISE YOUR STORAGE TANK MAINTENANCE

Risk-based inspection systems and advanced non-destructive testing methods are helping storage tank owners comply with ever-increasing stringent regulations, as well as reducing maintenance costs, says Tim Bradshaw, General Manager, MISTRAS GROUP, UK Operations.

or owners of above ground process storage tanks, including both atmospheric and pressurised storage systems such as bullets and spheres, tank inspection programmes are normally based around EEMUA 157 and/or API 653. According to both of these standards, the purpose of an inspection is to determine if tanks are safe for continued service in terms of their mechanical integrity. Originally, inspection plans were strictly regulatory compliant, utilising traditional manual, non-destructive testing (NDT) techniques such as visual, ultrasonic and settlement surveys, which were used for both in-service and out-of- service inspections. To help tank owners comply with ever-increasing stringent regulations, risk-based inspection (RBI) systems and advanced non-destructive testing (ANDT) methods can be used to assess the condition and mechanical integrity of an individual tank or a complete tank farm. This tank-specific RBI approach enables owners to focus their inspection on those assets that have the highest probability of potential problems. It also considers the consequences of such a failure. As a result, out-of- service tanks that exhibit potential problems can be inspected, while continuing to operate assets that are in good condition. A combination of inspection methods can be used to monitor and grade the condition of tanks. One of these is techniques is acoustic emission (AE). The application of mechanical or thermal stress to a material results in elastic energy being stored in that material. The stress field sustained by the material tends to concentrate at localised mechanical instabilities, which exist in almost all practical mechanical structures. If the applied stress is high enough, the material will fail at such local stress concentrations and crack, until the propagation of the crack is such that the material has become stress free and the stored elastic energy has been dissipated. The method by which this energy is released is a step-like process, where the crack grows in a chaotic cascade of distinct, discrete snaps. Each snap provides a discrete pulse of energy that propagates throughout the surrounding material in the form of a transient elastic wave. The frequency content of these pulse-like transient waves is broadband, ranging from a few KHz to a few MHz. Much of this is in the ultrasonic region, detectable by using specialised AE sensors. The identification, location and evaluation of structural defects and active cracks in pressure vessels, pipelines and storage tanks is now routinely applied to process plants. But active cracking is not the only source of AE. Chemical processes such as corrosion spalling, fracture and debonding are very emissive. The AE arising from the corrosion process on the floor of a storage tank, for example, will travel through the product in the tank, through the tank wall and into the sensors attached to the outside. A ring of sensors can be used to pinpoint the location of the AE from within the tank and so, in the space of an hour or so, provide a very detailed picture of where the corrosion is, and how bad it is. Tank floors remain largely unseen and are traditionally uninspectable during operation. Normally, this involves costly shutdown and

decontamination followed by detailed local inspection. Often, this is executed from an inspection schedule according to a predetermined period of time in service. To know when the condition of a tank justifies being taken offline and cleaned out, in order to prioritise and target inspection and maintenance activity accordingly, is of huge economic(and environmental) benefit to tank owners.

AE PROCESS FOR TANK FLOORS AE sensors are mounted on the wall around the tank’s circumference and connected to a data acquisition system. To assess the condition of the tank floor, a window of one hour is required to gather enough data for a valid statistical assessment of the floor. To achieve a ‘quiet hour’ all activity likely to cause product movement must have been stopped and the tank allowed to settle for a period of 6 to 12 hours. Agitators, heater coils, level measurement systems, etc. Must all be turned off. Disruption to operations is thus no more than one working day per tank. The result of the condition monitoring exercise is a tank floor grading, from A (no damage) to E (major repair required).Also, plots are presented to show the location(s) of any particularly active areas and/or potential leak sites. MISTRAS has conducted more than 1,000 such tests on tanks in Europe alone and more than 3,000 worldwide.

HUGE SAVINGS TO BE MADE The overall tank floor and potential leak grades can be used by plant management to prioritise tank inspection and maintenance programmes. Cost savings from the use of this technology are very clear. If the vessel is in good condition, leading to the deferral of internal inspection, savings are enormous. The cost of preparing a large crude oil tank for internal inspection can reach £350,000 and for large cryogenic tanks up to £750,000. More than 50% of the ‘suspect’ tanks inspected by MISTRAS were proven not to require subsequent offline inspection and maintenance, saving millions of pounds for refinery and distribution terminal operators. For pressure vessels, the figure increases to 95%. This reveals how poorly targeted most shutdown maintenance is. At the other end of the scale, the skeptic might suggest that a £7,000 AE assessment which confirms that a suspected poor vessel does not need to be opened for repair is money wasted. However, costs can be measured in safety and environmental terms, as well as in pounds.

COMPLEMENTARY METHODS It is important to treat the AE method as complementary to other methods. This is because, unlike ultrasonic testing, AE integrity assessment does not detect static, non-growing defects, nor does it measure their size. On the other hand, it will detect and locate regions of overstress or areas where micro structural problems exist,

which are structurally significant and which are easily missed by conventional localised methods. The effectiveness of both methods is improved by using them together. AE should thought of as condition monitoring for static plant: a tool for determining which tanks need conventional inspection, where and when. It should not be assigned to, or used by, inspection departments. It is a management tool to be employed by senior maintenance personnel with a direct interest in managing maintenance budgets and directing inspection personnel to where they are really needed. There is often a temptation to repair tanks simply because they are offline, particularly when inactive cracks not identified by AE are found by other methods. Unnecessary repair often introduces new stresses to the vessel which were otherwise not present.

ANNULAR ULTRASONIC TESTING Tank Annular Long Range Ultrasonic Testing (TALRUT) is an automated long range ultrasonic technique developed by MISTRAS to qualitatively map the condition of the annular. The system wall needs to be free of obstructions. The method involves sending long range ultrasonic signals into the tank from the outside annular (which must be in reasonable condition). The tank itself does not need to be removed from service. Indications are compared to a test plate in order to evaluate the severity of corrosion. This technique can be used on steel and fiberglass tanks and vessels. Remote UTcrawlers and cameras can also be used to map the thickness of hard to reach areas.

MAGNETIC FLUX EXCLUSION To more accurately determine the extent of potentially flawed areas, Magnetic Flux Exclusion (MFE) or Low Frequency Electromagnetic Technique (LFET) scanning tools can be used to inspect 100% of the tank floor. Characterisation of defects is performed using traditional non-destructive testing techniques including ultrasonics, penetrant, magnetic particle and vacuum box inspections. The most effective approach to tank inspection blends the regulatory compliance to current codes and standards with Risk Based Inspection and Advanced Non Destructive Testing methods. The Tank Specific RBI approach allows owners to concentrate inspection on those assets that have the highest probability of potential problems. It also considers the consequences of such a failure. As a result, Out-of- Service inspection of tanks can be recommended that exhibit potential problems, while continuing to operate assets that are in good condition. The continued operation of healthy tanks, along with large reductions in budget spent on preparing tanks for traditional internal inspections (including cleaning, degassing and waste disposal) provides tank owners with better profitability and improved operational effectiveness.

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