Process Industry Informer September 2014

PROCESS INDUSTRY INFORMER.

SEPT 2014 Volume 10 No. 5

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

What’s the future for the food industry?

See inside...

In this issue...

• 9 Generic Editorial Articles • News & Events • Case Studies • Product Introductions • WWEM Preview • BPMA News

We consider what is happening to the food industry, look to the future of the process industry, check out asset management, have a peep into new technology, how thermal imaging is helping in the food industry, management of energy & utilities, help with level measurement, clean up process water and take care with compressed air.

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

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The Emerson logo is a trademark and a service mark of Emerson Electric Co. The ASCO logo is a registered trademark of ASCO Valve Inc. Š 2014 ASCO. All rights reserved.

CONTENTS

EDITORIAL FEATURES Process Water Filtration shouldn’t

News & Events 4-6

Thermal Imaging Cameras 35

Applications 7-10

Welding Services 35

Under Pressure - will the food

Materials Handling 10

Calibration 35

Tank Level Measurement Options

Slide Valves 10

Network & Communications 37

Make it safety first

WWEM 13-17

Process Control 37

Particle Sizing 18

Process Measurement & Instrumentation 38-39

Analysers 18

Gas Detection 41

Level Measurement 22

Coding Units 41

Heat Energy & Transfer 22

Power Conversion 41

BPMA News from The British Pump Manufacturing Association 23-30

Filtration & Separation 41

The Future is Here 43

Industrial Fans & Blowers 32

Fluids & Liquids Handling inc. Pumps & Valves 42 + 45-47

Management into

Dust Control 32

Health & Safety 48-49

Compressed Air Line Equipment 32

Product & Services Directory 50-51

be as clear as mud! 12

industry crack? 19

for Powders & Solids 20-21

with compressed air 33 Five ways to improve Food Processing efficiency with thermal imaging 34 Process Control & Automation Technology can help keep operations healthy 36

Editor Phil Black philblack@piimag.com Publisher/Advertising Manager Peter Ullmann peterullmann@piimag.com Digital Marketing Manager Guy Ullmann guyullmann@piimag.com Supplements Manager David Harling davidharling@piimag.com Office Manager Diane Lawrence dianelawrence@piimag.com

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

Achieving excellence in energy and utilities management 40 Virtualisation:

ISO 5500 - Taking Asset the Boardroom 44 An explanation of the revised EN ISO 14119 standard 48

All product announcements published in Process Industry Informer are paid for. All copy submitted for publication in Process Industry Informer must be legal and must comply with the British Code of Advertising Practice and is accepted for publication, or not, at the publishers’ absolute discretion. When deemed necessary all copy may be edited and classified at the publishers’ discretion.

All material contained in Process Industry Informer is published in good faith, but it is emphasised that the publishers do not in any circumstances accept responsibility for the accuracy or otherwise of any advertisement or message published (nor is any kind of warranty expressed or implied by such publication) and that the publishers specifically disclaim all and any liability to advertisers, readers and user of any kind for loss or damage of

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NEWS & EVENTS

ABB chosen

by Shell as global supplier for lowvoltage switchgear & motor control centres Five-year global single source agreement signed

ABB has signed a five-year agreement with Shell to become its global single-source supplier of low-voltage switchgear, motor control centres and related services.

“This global agreement demonstrates that ABB’s commitment to provide premium low-voltage solutions and services creates value for a global company like Shell, focused on safety, reliability and energy efficiency,” said Tarak Mehta, head of ABB’s Low Voltage Products division.

“Over 40 years of experience have gone into ABB switchgear designs. We have installed millions of units globally for our customers, in some of the world’s most harsh environments. The reliability of our products, together with our focus on supporting our customers’ service needs, were fundamental aspects in securing this important contract.”

The five-year global agreement, with an option for an additional five-year extension, covers the sales, support and service of low-voltage switchgear and motor control centres across both IEC* and NEMA* geographies for green-field and brown-field sites.

ABB’s Low Voltage Products division is a leading provider of protection, control and measurement solutions for a wide range of electrical installations, enclosures, switchboards, electronics and electromechanical devices across all major industries including the residential sector.

For more information contact ABB Ltd Process Automation, St Neots, Cambs. Tel: 01480 475 321 Fax: 01480 488 283 E-mail: oilandgas@gb.abb.com Web: www.abb.com/oilandgas

Sponsored by

EXPERT OPINION & ARBITRATION SERVICES FROM AXION CONSULTING Resource recovery specialist Axion Consulting has launched a new range of Expert Opinion and Arbitration advice services providing engineering expert advice on recycling and waste processes in cases of industrial and commercial disputes.

Issues covered for clients by Axion’s qualified and experienced engineers include litigation, arbitration, adjudication and mediation.

Drawing on their unique experience as both plant supplier and plant operator, Axion’s team can offer advice and opinion in disputes over processing plants or items of equipment that are not achieving their design requirements or capabilities, in terms of tonnage, machine availability, product yield and purity, or machine effectiveness.

“From our own thorough technical understanding of recycling processes and plants, we have noticed an increasing demand from clients requesting help in this highly-specialised area,” explains Axion Principal Engineer Simon Wilkinson.

“We understand that changes to infeed material - such as variations in composition, biodegradability, density or moisture - can have detrimental effects on waste processing and recycling plant performance leading to contractual disputes that need to be resolved.”

He adds: “We can examine evidence and provide independent technical reports on whole plants, processes and individual pieces of equipment that are not operating according to design specifications. Capital (CAPEX) and operating (OPEX) estimates for plant modifications or replacement equipment and machinery can also be supplied.”

For more information, contact Axion Consulting, Bramhall, Cheshire Tel: 0161 426 7731 or visit the website - www.axionconsulting.co.uk

MOTOVARIO’S NEW ASSEMBLY CENTRE OFFERS FAST AND EFFICIENT BUILD SERVICE Following its £650k investment Motovario Ltd, a leading manufacturer of industrial gear units and electric motors, has opened its MAC – Motovario Assembly Centre at its Droitwich facility. The centre which assembles gear units from component parts at reduced leads times can now offer a fast build service within one hour for a size range up to 14,000 Nm. In addition, the facility also houses a new warehouse which has doubled storage capacity at the site and enabled stock levels to grow to in excess of £1.25m, which has also improved productivity. A training facility has also been created for the development of staff, distributors and customers.

Ivan Partridge, Motovario Ltd Managing Director, commented, “this is the largest investment in the history of Motovario’s UK subsidiary. “We aim to double our turnover over the next five years and this investment was necessary for us to continue to increase market share and customer loyalty to the Motovario brand”.

This is the third MAC centre to be opened in the UK, with the other two strategically located at the company’s partners Betech, West Yorkshire and JJ Loughran, Northern Ireland.

For more information please contact Motovario Ltd, Droitwich, Worcestershire Tel: 01299 250859 E-mail: sales@motovario.co.uk Web: www.motovario-group-com

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Smith Flow Control announces new Distributor Agreement in Iran Smith Flow Control (SFC), specialists in mechanical valve control equipment and valve management systems, is pleased to announce the appointment of Arsam Energy Pars as its distributor in Iran, providing technical and commercial support.

Siavash Barkhordar, Arsam Energy’s Sales and Marketing Director, commented, “Following an introduction to Smith Flow Control at Adipec, we immediately saw the benefit of being associated with the company; their products and services are of significant interest in Iran and are a good fit for our business. We look forward to developing a mutually beneficial and long-lasting relationship.”

With a multi-disciplined and talented engineering team, Arsam Energy is recognised as a leading supplier to the Iranian oil and gas market. The company has been operational for over 20 years, developing partnerships between local and international companies.

Siavash continued, “We are thrilled to incorporate valve interlocks and valve management systems in to our existing portfolio of products.”

Mike Fynes, SFC’s Sales and Marketing Director, added, “Following discussions at Adipec, we are thrilled to appoint Arsam Energy as our official distributor in Iran to help support growing demand for our technology in the country. With their commitment to quality and professionalism, we can see this developing into a very successful and exciting relationship.”

For more information contact Smith Flow Control Ltd, Witham, Essex Tel: +44 (0)1376 517901 Fax: +44 (0)1376 519720 E-mail: enquiries@smithflowcontrol. com Web: www.smithflowcontrol.com

ABB Appoints New Head Of UK Discrete Automation And Motion Division Neil Ritchie has been appointed head of ABB’s Discrete Automation and Motion division in the UK, following the retirement of Chris Withey.

The division encompasses ABB’s motors, generators, variable-speed drives, motion control, programmable logic controllers (PLCs), power electronics and robotics businesses. The leading position in wind generators and a growing offering in solar complement the industrial focus, leveraging joint technology, channels and operations platforms.

“I am looking forward to this new challenge,” says Neil. “ABB’s portfolio in Discrete Automation and Motion is more complementary than ever and offers our customers a great deal of choice and some real innovation to drive their businesses forward.”

From 2011 Neil was running the Drives and Controls business. Prior to that Neil was managing ABB’s service activities for drives and motors, a post he held since joining ABB in 1989. Neil has worked for ABB for the last 25 years.

For more information contact ABB Ltd, Discrete Automation & Motion Tel: 01925 741 111 Fax: 01925 741 212 E-mail: energy@gb.abb.com Web: www.abb.co.uk/energy

PROCESS INDUSTRY INFORMER September 2014

NEWS & EVENTS

Sponsored by

HANOVIA OPENS UV APPLICATION CENTRE IN CHINA New R&D centre of excellence for emerging UV applications Ultraviolet (UV) treatment specialist Hanovia has launched a new UV Application Centre in Shanghai, China.

Serving as an R&D centre of excellence for research into the science of UV for new and emerging applications worldwide, the centre will directly support existing and future requirements in Hanovia’s traditional markets for food & beverage, pharmaceutical and high purity water.

Working in collaboration with leading universities from around the world, such as Imperial College in London and Karlsruhe Institute of Technology in Germany, as well as some of the leading global brands in the pharmaceutical, food and beverage industry, the centre is already enhancing our understanding of UV efficiency in the control and destruction of inorganic compounds.

“The centre is completely customer-driven and is set up with a very clear mission: to develop UV application science that our customers actually need and to answer those searching questions that only empirical test work can answer,” comments Hanovia’s Technical Director Dr. Mark Aston. “This means working as a partner with our customers to push the boundaries of UV science and align our product range with their existing and future needs. This will directly help them achieve their primary goal of meeting all necessary quality standards with ever increasing efficiency and security.”

The centre’s Principle Engineer, Dr Elaine Feng, added: “Why speculate about UV performance for a new application when a series of targeted experiments will bring certainty to UV performance and efficiency? We believe our investment in the science will allow our customers to enjoy scientific rigour in their process development, gaining the peace of mind that comes with the hands on experience of moving from bench top to pilot to full scale”.

Since 1924 Hanovia has been dedicated to improving UV technology to aid industry in helping life sciences. 90 years of research development has made the company a world leader in the field, from manufacturing UV lamps to complete systems. The application centre is another example of Hanovia’s commitment to providing customers with a dedicated, nonchemical option in treating applications with UV light.

For more information contact: Hanovia Ltd, Slough, Berkshire Tel: +44 (0) 1753 515300 Fax: +44 (0)1753 515301 E-mail: gunvinder.bhogal@hanovia.com Web: www.hanovia.com

Axion Consulting Offers New Engineering Advisory Service To Assist With Insurance Claims Resource recovery specialist Axion Consulting has introduced an Engineering Advisory Service to assist with insurance claims for recycling and waste reprocessing plants that have been damaged by fire, explosion or other catastrophic events.

Axion’s team of skilled and experienced engineers can provide rapid assessment following damage claims for plant and equipment, business operation interruption and consequential loss within the recycling and waste reprocessing sector.

Drawing on their extensive technical knowledge of the sector, the team can supply specialist advice to insurers, reinsurers, loss adjusters, brokers, solicitors, owners and other insurance industry professionals to determine solutions and associated costs for repair or replacement.

“Major damage, whatever its cause, deals a devastating blow to any business as exemplified by several recent high-profile disasters in our sector,” comments Axion Principal Engineer Simon Wilkinson. “While there are many professionals who can assess damage to buildings and structures, few can assess and accurately quantify damage to the actual process and equipment.

Axion’s service can report on the scope of the damage and evaluate equipment and machinery, from single machines to entire reprocessing facilities. On-site inspections of plant, equipment, machinery, mechanical and electrical services are carried out to accurately assess whether repair or replacement is required and to draw up reinstatement estimates as well as consequential losses.

Simon adds: “The comprehensive service includes assessment of business interruption losses, evaluations of reinstatement proposals and estimating costs of any permanent or temporary reinstatement works.”

For more information, contact Axion Consulting, Bramhall, Cheshire Tel: 0161 426 7731 E-mail: info@axionconsulting.co.uk or visit the website - http://www.axionconsulting.co.uk/ engineering/engineering-advisory-service/.

PUMPING

Thick, viscous liquids?

CSF Air-operated piston pumps are perfect for transferring thick, high viscosity liquids from tanks, drums and IBC’s.

New On-Line Resource For Materials Engineers And Processors Hosokawa Micron Ltd announces the launch of their new on-line resource for materials engineers and processors, www.hosokawa.co.uk .

The easy to navigate site is designed to inform and help plant buyers and engineers select the right equipment to meet specific processing requirements.

Search capability by industry, brand or technology and application to find information and data to assist in defining specific operating criteria on equipment wish lists or check out what’s available from powder and particle specialists, Hosokawa Micron Ltd. The resource is packed with information on Hosokawa Micron’s latest product developments, company news, how to get the best from your existing plant, toll processing, test and lab services as well as videos and downloadable brochures and information sheets to create an extensive resource hub for those in materials processing.

For more information contact Hosokawa Micron Ltd, Runcorn, Cheshire Tel: (01928) 755100 Fax: (01928) 714325 E-mail: info@hmluk.hosokawa.com Web: www.hosokawa.co.uk

PROCESS INDUSTRY INFORMER September 2014

● Pump creams, pastes,

gels and syrups ● Quick-strip versions are easy

to dismantle for cleaning ● Ideal for food, brewing and

pharmaceutical applications ● Choose from a range

including models for flow rates up to 100 lit/min and pressures up to 150 bar

Pick the perfect pump – From Pump Engineering

PUMP ENGINEERING Tel: 01903 730900 sales@pumpeng.co.uk

www.pumpeng.co.uk

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NEWS & EVENTS

Going to ADIPEC? Need advice about valve operations? Don’t spend hours looking for the answer!

Is this you?

1. You’re going to ADIPEC in Abu Dhabi this November 2. You’re looking for a simpler way to operate your valves The first part is easy – just book your ticket and turn up at the show.

The second part is more tricky. With over 1,600 exhibitors, finding one that offers the right solution to your valve operation problems could take hours – and a lot of walking. Unless, of course, you pay a visit to Smith Flow Control at booth number 8350.

What’s so special about Smith Flow Control (or SFC, as the company likes to call itself)? Well, it makes products which simplify valve operations: • Do your workers operate valves with many handwheel turns, high torque or in challenging climatic conditions? EasiDrive is the answer • Do you have remote or inaccessible valves?

FlexiDrive can help • Is over-torqueing a problem? TorkDrive prevents excessive torque being applied • Do you just need enhanced process safety? Then SFCs vast range of interlocks, operating panels and key cabinets and specials ensure compliance So, instead of walking around for hours with a bag full of brochures, just call past SFC’s booth and talk to our friendly, helpful and – above all – knowledgeable staff. They will solve your valve operating problems on the spot. Then you can treat yourself to a well-earned early lunch.

For more information contact Smith Flow Control Ltd, Witham, Essex Tel: +44 (0)1376 517901 Fax: +44 (0)1376 519720 E-mail: enquiries@smithflowcontrol.com Web: www.smithflowcontrol.com

Sponsored by

THE LATEST IN FLAME DETECTION AND WIDE AREA SMOKE DETECTION AT SECURITY ESSEN Fire Fighting Enterprises (FFE) will be showing the latest in flame and smoke detection at Security Essen this September. The company, which manufactures the industry-leading Fireray optical beam smoke detectors and Talentum flame detectors, will be in the UK Pavilion, Hall 3, Stand 502B. Talentum flame detectors are used in sensitive or dangerous environments to detect fires even before there is any smoke produced, or where smokeless fires may occur. By watching for and recognising the non-visible ultraviolet (UV) and infrared (IR) signatures of the flames themselves, the Talentum range does not need smoke to know if there is a fire.

“The Talentum brand was acquired last year,” said Tracy Kirk, Fire Fighting Enterprises’ Sales Director. “By bringing together Talentum flame detectors with Fireray optical beam smoke detectors we’re able to offer the best of British design, engineering, manufacturing and experience for specialised fire protection applications.”

Fire Fighting Enterprises (FFE) has years of experience, a track record of innovation and a close relationship with customers and installers to make sure that its products offer exactly what’s needed to those who specify and use them.

For more information contact Fire Fighting Enterprises, Hitchin, Herts.

Tel: +44 (0)1462 444 740 Fax: +44 (0)1462 444 789 E-mail: sales@ffeuk.com Web: www.ffeuk.com

New White Paper explains how to unlock energy savings and lower maintenance costs in steam boiler feedwater storage systems The new Spirax Sarco Steam Boiler Feedwater Storage Technology White Paper outlines how best practice feedwater storage system design and operation can unlock higher energy efficiency and lower operating costs.

The White Paper highlights new technologies that can help steam plant owners and operators to get the most from their steam boiler feedwater storage system. These include deaeration, a process of heating feedwater to remove oxygen from the feedwater. Deaeration substantially reduces the amount of oxygenscavenging chemicals that need to be introduced into the feedwater system to help eliminate dissolved oxygen, reducing the cost of treatment chemicals.

It also describes the different types of deaerator available and explains how correctly specifying the

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right type of deaerator can help steam system operators to achieve a host of benefits, including: • Greater energy efficiency • Improved boiler efficiency • Increased productivity • Reduced operating costs Finally, the White Paper invites steam system operators to take advantage of a professional survey of their installed feedwater storage system to ascertain the most effective ways to comply with industry best practice and Health & Safety legislation.

For more information contact Spirax Sarco, Cheltenham, Glos. Tel: 01242 521361 E-mail: ukenquiries@spiraxsarco.com Web: www.SpiraxSarco.com/uk

HANOVIA

SPONSORS WATER CATEGORY OF WORLD BEVERAGE INNOVATION AWARDS 2014 Awards to be held at BrauBeviale in Germany on 12 November UV disinfection specialist Hanovia is sponsoring the ‘Best Packaged Water Category’ in FoodBev Media’s World Beverage Innovation Awards 2014.

“This is the first time we’ve sponsored the award and we’re absolutely delighted to be involved,” commented Tim McDougle, Hanovia’s Sales and Marketing Director.

Held annually since 2003, the World Beverage Innovation Awards celebrate excellence and innovation across every aspect of the global beverage industry, with categories including best juice or juice drink, best new beverage concept, as well as brands, ingredients, packaging, design, manufacturing and processing, sustainability and marketing and communications.

All entries will be shown and finalists and winners will be announced at a special event during the world’s largest beverage industry trade event, BrauBeviale in Nuremberg, Germany, on 12 November.

“Hanovia invests heavily in R&D to develop the science behind UV disinfection technology. Continuous innovation is our mantra,” added Tim. “Ensuring bio-security in the food and beverage industry – without resorting to chemicals – is a highly desirable outcome for manufacturers. We’re working closely with some of the leading brands and top research institutes to push the boundaries of UV science. Our involvement with these awards allows us to celebrate the success of the beverage industry’s continued innovation”.

“We’re delighted to welcome Hanovia as a category sponsor for the industry’s most established awards scheme,” said FoodBev Media Director Bill Bruce.

“This is the 10th anniversary of our awards scheme in the international beverage industry and comes at a time when the pace of change has never been faster, or the challenges greater. We are expecting to see all the major trends from ingredients to packaging and environmental responsibility reflected in the entries, and look forward to celebrating the best innovation and creativity from around the world.”

This year Hanovia celebrates its 90th anniversary, so it’s a very special time for the company. It recently established a global UV Application R&D Centre in Shanghai, China and will continue to innovate and provide better and safer UV technology to the food and beverage industry.

For more information contact Hanovia Ltd, Slough, Berks. Tel: +44 (0) 1753 515300 Fax: +44 (0)1753 515301 E-mail: gunvinder.bhogal@hanovia.com Web: http://www.hanovia.com

PROCESS INDUSTRY INFORMER September 2014

APPLICATIONS FLASH STEAM RECOVERY TRIMS BIOMAR’S GAS BILL AROUND 10% Biomar Grangemouth has sliced between 9 and 10% off its annual gas bill with the help of a system to recover energy from flash steam that would otherwise be lost to atmosphere.

The aquaculture manufacturer says the energy savings alone mean that the Flash Recovery Energy Management Equipment (FREME) engineered system from Spirax Sarco has paid for

Jacquet Weston Engineering Turnkey Stripping System Offers Key Gains For Specialist Valve Manufacturer Process plant manufacturer, Jacquet Weston Engineering, has completed the installation of a new electro-chemical stripping cell which is now providing significant benefits for specialist valve manufacturer, BEL Valves. The facility, at the company’s Newcastle upon Tyne premises, is playing a dual role – both as part of the ongoing manufacturing process and also as a highly effective element at the heart of the company’s servicing procedures.

“The installation comprises two 80 litre tanks – one for the stripping process and the other as a wash and rinse facility – alongside a 1,000 amp rectifier,” explains Andy Jones, Jacquet Weston’s Engineering Director. “The prime requirement is to aid the stripping of hard facing coating on the internal sealing surfaces of a range of valves manufactured by the company to return the substrate back to its base metal ahead of re-coating. The stripping tank contains a sodium carbonate/tartaric acid solution which attacks the binder used in the tungsten-carbide coating. The products are then transferred manually into the wash solution ahead of assessment and the re-coating process.”

The installation provides the versatility to focus on either one or a number of valve components per operation depending on the size of each unit.

This is assessed via a measure of amps per square inch – clearly the smaller the valve construction, the more units that can be handled by each process cycle.

“Before the Jacquet Weston installation we used a time consuming grinding process for this operation,” comments Karl Brown, Group Laboratory Technician at BEL Valves. “Although this was effective and fulfilled the requirement, clearly we are now able to undertake the operation with a high degree of consistency and, importantly, more quickly.

Andy Jones says “We believe it is an excellent example of our ability to provide purpose-built, turnkey solutions and to apply advanced system design.

For more information contact Jacquet Weston Engineering, Hungerford, Berks.

Tel: 01488 674400 Fax: 01488 674405 E-mail: info@jweltd.com Web: www.jweltd.com

itself around 10 times in the four years since installation.

“We decided to recover this wasted energy as part of a group wide policy to save energy and reduce visible emissions,” explains Christopher Strain, Engineering Manager at Biomar Grangemouth. “Spirax Sarco worked with Biomar to design, build and deliver a complete package flash steam recovery system. Close co-ordination between Spirax Sarco and our team ensured the system was delivered on time,

GEORGE KOCH WASTEWATER SYSTEM BRINGS KEY COST AND ENVIRONMENTAL BENEFITS TO BAE SYSTEMS

on specification and on budget.”

Biomar has experienced a range of benefits following the installation, including substantial energy and water savings, improvements in the stability of the steam system, reduced water treatment and boiler maintenance costs, and elimination of unsightly plumes of steam from outside the building.

For more information contact Spirax Sarco, Cheltenham, Glos. Tel: 01242 521361 E-mail: ukenquiries@spiraxsarco.com Web: www.SpiraxSarco.com/uk

DISPLAY SYSTEM GETS THE MESSAGE ACROSS ABOUT WORK PLACE HAZARDS

George Koch Sons Europe has completed the installation of a major wastewater treatment system for one of the world’s leading aircraft component manufacturers – with clear-cut benefits in terms of water usage and disposal costs. The installation, at BAE Systems’ premises in Samlesbury, near Blackburn in Lancashire, is focused on the organisation’s Central Treatment Facility (CTF) which is key to the production of a wide range of high precision components for sophisticated military aircraft.

“BAE Systems identified a number of objectives which centred on the upgrade of the chromate reduction plant, the production of de-ionised water in-house, dye recovery and significant reduction in water consumption,” says Mike Fisher, Environmental Manager at George Koch. “The multi-faceted project therefore addressed the recycling of wastes from rinsing operations in order to markedly reduce the volume and cost of ‘bought-in’ water, and to lower the volume of effluent discharge – both elements clearly linked to cost saving potential.”

“Key elements of the installation have included an advanced system of specialised filtration units. Designed to remove solids or organic material prior to dual ion exchange columns, these produce highly purified water, suitable for critical rinsing applications,” continues Mike Fisher.

“The overall result is that the combined system reduces water consumption and wastewater disposal – and their considerable associated costs – while promoting an environmentally sustainable future for the CTF,” comments Tom Mercer, General Manager at George Koch’s UK offices in Lichfield, Staffordshire.

“The new CTF water recirculation and effluent treatment plant has achieved, and in some aspects exceeded, its original operational requirements,” adds Neil Lord, Facilities Manager at BAE Systems Military Air and Information (MAI). “We have seen a significant reduction in water usage and a subsequent reduction in cost of chemicals used in the treatment of both incoming and effluent waste.”

Providing information and communicating with staff and colleagues in the workplace is essential, particularly when hazards, incidents or near-misses occur which may impact on others. An effective, lowcost solution to ‘getting the message across’ is the Near Miss / Incident Reporting System available from T Cards Direct which is an easy way to manage and document health and safety issues.

The standard display board is available in a 3 column format with standard 50 or 30 cards deep and measures 409mm wide and is supplied fully assembled, complete with headings and 200 Incident T Cards. There is also the option to have the system made to a bespoke format.

A good example of where the T Cards Near Miss Incident Reporting System has been appreciated is at the Greencore Grocery facility in Evercreech. The site is part of Greencore Group, a leading producer of convenience foods with 22 manufacturing sites globally.

David Brady, Health and Safety Manager at the Evercreech site, comments, “Safety is of paramount importance at our site, identifying and communicating potential hazards to all staff is a crucial part of our day to day activities”. David continued, “The T Cards Incident Reporting System has proven to be an effective and very visible way of informing our staff of the situation and status of incidents”. A Near Miss, Incident Station is sited at the entrance to a specific department. The risk or hazard is recorded on a T Card and then placed in the Near Miss Station for all to view.

The information is then transferred onto a T-Card, inserted into the T-Card board and communicated to Line Managers who can decide the best form of action.

The Near Miss / Incident Reporting System is one of a range of display and information systems available from T Cards Direct who offer over 45 years of experience in providing effective and affordable information systems.

Click here for more information: http://www.tcardsdirect.co.uk/index.php/near-missreporting-system.html

For more information contact George Koch Sons Europe Limited, Lichfield, Staffs Tel: 01543 444001 E-mail: tom.mercer@kocheurope.com Web: www.kocheurope.com

For more information contact T Cards Direct, Addington, West Malling, Kent. Tel: +44 (0) 1732 871417 E-mail: philip@tcardsdirect.com Web: www.tcardsdirect.com

PROCESS INDUSTRY INFORMER September 2014

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APPLICATIONS HANOVIA ENSURES SAFETY OF PURIFIED WATER FOR PRODUCTION IN CHINA’S NATIONAL VACCINE PRODUCTION BASE UV disinfection specialist Hanovia has supplied three UV water disinfection systems to the Institute of Medical Biology of the Chinese Academy of Sciences in Kunming. The PharmaLine PQL units destroy any unwanted microorganism in the purified water used in the production of vaccines. Moreover, these systems can display the verified ultraviolet irradiation dose online, further reducing the risk of microbial contamination.

The Institute of Medical Biology is the largest oral, antipoliomyelitis vaccine production base in China. Since the 1960s it has produced over 5 billion vaccines for the National Planned Child Immunization programme in China. It is also the largest Chinese base for the development of Hepatitis A vaccines.

Because the Institute has always had very strict quality controls of its production process, when a new production facility was built in 2013 the Institute opted for Hanovia’s PharmaLine PQL UV technology.

Commenting on the Hanovia equipment, Shen Feng, the senior engineer and water treatment equipment expert at the Institute, said, “Compared with other UV disinfection systems, Hanovia’s PharmaLine PQL offers validated disinfection that has been certified by an independent third party. It also displays the UV dose online, meeting the stringent requirements of the pharmaceutical industry for verification and risk management.”

Purified Water has had almost all electrolytes removed, making it as inert as possible. The removal of any potential microbial contamination is of course also vital. Purified Water is an essential raw material for the production of vaccines and indicators (TOC, bacterial endotoxins, microorganisms, pH and conductivity) are strictly required in the pharmacopeia of many countries. Of these indicators, all but microorganisms and bacterial endotoxins can be controlled by water preparation technology.

UV kills 99.9% of the microorganisms, ensuring the concentration in purified water remains at an extremely low level (≤5cfu/ml). UV also does not produce any unwanted disinfection by-products that might contaminate the purified water downstream.

For more information contact Hanovia Ltd, Slough, Berks. Tel: +44 (0) 1753 515300 Fax: +44 (0)1753 515301 E-mail: gunvinder.bhogal@hanovia.com Web: http://www.hanovia.com

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Innovative Operating Panel Allows Safe and Efficient Control of Actuated Valves Smith Flow Control (SFC) has designed a specialist pigging panel to be installed on an FPSO built for the use in the Goliat field, the first oilfield to be developed in the Barents Sea. SFC’s custom-built pigging panels will be used to control a series of actuated valves and ensures the safe opening of the pig vessel closure door. The panel itself is designed and built to exacting standards which incorporates the strict environmental requirements stipulated for operations in the Barents Sea. The stainless steel electronic panel, specifically engineered for Arctic conditions, conforms to Zone 1 Ex de classification and protection class IP66. It is designed to support applications in the most aggressive environments, suitable for temperatures ranging between -40 to +55 degrees Celsius (-40 to +131 degrees Fahrenheit) with an anti-reflective coating that eliminates glare from the sun. The innovative panel is designed to meet strict safety guidelines and regulatory body requirements and works as a communication and verification system, improving efficiency and safety in the most testing conditions.

The panel is designed around the requirement to isolate power to the panel, with two interlocked key units to ensure a specific sequence of operation:

Progressing Cavity Pumps From NOV Mono Chosen For Major New £300 Million Wastewater Facility NOV Mono has provided ten progressing cavity pumps which are installed at the heart of a new wastewater treatment works in Sussex. The Southern Water works in Peacehaven forms part of a £300 million environmental improvement and features a number of different Mono™ pumps, including EZstrip™ cake pumps, LF injection pumps and Widethroat pumps.

Mono worked with two of the sludge processing equipment providers involved in the project, the ANDRITZ GROUP and Saxlund International, to offer the most efficient pumping solutions featuring their innovative EZstrip™ technology.

The EZstrip™ design allows the cake pumps to be dismantled without disconnecting or removing any pipework, giving immediate access to the rotating parts so that blockages can be removed easily. The time taken to remove a full drive train, including rotor, stator and screw conveyor is reduced from a full day, down to just eight minutes.

For more information contact Nov Mono, Audenshaw, Manchester Tel: +44 (0)161 339 9000 or visit Web: www.mono-pumps.com

• The operator selects to close the valves as required • Red LED lights verify that the valves have reached their fully closed position • When all valves are closed, the operator can isolate the panel by removing the ‘A’ Key • The ‘A’ key is then entered into the solenoid key unit and only when the safety and automation system confirms all valves are closed, a permissive signal is sent to energise the solenoid and release the ‘B’ key • This allows the operator to safely continue the mechanical interlocking sequence and, in this instance, only after the panel has been isolated and all the valves have been closed and locked, will the key be available to manually unlock the pig trap door to load or unload a pig.

The operating panel can be used in a wide variety of applications involving actuated valves. Manual valves can also be included within the key system logic (vent & drain), for example to launch or receive a pig. The panel has been designed with the operator in mind, providing a safe and simple means of controlling valves for the most complex of processes.

For more information about the operating panel and how it can be used, please call Smith Flow Control, Witham, Essex on Tel: +44 (0)1376 517901 or E-mail: enquiries@smithflowcontrol.com Web: www.smithflowcontrol.com

WASTEWATER EVAPORATION SYSTEM BENEFITS – PROVEN IN SWEDEN AND NOW AVAILABLE IN THE UK The benefits arising from the recent addition of H2O GmbH wastewater evaporation systems to the capability available from Lancy Technology, are being clearly demonstrated

by Norman Hay Group sister company, Sifco ASC. The Swedish factory of the advanced selective plating supplier is reporting significant environmental and performance gains as a result of its use of an H2O Vacudest system.

“The installation has produced significant savings in terms of expenditure and processing time,” comments Michael Olsén, Service Manager at Sifco ASC. “We have reduced the cost of sending waste off-site for disposal by 90% which not only has a direct cost benefit, but is also in line with the environmental commitment and vision that we adhere to at Sifco ASC.” In the UK, Lancy Technology is now able to offer the full range of systems from German manufacturer H2O to its customers. Each unit is based on a modular design which enables it to be tailored to meet precise installation requirements while additional factors such as a maintenance-friendly design and simple control systems, including internet connection for remote diagnostic purposes, are seen as further factors that help to produce the highest quality distillate from each Vacudest facility.

For more information contact NHE, Coventry, West Midlands Tel: 024 7625 3099 E-mail: keith.allen@nhe.uk.com Web: www.nhe.uk.com

PROCESS INDUSTRY INFORMER September 2014

APPLICATIONS

Sumitomo’s CASTELL Riley supplies Hydraulic Tackles PROVIDES SAFETY pre-owned powder INTERLOCKS TO coating plant to Escalating LARGEST Philippines curtain Energy Costs ZAMBIA’S POWER STATION rail manufacturer

Reducing running costs remains a common challenge for all manufacturers and energy consumption power, water and other operating resources - is a key consideration when calculating ‘total cost of ownership’. Initial outlay for hydraulic machines can be less than switching to all-electric, often at another cost; conventional applications are traditionally more energy intensive. But there are other alternatives highlight Sumitomo (SHI) Demag, the specialists in injection moulding machines and systems.

A growing number of injection moulders who want to save on energy costs are turning towards hydraulic machines equipped with a servo drive. Sumitomo (SHI) Demag reports that over half of the hydraulic machines they have delivered to customers in the last year now feature the company’s activeDrive hybrid technology, which reduces energy consumption by up to 60%.

Managing partners Norbert and Sven Borscheid and Carlo Wenig of the German-based plastics manufacturer Borscheid + Wenig GmbH has adopted this technology and is extremely satisfied by the hybrid’s performance.

So much so, they are about to take delivery of a new Systec 50-310 machine featuring activeDrive, which the partners advocate further supports their company environmental policy. “It offers a good price/performance ratio, energy-efficiency, and considerably reduces cycle time,” they say.

While the argument for all-electric machines is a compelling one, hydraulic machines are far from redundant. Zero energy waste is the real target, and thanks to technologies like activeDrive, fully hydraulic machines are closing the energy-efficiency gap, boosting business profits, without compromising on product quality or cycle times.

For more information contact Sumitomo (SHI) Demag, Stoke Mandeville, Bucks. Tel: +44 (0)1296 739500 Fax: +44 (0)1296 739501 E-mail: nigel.flowers@dpg.com Web: http://uk.sumitomo-shi-demag.eu/

ZESCO chooses British firm as partner for Kariba North Bank extension project

Industrial safety specialist Castell has provided several K Locks and key exchanges boxes to the Kariba hydropower station North Bank extension project in Zambia.

In the early 1960s, Castell provided interlocks to the power station; more than half a century later, the interlocks are still performing well. When the station was due to add a north bank extension, project owner Zambia Electricity Supply Corporation (ZESCO) recommended Castell to the project contractor SINOHYDRO. Castell’s interlocks force workers to follow a predetermined process when operating or maintaining machinery and equipment, to prevent human error and safeguard workers’ access to dangerous areas.

Christy Zhang, senior sales manager at Castell China, said: “It is an honour for Castell to provide safety interlocks to the Kariba North Bank extension project. The client’s trust in us stems from the longterm performance of our interlocks.”

The Kariba hydropower station is located in the middle of the Zambezi River, 125 miles from Lusaka, Zambia’s capital. The extension project has added two 180 MW generator units, taking the total capacity to 1,080 MW and making Kariba the largest power station in Zambia.

For more information contact Castell Safety International Ltd, 217 Kingsbury Road, London, NW9 9PQ Tel: +44 (0)20 8200 1200 Fax: +44 (0)20 8205 0055 E-mail: pr@castell.com Web: www.castell.com

Drapery Hardware Inc based in the Philippines, is a manufacturer and importer of curtain rails and accessories, dealing in domestic products as well as heavy duty tracks for stages, auditoriums, sky lights and motorised curtains and blinds.

The Drapeware range is produced at the company’s own manufacturing facility, which includes a selection of metal stamping and electroplating processes using brass and nickel finishes.

Drapery Hardware recently purchased a complete, preowned powder coating system from Riley Surface World, to be used for post finishing of a selection of the metal stampings as an alternative process to electroplating.

The main reason for the change in production is to eliminate all potentially harmful solvents from the finishing process, making it safer for the company’s employees.

The system comprises a Eurotec powder spray booth with multi-cyclone powder recovery and automatic system control console. There are also four automatic powder guns and an additional manual powder coating system.

The booth has a completely stainless steel interior, which makes cleaning and colour changing a simple and rapid process.

Drapery Hardware’s managing director, Howard Ang, says “buying the pre-owned powder coating system from Riley Surface World makes sound economic sense when compared to the price of new equipment. It also enhances the company’s environmental credentials to be using recycled machinery”.

For technical and product information contact Helen Wilkinson, Riley Surface World Tel: +44 (0) 1922 45 8000 Fax: +44 (0) 1922 45 8001 E-mail: helen@rileysurfaceworld.co.uk

‘SUPER’ CHOPPER PUMPS BANISH BLOCKAGES FOR ANGLIAN WATER THE PROBLEM Blocked pumps are often the cause of pumping station and sewage treatment works failures resulting in disruption, downtime and in extreme situations the inconvenience and associated health and safety issues in having to ‘lift’ submersible pumps to clear blockages. There are many reasons why pumps become blocked, but at Anglian Water’s pumping station in the Cambridgeshire village of Cambourne it seemed a baby boom creating high volumes of baby wipes and other unflushables occurring in sewage streams, that caused the station being regularly out of action.

THE SOLUTION In the summer of 2013 Anglian Water approached Huntingdon based solids pumping specialist P&M

PUMPS for a solution to replace the failing existing submersible pumps.

As the UK distributor for Vaughan Chopper Pumps, P&M pumps were well placed to provide a solution having previously supplied pumps which had proved effective at other Anglian Water sites.

Following discussions between Anglian Water technicians and P&M Pumps the decision was taken to invest in two new ‘super pumps’. These were Vaughan 30kW/1460rpm SE6W chopper pumps, specified to handle flows up to 400m3/ hr at a head of 17.8 metres and installed during a simple and quick retro fit utilising all the existing installation hardware. The innovative design of the Vaughan Chopper pump makes it particularly effective even in the most challenging solids pumping applications that cause other solids handling pumps to fail, and immediately proved

PROCESS INDUSTRY INFORMER September 2014

successful for this application.

THE BENEFITS The pumps were installed during the autumn of 2014 and during the early months of their operation, Graham Powell, Area Maintenance Manager at Anglian Water said, “The pumps are performing very well and we are singing their praises across the business”.

More recently, Andy Spencer, Maintenance Support Technician has confirmed, “At this present time since the two Vaughan Pumps were installed we have yet to return to the site to unblock either of the pumps, where before we may have been on-site at least once a week with two operatives”.

Further information on Vaughan Chopper Pumps is available from: P&M Pumps, Sawtry, Huntingdon Tel: 01487 830123. 832888 E-mail: sales@thesolidsolution.co.uk Web: www.pandmpumps.co.uk

9

APPLICATIONS

GO WITH THE FLOW! Babcock Wanson Boiler

BABCOCK WANSON Helps Convert Food Waste THERMAL FLUID HEATERS Into Renewable Electricity KEEP BITUMEN FLUID

Total UK Ltd has installed two Babcock Wanson high efficiency Thermal Fluid Heaters at its Preston based Bitumen Division to improve operating costs and cut emissions.

The new Babcock Wanson EPC ES Thermal Fluid Heaters are being used to heat the bitumen to a constant 180°C to maintain its fluid state. If the bitumen falls below this temperature it becomes difficult – and eventually impossible – to pump the product to where it needs to go. An accurate and reliable heat source is therefore essential.

The Babcock Wanson EPC ES fully automatic coil type, multi-pass Thermal Fluid Heaters were chosen Total Bitumen to meet this need. They provide optimal distribution of the heat, high fluid velocity in the exchange tubes and continuous flow monitoring to ensure long fluid life and the highest level of safety.

For Duncan McLeod, Engineering Manager at Total Bitumen Preston, the key benefits already reaped from the EPC heaters include a reduction in fuel costs and stack emissions, greater efficiency and a move to natural gas instead of heavy fuel, which has removed the need for on site fuel storage.

Viridor, one of the UK’s leading recycling, renewable energy and waste management companies, has installed a Babcock Wanson HEB 1050 Hot Water Boiler into its anaerobic digestion plant at Walpole near Bridgwater, Somerset.

Each year, Viridor transforms over two million tonnes of materials into high quality recyclate, and yet more into over 760 gigawatt hours of renewable energy. It operates several Anaerobic Digestion (AD) facilities across the UK which uses renewable energy technology to capture methane expelled by digesting unwanted food within enclosed tanks.

To aid the production of methane, the digestors are warmed by circulating hot water around them. The new Walpole site has one boiler, a Babcock Wanson HEB 1050 Hot Water Boiler which has been used to start the initial AD process and will acts as a standby, should the Combined Heat and Power (CHP) system require maintenance or supplementary heat. Gas Oil fired, the boiler has been supplied by Babcock Wanson as a fully containerised solution for ease of installation and operation.

The Walpole AD plant will be able to process up to 30,000 tonnes of food waste per year and is expected to save Somerset council tax payers £200,000 a year. Gas from the plant will be used initially to generate electricity - about 9,500 MWh a year - with nearly four-fifths exported to the National Grid, enough to power more than 1,700 homes.

For more information, please contact Babcock Wanson on 020 8953 7111 or info@babcock-wanson.co.uk or go to www.babcock-wanson.co.uk

For more information, please contact Babcock Wanson on 020 8953 7111 or info@babcock-wanson.co.uk or go to www.babcock-wanson.co.uk

MATERIALS HANDLING

SIMPLE AND DIRECT INTEGRATION: DEMAG DC-ProDC CHAIN HOISTS • Installation components for direct control • Rugged hoist engineering for arduous applications • Load capacity up to 5 t Terex Material Handling is now offering an additional model within its Demag DC chain hoist family. The DC-ProDC models feature direct control offering a reliable solution for a wide range of industrial, warehouse and logistics’ applications. Direct controlled Demag DC-ProDC chain hoists are also suitable for the refurbishment and upgrade of existing material handling systems, with the chain hoist operated by an existing control system with a line supply.

DC-ProDC chain hoist: direct control for loads up to 5 t DC-ProDC chain hoists with direct control are available in seven sizes with load capacities between 80 and

5,000 kg. Depending on the load capacity, lifting speeds range from 4 to 24 m/min. The chain hoist can be controlled direct via a line supply. A terminal strip integrated in the unit provides for direct and simple connection. Alternatively, DC-ProDC units may be operated with Demag DSK or DST control pendants.

Operating limit switches can be incorporated safety cut off of the lifting motions. As with all other chain hoists in the DC product range, the DC-ProDC gearbox is maintenance free for up to 10 years.

Rugged and reliable at higher temperatures Advanced engineering ensures that DC-ProDC chain hoists may be employed under extremely arduous ambient conditions and at very high temperatures. The rugged design provides for operation at temperatures up to 80°C and offers ease of maintenance.

On line hoist selection facility The Demag product configurator (Hoist Designer) can be used to specify a chain hoist with direct control. This user friendly online planning tool enables a large number of possible variants to be configured to select the correct hoist for a specific application. The hoist may then be ordered direct via the Demag Shop system.

For more information contact Demag Cranes & Components Ltd, Banbury, Oxfordshire Tel: 01295 676100 Fax enquiries to: 01295 271408 E-mail enquiries to: bnb-help@demagcranes.com Web: www.demagcranes.co.uk

SLIDE VALVES The New Mucon Series DSV Double Flange Slide Valve Mucon has launched its new DSV double flange slide valve after the success of its low cost SV range of single flanged Slide valves.

This simple, feature rich slide valve is ideal for controlling and isolating the flow of powders, granules and pellets in open discharge or in-line applications. For example; • In-line installation into pipes, ducts and hopper outlets.

• Open discharge from rigid or semi-rigid intermediate bulk containers, bins, hoppers and other storage vessels.

The features and benefits of the Mucon DSV Slide valve include the following; • Unlike other manual slide valves the DSV has tapered

10

supports which are set at an angle to allow the blade to be easily adjusted.

• Tapered supports can be easily replaced while the slide gate remains in-situ and in the closed position.

• Slim Design • Robust valve construction, with integrated metal handle • Anti-tamper locking facility – allowing the user to lock or tag the valve in the closed position • Provision for ‘earth’ tag - where there is potential for static electricity generation All manual DSV slide valves are available from stock.

The DSV Slide valve will soon to be available with a lightweight pneumatic actuator assembly and will be

officially launched at the POWTECH exhibition in Nuremberg.

This lightweight pneumatic actuator has been specifically designed so that it can also be added retrospectively in just a few minutes to an existing manual DSV Slide Valve.

For more information contact Mucon to learn more about the new DSV Slide valve range. Tel: 1625 412000 E-mail: sales@mucon.com Web: www.mucon.com

PROCESS INDUSTRY INFORMER September 2014

More compact.

More powerful.

More intelligent.

New telecontrol variants now added to cover IEC 60870 and 61850 OUR NEW, SUPER-FAST PFC200 CONTROLLER DELIVERS MAXIMUM PERFORMANCE IN MINIMUM SPACE

• Ideal for automation applications in industries

including manufacturing, processing and building services • A major development in measuring, controlling and visualising technology • Combines compact design, high speed and outstanding processing power • Incorporates 600 MHz Cortex A8 processor and 256 MB memory • Two Ethernet connections with integrated switch and SD slot for Max 32GB SD and SDHC cards for removable memory • Additional interfaces available e.g. CAN RS232/RS485 and PROFIBUS

WAGO Limited Triton Park Swift Valley Industrial Estate Rugby CV21 1SG. Tel: 01788 568008 Fax: 01788 568050 E-mail: ukmarketing@wago.com www.wago.com

For more information, call 0870 264 0773 or email ukmarketing@wago.com

Process Water Filtration shouldn’t be clear as mud!

By Steve Cupples – Engineer and Managing director of UK based industrial water filtration company Industrial Purification Systems (IPS).

Water is becoming more important not only for drinking but for manufacturing where advanced filtration enables the reuse of this valuable resource. Finding effective water filtration technology that will provide significant savings on water, downtime and energy whilst increasing productivity and efficiency has to be a priority.

Industry worldwide uses water in many different ways and in different amounts, therefore water saving technology, in many cases, is used in multiple applications. The commonalities however are that highly efficient water saving techniques are proven to not only reduce an organisations carbon footprint but also to make huge savings on energy bills and improve production and performance.

Ask any maintenance engineer what colour the water is in this system and this will range from pale straw (usually found in a new system) to black (found in a typical system). This discoloration is not just ‘yucky’ it is actually having a major negative effect on the system.

In many operations within the manufacturing, industrial and commercial sectors the use of water is often an accepted process cost. There is scant attention paid to reducing such a significant service cost with fixing leaking taps often being the extent of energy saving in this area.

From our experience, it is not uncommon to see large commercial buildings lose between 15-20% of its total heating energy input just because the water is dirty.

With water, unlike with electricity or gas, the consumer pays for both the supply of water to the plant and once used he pays again for its disposal. Pity the process that contaminates this valuable resource as the cost of treating water effluent is based on many factors, including added solids, heat, pH and volume. And under the policy of “the polluter pays” this cost of effluent treatment is ever increasing.

The discoloration is a product of the corrosion which is taking place naturally within the system, and this corrosion reduces the heat transfer from the heat source to the water, and then from the water to the heating/cooling outlet. A double energy whammy!

Backwash water

In addition, if chemicals are used to treat this dirty water, then the effectiveness of the chemical treatment will be reduced because of the high solid load within the water. Past examinations of this process have shown filtration to remove particulates down to 10 micron can improve heat transfer significantly, but our tests on many systems also shows that the majority of this contamination is between 1.0 micron and 10 micron. We believe that saving of 15-20% in total energy costs in this process can be readily achieved.

The simple fact is if an organisation can clean up this process water and re-use it just one more time it will effectively reduce its process water costs by a staggering 50%.

Yet, interest in this area of ‘process’ is given little attention.

True, the re-use of process water involves the installation of additional filter and sometime treatment technology to provide the necessary clean water. However, having high efficiency filtration technology that filters out particulates down to 0.45 micron with efficiencies up to 99% can now make a significant return on investment for industry.

If, say, a food processing plant uses 10 m3/hr (10,000 litres) and is a 24 hour operation, the water bill for this operation could well be in the region of six figures. Yet having the ability to remove solids of 1.0 micron and less, plus any additional treatments, to enable process water re-use would cost just $50,000 (US) to $80,000 (US) giving a payback within 6 months. This is a fantastic ROI. Industry will also see a reduction in plant down time, increase productivity and reduce wastage without effecting the quality of the finished product.

Process water that is normally accepted

So what are the savings against cost?

A typical system using 100kw chiller and equivalent heater can use 250,000 kw per annum for a nine hour operation, five days a week. Many systems are running continuously to minimise energy losses so this figure could be as high as 870,000 kw hrs per annum.

In the commercial sector, for businesses that have large space cooling or heating systems the cost reductions are not based on the cost of the water, so much as the cost of electricity. These systems are often closed loop water heating or cooling systems. Typical areas for quick return on investment in this sector may well be hotels, computer suites, Universities, banks, large office complexes, and other public buildings in fact anywhere where water is used to heat or cool the work environment.

So how can savings be made?

The solution is to clean up the heating/cooling water using reliable filtration to less than 1.0 micron connected to both the hot and cold water system. If the water in the system is anything but clear then energy is being wasted. The darker the water the more it is costing a business.

Assuming the losses are only 15%, this means a loss of 35,000 kw per hour per annum. If the system is on 24 hours a day this cost increases to over 130,000 kw per hour per annum, all of which could be recovered through investing in proper filtration which could give a return on investment in less than 10 months.

Process water that should be accepted

A typical chiller for a medium sized building with computers may well have installed refrigeration chillers which have 200-300kw of electrical energy. Larger buildings with high populations or personnel and or computers can be much bigger.

Many public buildings require heating in winter and so use a combined system of chilled water and hot water. On the hot water systems this would be connected to the hot water boiler, very often driven by oil or gas. On the cooling side there is a cool a water circuit, connected to refrigeration chillers to enable cooling to occur.

The energy input by the boiler or the chiller is significant whether using gas, oil or electricity to achieve the heating/cooling.

12

PROCESS INDUSTRY INFORMER September 2014

It’s

show time!

WWEM 2014 is opening its doors at the Telford International Centre, UK over the 5-6th November. The Exhibition opening hours are 9.30am – 5.00pm Wednesday 5th and 9.30am – 4.30pm Thursday 6th.

With several new attractions, WWEM 2014, the international Water, Wastewater and Environmental Monitoring conference and exhibition, will be bigger and busier than ever before.

sites have had MCERTS flow inspections, and Nick Richardson from Siris Environmental will finish the first day by sharing his experiences with the scheme, outlining ‘the good, the bad and the ugly’ of flow monitoring.

The five previous WWEM events, which stretch back to 2005, have included conferences addressing testing and monitoring themes within the Process and Laboratory sectors, in addition to an international exhibition and scores of workshops. However, this year’s event will also include:

The second day’s Conference ‘Laboratory Techniques and Quality Procedures’ will address the latest issues facing environmental laboratories.

1. Flow Forum: “The Do’s and Don’ts of Installation and Measurement” 2. ‘SMART’ Water Forum: “What does the future hold for water monitoring?”

3. Instrumentation Demonstration Area 4. British Water Innovation Exchange 5. BMSS Seminar: ‘The application of chromatographymass spectrometry to environmental water analysis.’

The event (www.wwem.uk.com) has been designed to offer everyone with a professional interest in water, and environmental testing and monitoring with an opportunity to hear about the latest developments in techniques, technologies, methods, standards and regulatory requirements that relate to the monitoring which takes place both on-site and in the laboratory, covering sampling, field analysis, gas detection and continuous water and wastewater monitoring applications. Visitors to WWEM 2014 will be able to claim Continuing Professional Development (CPD) time for the event’s Conferences, Forums and Workshops.

Conference: ‘Regulation Updates for Process Operators’ The first day’s Conference will focus on the monitoring aspects of industrial and municipal monitoring, beginning with the Environment Agency’s Rick Gould, who will provide a training presentation on the Agency’s Operator Monitoring Assessment (OMA) tool. A further EA presentation by Andy Chappell will provide an update on the development of 3 CEN standards for the assessment of water quality monitoring equipment (auto-samplers, continuous monitors and portable monitors). An update will also be provided for a similar project looking at CEN standards for flow monitoring devices.

Emily Jarvis from CSA-Sira will explain how schemes such as MCERTS have shown that independent approval of instrument manufacturers’ specifications is still required, and she will demonstrate this with case studies and examples. To complement this, Andy Godley from WRc will describe the process for independent instrument testing under MCERTS from the agreement of the test programme, to delivery of the report.

Over the past 10 years thousands of municipal and industrial

New: Flow Forum Building on the event’s monitoring theme, the Flow Forum will take place on Wednesday 5th November including presentations from Water Companies, MCERTS Inspectors and construction partners who will share their experiences in flow measurement. Flow meter manufacturers will also present some of the latest measurement techniques and an open forum session will provide attendees with an opportunity to challenge the panel with questions and problems.

An Apprentice Instrumentation Competition will also take place during the afternoon session of the Flow Forum.

Contestants from the UK’s water and sewerage companies will be required to perform a range of instrumentation related tasks in front of a live audience of industry professionals.

Competition prizes are being provided by a number of industry sponsors, including ABB, Siemens & Partech. The prizes include training packages and complementary tickets to the WWEM 2014 Gala Dinner.

New: SMART Water Forum Taking place on the second day of WWEM (6thinclude a UKWIR dissemination workshop, featuring a study which has been ongoing for 18 months on Instrumentation, Process Automation & Control in wastewater. This will be followed by presentations on SMART technologies, including the ‘Internet of Things’.

Both Forums will be hosted by Oliver Grievson, a Director of the Sensors for Water Interest Group (SWIG) and Manager of the LinkedIn Group Water Industry Process Automation & Control (WIPAC).

British Water & WWEM 2014 Innovation Exchange Running throughout the first day of WWEM 2014 include concurrent workshops on Water Monitoring, Wastewater Monitoring, and Environmental Monitoring, led by British Water, Black & Veatch, and J.Murphy & Sons respectively. The participants will include Affinity Water, Bristol Water, United Utilities, Yorkshire Water, Dŵr Cymru Welsh Water, Thames Water and many of the industry’s key contractors. For anyone wishing to participate, a booking form is available from the Events page of www.britishwater.co.uk .

International Exhibition – what’s new in process monitoring

wwem.uk.com/work-shop .

However, for those interested in process monitoring, there will be flow-related presentations covering technologies such as laser, ultrasonics, clamp-on, magnetic flow and integrated flow and pressure metering. Water quality workshops will cover the measurement of almost every parameter of interest including TOC, turbidity, dissolved oxygen, nitrate, trace metals, organic loading and toxicity. These presentations will include handheld instruments as well as continuous and remote monitors, and will also address data collection techniques and data management software.

Many of the process monitoring workshops will address common operational issues such as chemical precipitation in wastewater treatment, asset monitoring, real-time sewer and CSO monitoring, and leakage monitoring and management.

Two of the eight Workshop rooms will be dedicated to gas detection and monitoring and these presentations will cover technologies such as PID, NDIR, electrochemical and pyroelectric sensors. Workplace exposure, instrument calibration and the creation and certification of calibration standards will be amongst the themes of these workshops.

Organiser Marcus Pattison says: “Whether it’s wastewater flow and quality monitoring, drinking water testing, laboratory sampling and analysis, or gas detection in confined spaces, WWEM will have something for everyone.

This year’s event will be the busiest yet, so I cannot emphasise enough how important it is to plan your visit in advance – WWEM is a working event and visitors need to ensure that they make the most of everything available.”

Summary

Featuring over 130 stands representing more than 250 of the world’s leading providers of test and monitoring equipment and related services, the WWEM 2014 Exhibition will be free to enter for pre-registered visitors. Many of the exhibitors will launch new products at the show, a few of which are featured in the following pages.

With a heavy focus on water and environmental monitoring, the WWEM events attract delegates such as regulators, industrial process operators, water utilities, accreditation organisations, commercial laboratories, instrument manufacturers, consultants, analytical service providers, researchers and academics.

Exhibition will be free to enter for pre-registered visitors. Many of the exhibitors will launching new products at the show.

The day-delegate conference rate is £55. However, registration for the event is FREE of charge and pre-registered visitors (www.wwem.uk.com) are provided with free access to the exhibition, the Forums and to the workshops, in addition to free on-site parking, and complimentary lunch and refreshments.

Over 80 Workshops to choose from The 80 WWEM workshops represent 80 of the reasons why WWEM is known as a ‘working event’. Careful planning is necessary if visitors wish to pick the subjects of greatest interest and make the most of their time at WWEM 2014.

The full Workshop programme is published on www.

PROCESS INDUSTRY INFORMER September 2014

For information on the Conference contact: Marcus Pattison Tel. +44 (0) 1727 858840 E-mail info@wwem.uk.com or visit www.wwem.co.uk.

13

WWEM 2014

STAND NO: 11

KROHNE SHOWS SMARTSENS: THE FIRST FAMILY OF ANALYTICAL SENSORS THAT NO LONGER REQUIRE AN EXTERNAL TRANSMITTER, AT WWEM 2014

STAND NO: 115/116

HACH LANGE

WILL DISPLAY THE LATEST TECHNOLOGY FOR TESTING AND MONITORING WATER AND WASTEWATER IN ANY APPLICATION AT

WWEM

On the 5th & 6th November, KROHNE will return to the Telford International Centre to showcase their comprehensive range of analytical solutions on stand 11 of the “must attend” event of the year for Water/Wastewater and Environmental Monitoring professionals.

KROHNE has introduced the SMARTSENS range of analytical sensors marking a turning point in analysis. As the first family of 2-wire, loop powered analytical sensors incorporating integrated transmitter technology, SMARTSENS sensors significantly reduce the risk of failures along the chain from sensor to the process control system whilst easing the handling of analytical sensors in a revolutionary way.

Until today, analytical sensors required the use of an external (proprietary) transmitter in order to translate the sensor signal for use in the control process. Considering the possible error by the requirements of IEC 61508/IEC 61511 in the chain from sensor to process control system, the transmitter represents the main source of error in percentage. Poor installation, cabling or configuration of the transmitter are frequently occurring issues. To eliminate these risks, KROHNE miniaturised the transmitter and fitted it into the sensor head. Any SMARTSENS sensor can be connected directly to the process control system, featuring direct communication via 4…20 mA/ HART. KROHNE is the first provider to offer a direct connection from the sensor to the process control system via a standardised fieldbus.

KROHNE, a full-service provider for process measuring technology is the market leader in electromagnetic flowmeter technology providing solutions for the toughest applications whilst also offering MCERTS approved flowmetering solutions typically required for wastewater applications. For the opportunity to discuss your applications with our industry and product experts and to learn more about the comprehensive range of products and solutions that KROHNE offer, please visit us on stand 11 at the WWEM exhibition.

For more information contact KROHNE LTD, Wellingborough, Northants.

Tel: +44 (0)1933 408518 Fax: +44 (0)1933 408589 E-mail: t.mchugh@krohne.com Web: www.krohne.co.uk

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HACH LANGE’s process monitoring team will unveil the latest MCERTS approved instruments at WWEM 2014 on stand 115/116.

The company’s real-time control solutions for wastewater treatment (RTC)) has been receiving rave reviews by companies that have installed the system and experts will be available to discuss the efficiency and cost savings that are possible with RTC, which has dramatically reduced energy and chemical costs at plants that have already incorporated this technology.

In addition HACH LANGE will run a Workshop entitled ‘Phosphate Removal Using Chemical Precipitation – Common Misconceptions and Working Solutions.’

As well as the latest process monitoring equipment, the HACH LANGE stand will also feature some of the company’s latest innovations in laboratory analysis including pocket colorimeters, portable water quality meters and sophisticated UV-VIS/VIS Spectrophotometers for the field and in the lab.

WWEM visitors involved in laboratory, field or online testing and measurement will have the opportunity to handle the latest water monitoring instrumentation.

Visit stand 115/116 and find out more.

For more information contact HACH LANGE LTD, Salford, Manchester Tel: +44(0)161 872 1487 Fax: +44(0)161 848 7324 E-mail: info@hach-lange.co.uk Web: www.hach-lange.co.uk

STAND NO: 113

SLUDGE FINDER 2 HELPS SEVERN TRENT WATER SITE TO BECOME ENERGY SELFSUFFICIENT Severn Trent Water has recently completed a Process Improvement Project which sees their Stoke Bardolph site generate 5.5MW (5500kW) at full power which is enough produced energy, to not only power equipment on site, but to also return a net surplus of electricity to the Grid; making the site energy self-sufficient.

Stoke Bardolph wanted to increase sludge density from an average of around 2% up to a target of 6% and selected Pulsar’s Sludge Finder 2 to help this process. The eight Pulsar sludge interface monitors installed have reliably and consistently measured the sludge blanket level in order to optimise the pump and ensure maximum amount of correct density sludge is efficiently transferred to the digesters.

Pulsar’s Sludge Finder 2 features a self-cleaning ultrasonic transducer that provides maintenancefree continuous sludge blanket level measurement.

For more information contact Pulsar Process Measurement Ltd, Malvern, Worcs.

Tel: +44 (0) 1684 891371 Fax: +44 (0) 1684 575985 E-mail: info@pulsar-pm.com Web: www.pulsar-pm.com

STAND NO’S: 2 & 3

INTERNATIONAL SAFETY EXPERT DRÄGER OFFERS INSIGHT INTO SOLUTIONS TO PROTECT THE WATER INDUSTRY Blyth - In the year of its 125th anniversary, Dräger will be showcasing a range of safety solutions at this year’s WWEM conference – aiming to help the water industry stay on top of the testing and calibration of its portable gas detection instruments, whilst saving time and money.

Solutions will include the Dräger X-dock, an instrument calibration and management system which allows companies to complete automatic bump testing and calibration in seconds, using just a fraction of the test gas traditionally used with many other systems.

The X-dock offers a robust documentation and reporting function so users can see the status of their portable gas detection instrument fleet at a glance and can produce calibration certificates without the need for a computer or printer.

It also has the flexibility and range of multiple gas inlets to facilitate the use of different gas mixtures for testing and calibration, making it a highly advanced piece of technology.

Dräger will also be demonstrating the innovative new communications system, the X-zone Com, which enables users to track gas detection levels from outside the areas being monitored.

Dräger’s Kevin Honner will be speaking at the event on calibration and function testing for portable gas detectors and Trevor Carol from Dräger will also be giving a talk on protecting the water industry.

To find out more about Dräger in the UK, visit stands 2 & 3 at WWEM. You can also visit www.draeger.com

PROCESS INDUSTRY INFORMER September 2014

WWEM 2014

STAND NO: 83

WWEM PROVIDES OPPORTUNITY TO SEE NEW QDOS 60 METERING PUMP FOR HIGH ACCURACY APPLICATIONS WWEM 2014 provides an ideal opportunity to see the latest in high-accuracy metering pump technology from Watson Marlow Pumps Group (WMPG). The Qdos 60 is an innovative and versatile new pump which is designed to save costs in chemical metering applications thanks to its inherent higher accuracy metering. The addition of Qdos 60 (which follows on from the highly successful Qdos 30), expands the range to incorporate flow rates from 0.1 to 1,000 ml/min (0.001 to 15 USGPH) at 7 bar (100psi). Furthermore, simple installation and easy, tool-free maintenance ensure total cost of ownership is minimised.

The Qdos 60 negates the need for ancillaries, boosts productivity and cuts chemical wastage via more accurate, linear and repeatable metering than conventional solenoid or stepper-driven diaphragm metering pumps. As a result, Qdos 60 is able to reduce chemical costs even when metering difficult fluids, or when pressure, viscosity and solids content vary. This capability combines with peristaltic technology to ensures precise, continuous smooth flow for optimal fluid mixing.

Typical applications for Qdos 60 include disinfection, pH adjustment and flocculation of drinking water, wastewater and industrial process water, as well as reagent dosing/metering in mineral processing tasks. The new pump is especially suited to chemical metering applications found in larger water treatment plants where flow demand is greater than that provided by the existing Qdos 30 model.

Advanced control features include fluid level monitoring, fluid recovery, line priming and intuitive flow calibration.

Also on show at WWEM is the APEX range of pumps – which are designed to suit all dosing, metering and transfer applications from 2.8 to 1,200 litre/ hour across a broad range of applications. APEX pumps are now the first choice for processing plants the worldwide. Unlike other pump types, APEX hose pumps have no expensive wearing components such as seals, valves, membranes, stators, rotors or glands. Subsequently, they are ideally suited for handling ‘difficult’ fluids – abrasive, corrosive, viscous, shear-sensitive, crystallising or even fluids presenting a combination of these properties.

For more information contact Watson-Marlow Pumps Group, Falmouth, Cornwall Tel: 01326 370370 Fax: 01326 376009 E-mail: info@wmpg.co.uk Web: www.wmpg.co.uk

VEGA Water Radar: The non contact solution for open water level measurement.

STAND NO: 72

THE HIQ EXPERT TEAM FROM BOC UK WILL BE AT THE 6TH INTERNATIONAL CONFERENCE AND EXHIBITION ON WATER, WASTE WATER AND ENVIRONMENTAL MONITORING (WWEM) With the focus on measurement, testing and analysis for the water and wastewater and environmental industry, a variety of products will be presented, for example, the ECOCYL portable gas cylinder with built-in regulator and a range of small cylinders for a variety of applications and ISO/IEC17025 UKAS accredited calibration gas mixtures, which can be used with the portable ECOCYL for continuous emission monitoring system (CEMS) calibration.

Specialty gas equipment used to maintain the integrity of specialty gases during usage in laboratories will be also featured.

Dr Kevin Cleaver, Technical Services Manager for BOC UK, will also be presenting a workshop on “The preparation and certification of a 30ppt gas calibration standard”.

BOC UK will be welcoming you at stand number 72 For more information contact BOC UK & Ireland, Guildford, Surrey.

Tel: 01483 244670 E-mail: Hannah.whelan@boc.com Web: www.boconline.co.uk

PROCESS INDUSTRY INFORMER September 2014

No echo loss from wind, rain or surface conditions, even cobwebs! Just reliable level monitoring for any open water or remote site. No stilling tubes, civil works or special mountings. Low cost unit, 15m range, 2mm accuracy and miserly enough on power to use with battery loggers.

So, what‘s stopping you changing the way you measure level? www.vega.com/wastewater/uk Phone: 01444 870055 E-Mail: info.uk@vega.com

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WWEM 2014

STAND NO: 99

UKAS ACCREDITATION: DELIVERING CONFIDENCE UKAS is the sole National Accreditation Body recognised by government to assess against internationally agreed standards. Accreditation by UKAS provides an internationally recognised mark of quality, which gives confidence that your organisation is competent, efficient and impartial. UKAS accreditation demonstrates that your organisation has met the requirements of a rigorous assessment process ensuring the delivery of a consistently high quality service.

UKAS accreditation has become the industry requirement for environmental testing and sampling.

If you would like further information about becoming accredited, or for technical updates, please contact UKAS: Tel: 020 8917 8400 E-mail: info@ukas.com Web: www.ukas.com Alternatively, please visit the UKAS stand at WWEM 2014 on 5th and 6th November 2014.

SLUDGE INTERFACE DETECTION

Sludge Finder 2 reliably measures primary, secondary and tertiary interface levels in treatment and process applications. l Remote monitoring – no need for site visit l Gives tank profile, status and blanket level in up to two tanks simultaneously l Self cleaning and maintenance free l 4-20mA with optional radio modem and RS485

Malvern, Worcs WR14 1JJ, UK Tel: +44 (0) 1684 891 371 info@pulsar-pm.com

www.pulsar-pm.com 16

STAND NO: 57

GAS DETECTION SYSTEMS OF THE HIGHEST STANDARD The new GMA200 family of programmable gas detection system controllers satisfies the highest demands of flexibility, reliability and economics. GMA200 includes comprehensive, easy to program outputs and relays, and data logging is standard.

The SIL 3 Certified GMA200 can control up to 16 transmitters, with 8 standard, and an optional, further 64 programmable relays. The optional GMA Gateway module allows integration of the GMA200 into a company’s existing internal IT or external Internet network.

For more information contact GfG Europe Ltd, Great Notley, Essex Tel: +44 (0) 1376 342236 Fax: +44 (0) 1376 341741 E-mail: john.balague@gfgeurope.com Web: www.gfgeurope.com

STAND NO: 74

AUTOMATED WATER & EFFLUENT LTD HAVE BEEN SUPPLYING INSTRUMENTATION, DOSING AND CONTROL EQUIPMENT FOR PROCESS CONTROL, WATER AND EFFLUENT TREATMENT SINCE 1982 Automated Water & Effluent ltd, have been supplying the water and waste water treatment sector since 1982. With over 30 years of experience covering a wide range of installation types, measuring disciplines and environments; AWE are well placed to assist with any technical challenges you may have.

At Automated Water & Effluent ltd we like to be able to offer a complete solution to our clients, from replacement parts, measuring instruments and sensor solutions - right through to a bespoke control panel with remote monitoring or an onsite service and calibration solution complete with certification to national standards - at Automated Water & Effluent Ltd we can offer a full spectrum of options to suit your needs.

At the WWEM 2014 exhibition AWE will be exhibiting a wide range of our measurement and control devices; including our new range of instrumentation and metering pumps and the friendly AWE team will be onsite to answer any of your queries.

For more information contact Automated Water & Effluent Ltd, Stafford, Staffordshire Tel: 01785 254 597 E-mail: sales@awe-ltd.co.uk Web: http://www.awe-ltd.co.uk

PROCESS INDUSTRY INFORMER September 2014

WWEM 2014

STAND NO’S: 104 & 105

STAND NO: 93

XYLEM ANALYTICS LAUNCHES MAJOR NEW PRODUCTS AT

LOVIBOND® WATER ANALYSIS EQUIPMENT

WWEM 2014

Xylem Analytics, the manufacturer of market leading instrumentation brands such as YSI, SonTek, Aanderaa, MJK and WTW, will unveil an exciting array of new products at WWEM 2014.

The company has booked a double stand (104 & 105), one half of which will focus on wastewater monitoring, featuring the new WTW family of spectral sensors that offer highly reliable continuous, chemical-free measurements with no routine service and IQSensorNet compatibility (up to 20 sensors on one digital platform). Designed for rugged long-term reliability with minimal operational costs, these UV-VIS probes are ideal for the detection of load changes in wastewater influent and effluent, and for the monitoring of organic loads in rivers and lakes.

The other half of the booth will feature a new ‘smart’ digital handheld meter from YSI (using EXO technology) which means that the meters offer a number of advanced features. For example, sensors are able to retain their calibration and thereby save considerable time in the field.

The new SonTek SL 3G for measuring water velocity and level in open channels will also be on display. These 3rd Generation models employ SmartPulseHD® technology, which continuously tracks water velocity and profiling range, depth, turbulence factors and signal-to-noise ratio, and automatically selects the optimum processing configuration to maintain high levels of accuracy.

For further information, please contact: Xylem Analytics UK Ltd, Letchworth, Herts. Tel: (+44) 1462 673581 Fax: (+44) 1462 673582 E-mail: salesuk@xyleminc.com Web: www.xylemanalytics.co.uk

WWEM provides an ideal opportunity for the Lovibond® team to discuss the issues of accurate, reliable water analysis. An established supplier of water testing equipment for the water, wastewater, industrial and environmental communities, Lovibond Tintometer is perfectly qualified to advise on all matters related to water quality.

The Lovibond® portable testing instruments and reagents offer rapid, reliable and accurate monitoring for quality testing at every stage of the water cycle. The reputable brand is synonymous with tried and trusted products, service and pure expertise.

The Lovibond® stand is exhibiting innovative solutions for the entire water cycle: Drinking Water; Waste Water; Process Water; Industrial Water; and Effluents: with instruments to analyse over 100 parameters from A-Z including, but not limited to: Alkalinity; pH; Chlorine; Chloride; TDS; Calcium Hardness; Phosphate; Sulphite; BOD and COD. Drop Test Kits for Boiler/Cooling water testing and traditional visual comparator kits and discs complete the ‘line-up’.

For more information contact The Tintometer Limited Tel: + 44 (0)1980 664800 E-mail: water.sales@tintometer.com Web: www.lovibondwater.com

Visit us at WWEM, stand 11

STAND NO: 128

BENEFITS OF WATER LEVEL RADARS ARE OUT IN THE OPEN VEGA will be showing their MCERTS non-contact microwave ‘water radar’ level transmitter for the UK water and environmental sectors on stand no. 128 at WWEM in Telford on 5th – 6th November.

Radar level sensors are being installed throughout the East Riding of Yorkshire Council drainage area. The council has undertaken a program of changing out existing ultrasonic and pressure sensors, as well as installing brand new measurement points. This has been enabled via VEGA’s non-contact water radar level sensor, accurate to 2mm, which was chosen as the replacement. Its measurement is unaffected by wind, rain or surface turbulence, which means no protective structures, like stilling tubes and conduits, are needed for the sensors.

The radar level transmitters are combined with Hydrologic Frog battery powered GSM/GPRS data loggers, no other civil engineering or electrical infrastructure work is required, saving EYRC time and money.

These ‘stand alone’ measurement systems are quicker to install, reducing safety risks of prolonged working at the waters edge. They are also cost effective: the low cost radar sensors use little enough power to operate between 2-3 years on the battery pack integrated into the Frog unit, but they still have a measuring range of 15m and are IP68 protected.

EYRC are happy to share their experience with others, for a case study document on the initial phase of the project, and details of EYRC engineers involved, please contact doug.anderson@vega.com for a copy or call 01444870055 to talk to a sales engineer for advice and prices. For more information about VEGA and our products please visit www.vega.com/uk

PROCESS INDUSTRY INFORMER September 2014

Goodbye transmitters!

SMARTSENS – The first family of analytical sensors that no longer require transmitters It integrates all of the transmitter technology in its head.

This not only reduces the costs of ownership, eases installation and maintenance but also allows for direct usage in explosive (zone 0) and hygienic areas.

SMARTSENS sensors can be easily configured and calibrated via PACTware™ (FDT/DTM) or HART® DD. Due to the offline calibration and regeneration, they feature accurate measurement and an extended service life.

So, you see – it’s time to say goodbye to your external transmitter!

goodbye-transmitters.com

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PARTICLE SIZING

ANALYSERS

XOPTIX HELPS REDUCE NOx EMISSIONS FROM COAL

What to consider when selecting a process analytical transmitter

Close monitoring of coal milling with the XO particle sizer from Xoptix Ltd, safeguards coal from being over milled and helps keep NOx emissions levels to a minimum.

Xoptix Ltd, based in Worcestershire, England, have developed the in-line particle sizer XO to maintain optimum coal milling production. As world coal sources vary greatly in fuel properties and loading profiles, uncontrolled combustion conditions force operators to apply boiler settings, which are conservative and far from ideally tuned. Particle sizing technology from Xoptix has been developed for coal milling and is based on over 30 years of knowledge of laser diffraction, which can be used to determine particle size.

With the XO inline particle sizer installed to monitor milling production, over milling and under milling can be easily and quickly be detected with real-time measurements, and the process can be adjusted accordingly. If the coal is excessively coarse due to under milling, then there will be higher levels of un-burnt carbon in the ash. This will adversely affect the efficiency of the process and create a less saleable by-product. Conversely coal feed which is milled too fine produces areas of high temperature which lead to higher levels of NOx emissions and flame instability. This results in loss of efficiency incurred by unnecessarily over grinding of the fuel. An optimum particle size distribution between these two extremes is highly desirable to ensure that power generation costs and emissions are kept to a minimum.

Richard Graves explains the importance of accurate milling to control NOx emissions, “Our XO particle sizer helps coal mills to ensure optimization of milling, which helps save production costs, but also reduces NOx emissions too. We place great importance on producing green technology that helps the environment and this ethos will always remain firmly rooted at the heart of the Xoptix culture.”

Generally coal should be pulverized until 92% is smaller than 74 microns and ideally there should be less than 2% greater than 300 microns. Xoptix Limited design, manufacture and distribute particle sizing products for process applications and are proud of their heritage in laser diffraction technology. The sizing of particles from 0.1 to 3000 micron is made easy with a robust and stable unit, with real-time inline monitoring to optimise processes.

Visit http://www.xoptix.co.uk/ for the full product overview or call +44 1684 899345

PT14_255x155_GB_Process_Industry_CL5.indd 1

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Transmitters for measurement of physical parameters often come integrated with the measuring element, but transmitters for analytical measurements are usually chosen separately from the sensor. With ever growing functionality, choosing the right analytical transmitter is not just a matter of process variable, power requirements and output signal.

Download METTLER TOLEDO’s latest PRO Insight – “What to consider when selecting a process analytical transmiter.”

PRO Insight is a short guide designed to help you choose the right instrument. Whatever the parameter, it is important to take a look at the function of the measurement point and to consider its role within the process. Does the measured value have an immediate and high impact on process stability, product quality and or safety, or is the measurement only for monitoring?

To find out more and download your copy, visit: www.mt.com/uk-PROInsight-transmitters For more information on the advantages of ISM in the chemical industry, contact Mettler-Toledo Ltd, Beaumont Leys, Leics.

Tel: 0116 234 5095 E-mail: enquire.mtuk@mt.com visit www.mt.com/ism-chem

27.05.14 06:53

PROCESS INDUSTRY INFORMER September 2014

UNDER PRESSURE - will the food industry crack?

Every sixteenth of a second, a Twinkie is born. It costs approximately $0.0536 to make and sells for $0.25 to $0.60. This minute detail from the food and beverage industry is indicative of how dynamic the sector is. In recent years, manufacturers around the world have been under growing pressure to increase production, while minimising costs as much as possible. Here, Jonathan Wilkins, marketing manager at Stafford based European Automation, explains how food and beverage manufacturers can remain productive in the context of increasing raw material prices, energy prices and pressure from retailers. all have to eat, don’t we? – its potential would be significantly limited should investment in innovation decrease.

How do you reduce costs?

Moving manufacturing operations to a cheaper territory stopped being a viable solution long ago. Cheap labour isn’t strategic in the long run and most industries have already turned their backs on this option.

Another way of protecting manufacturers’ interests would be to impose legal restrictions that ensure key obligations for retailers. One example would be guaranteeing that retailers give reasonable notice to change supply arrangements, that they deal fairly and lawfully and don’t constrain manufacturers to obtain goods, services or property from a preferred third party.

According to the 2013 food statistics pocketbook, food prices in the UK have risen in real terms by twelve per cent since 2007, following a long period during which they fell. This price increase is emulated internationally and is partly associated with the increasing costs of raw materials and energy. It also reflects the pressure giant retailers have been exercising on food and beverage manufacturers to provide cheaper end products.

Between a rock and a hard place This situation leaves manufacturers stuck between a rock and a hard place – they need to comply with retailer demands and respond to particularly precarious customer preferences, while also finding a way to reduce production expenses and not pass cost increases on to customers.

In a recent industry survey, 83 per cent of the food and beverage manufacturers that responded expressed concerns that pricing pressure from retailers was threatening the quality of own-label products. 74 per cent further estimated that this pressure was threatening to cut into new product development budgets. As in any other industry, lack of research and development limits innovation, which in turn, reduces investment, growth and profit. While the food and beverage industry is one of the only ones that will definitely not die out – we

When these codes exist, they are often limited by the free market and competition law, which means that reducing manufacturing costs needs to come from somewhere else.

Think ‘lean’ The fastest and most efficient way to reduce costs is by designing and managing a manufacturing process that results in the lowest possible unit cost. This means taking a good look at your operations and identifying how they can be improved. If you work in the industry, you probably know that many production lines today operate at less than 60 per cent, which means there is considerable room for improvement.

Batch automation allows the manufacturing of certain products in determinate batches, rather than in a continuous production process. Batch operations in the food and beverage industry include mixing, blending, mashing and fermenting, while continuous operations refer to baking, forming and pasteurisation.

A flexible production line guarantees consistent product quality for all batches, allows a more dynamic product offer and ensures efficient use of the shop floor.

Manage breakdowns Breakdowns are inevitable, but the way they are managed can make or break a business. Lean manufacturing principles state that when a breakdown occurs, the first step is to try all the options that don’t incur additional costs. Whether it’s a simple case of “turn-it-off-and-on-again”, checking the system for blockages or performing an emergency maintenance check you should use your internal resources first.

If the breakdown is due to faulty equipment, it’s likely that you’ll be able to resolve the situation by getting the part repaired or just purchasing a spare industrial automation component. Most parts, including variable speeds drives (VSDs), motors, programmable logic controls (PLCs) and human machine interfaces (HMIs), are easier to find than you might think, even if they are obsolete, for example a specialist like us can deliver them in as little as nine hours, which minimises down time and reduces costs.

If all else fails, then - and only then - look at purchasing completely new equipment or refurbishing the production line.

Busting the myth

Identifying planned losses (cleaning, preventative maintenance or decreasing product demand), operational losses (changeovers, stoppages or shortages) and quality losses (scrap products or defective materials) is the first step in making manufacturing lean.

One of the myths surrounding the food and beverage industry is that it’s an out of date and old fashioned sector, which doesn’t offer exciting professional prospects. Much like the infinite shelf life of the common Twinkie, this myth has no basis in reality.

The next step is utilising existing real-time data collection from the process equipment to improve Overall Equipment Effectiveness (OEE). Intelligent automation solutions help minimise process variability and maximise asset use and productive capacity.

The challenges and external pressures the food and beverage industry is faced with make the rhythm of innovation particularly swift. We have definitely sensed a shift towards intelligent automation, reflected in the purchases our clients make and our food and beverage clients have started purchasing newer generations of PLCs, HMIs, digital sensors and transmitters. This means that despite being under pressure, the food and beverage sectors is still a leader in innovation and has great potential for growth.

Become flexible A flexible manufacturing line allows companies to match their products to ever-changing consumer behaviours, which is essential in the food and beverage industry.

PROCESS INDUSTRY INFORMER September 2014

19

Tank Level Measu for Powders & So Inventory control.

Inventory turns.

Inventory accuracy. Inventory management. It’s all about inventory and controlling its related costs.

So, your job is to figure out just how much material you have on hand, when you need more, and don’t you dare run out. Simple in theory, not quite so easy when you are running multiple production lines or asked for month-end inventory in about an hour.

However, there are devices that can help make your inventory more accurate and your job easier. To select the appropriate device, it is helpful to consider the material being measured, whether the material surface is even or irregular, the regulatory environment, the size of the tank, and whether you need to know when inventory has reached a certain level in the tank (requiring a point level device) or you need continuous level measurement.

Rotary Level Indicators Rotaries are used for high or low level point level indication in bins, tanks, and silos. A rotary sends an alert via a horn, light or to an alarm panel when material reaches (for high level detection) or falls away from (for low level detection) the rotary paddle.

For thick bins walls, a horizontal extension allows for a rotary to be used to detect material levels through the sidewall. When a horizontal extension is combined with a collapsible paddle, the rotary can be installed through a 1-1/4 inch or 1-1/2 inch NPT opening without entering the bin.

Capacitance Probes Capacitance sensors are designed for a wide array of applications and materials and may be used in powders, granulars, pellets and other solid or slurry materials.

The sensors may be used for high, mid and low level detection in bins, silos, tanks, hoppers, chutes and other types of vessels where material is stored, processed, flowing or discharged.

Capacitance sensors operate by detecting the presence or absence of material in contact with the probe by sensing a change in capacitance caused by the difference between the dielectric constant of the material in the tank and the air. These sensors are able to detect very small changes in capacitance, typically one picofarad.

Rotaries are used in a wide range of powder and bulk solid materials and can be used in materials with a bulk density of 1 lb/cu ft3 to 150 lb/cu ft3, so they can be used in light powders, granulars, pellets and even very coarse materials such as aggregates.

Rotaries are applied in almost every industry including agriculture and food processing, chemical and pharmaceutical manufacturing, plastics and packaging materials, pulp and paper, mining, and many more.

When selecting a capacitance probe, understanding the radio frequency range of the device and its impact on other equipment in the plant is an important consideration. According to the Federal Communications Commission, signals in excess of 9 KHz are classified as “RF” and are prone to radiate.

The selection of rotary depends on how critical the role of the rotary is in the operation. For example, if a rotary is critical in starting, stopping, or controlling a process, or causing a work stoppage if a bin should become empty.

Most standard rotaries are designed to provide protection from system power failure. Some feature a motor that “goes to sleep” or “de-energizes” to automatically shut down when material is present.

When it is crucial to confirm the continuous operation of a rotary, the application calls for a genuine failsafe rotary that continually self-diagnoses, and in the event of a failure, sends an immediate warning and instantaneous corrective response.

20

when emptying the bin (cone down).

Capacitance sensors that emit RF signals may interfere with nearby electronic plant equipment. Conversely, capacitance probe designs that utilize RF may be prone to interference from other RF devices, such as two-way radios. There are capacitance probe designs that utilize electronic circuits incorporating frequency shift oscillators and balanced bridges and operate at frequencies between 100 KHz and 2 MHz in the RF range.

Alternatively, there are capacitance probe designs that use a discharge time constant detector circuit which sense capacitance changes of less than one picofarad and operate at only 6 KHz, which is well below the RF level of most plant equipment.

Rotaries are increasingly applied in new ways. For high level detection at the interior of a bin, a vertical extension on a rotary can allow it to be extended up to 12 feet down into the bin. This configuration is recommended for a center fill bin when the operation wants to allow a specific amount of headroom in the bin.

For food processing or pharmaceutical applications a shielded, Delrin-sleeved sanitary probe is often appropriate. A sanitary probe should be designed for quick disconnect from the device, so it may easily be removed from the tank for inspection and cleaning.

Sanitary probes are also designed so there are no exposed threads where material can build up and become contaminated.

Mounted on the top of the bin, a vertically- extended rotary can alert when material is higher toward the centre of the bin, versus simply detecting the level of material near the sidewall which could be at a lower level when filling the bin (cone up) and at a higher level

To guard against false readings from build-up on the probe or bridging between the sidewall and the probe, a portion of the probe should be shielded. A time delay feature can minimize false alarms in the case there is a sudden material shift caused by rapid filling

PROCESS INDUSTRY INFORMER September 2014

urement Options olids

By Jenny Christensen – BinMaster, Lincoln, USA

or emptying of tanks or process activities.

If continuous process operation is critical, look for a capacitance sensor that features fail-safe protection to eliminate process shut-downs, overfills, empty conditions, or accidents. To prevent overfills or material shortages, a high/low selectable switch allows the sensor to be set for fail-safe high or fail-safe low. An extended, flexible cable extension can be attached to the capacitance probe in instances when the sensor is mounted on top of the tank and will be used for high, mid or low level detection.

A flush mounted probe can be used in narrow or space constrained areas or in applications where material flow or bridging may damage a standard probe.

When the tank is small or has internal obstructions, a bendable probe can be used in the tank to avoid obstructions, while still allowing adequate probe surface area to detect the presence or absence of material.

If your facility has an explosion proof requirement, you will need to specify a capacitance sensor designed and certified for hazardous location applications. If the application is in a high temperature environment or in an area where there is excessive vibration, it is appropriate to install a capacitance probe that houses the electronics and probe in separate enclosures. This will protect the electronics from heat or vibration.

Vibrating Level Sensors The vibrating level sensor or vibrating rod is a piezoelectric driven vibration type level switch can be used for level detection in bins, silos, and hoppers filled with powders or dry bulk solid materials. A vibrating level sensor can detect extremely light, fluffy materials as light as 1.25 lb./ cu. ft.3, such as powders and flakes or can be used for heavy materials such as granulars or pellets. A vibrating level sensor can be utilized as a high, mid or low level alert and can be mounted on the top of the tank as a high level detector or in the bottom cone of a tank to sense when the tank is nearly empty.

Vibrating level sensors are piezoelectric devices with a single rod shaped vibrating element. The rod of the sensor vibrates when there is no material covering the active rod. When the rod is covered with material, the vibration is dampened and an electronic circuit causes a relay to switch and sends an alert. When the rod becomes uncovered, the vibration restarts and the relay will switch back. A vibrating rod features a single probe design that prevents material from bridging and giving a false signal.

Vibrating level sensors are known for high performance and reliability and since the sensitivity is located at the tip of the sensor, material built up on the vessel wall will not influence the function of a vibrating level sensor.

Plus, the combination of low energy and tip sensitivity will reduce false alarms due to rat-holing around an active sensor. Most vibrating rods do not require calibration and easily adjust to the desired sensitivity level. For process-critical applications, be sure to look for features such as a fail-safe alert that will provide notification when power is interrupted to the unit to avoid overfills and empty tank situations.

Bob-Style Sensors If minimal contact with the material in the tank is acceptable, a weight and cablebased sensor is an economical and accurate continuous level measurement choice.

Weight and cablebased or bobstyle sensors can be ideal for diverse applications for most any industry as they are not affected by dust, humidity, temperature, dielectric constant, or fumes that may be present.

Since there is limited contact with the material, there is minimal risk of contamination.

This type of sensor works in virtually any material regardless of particle size or bulk density including very light materials like fine powders to heavy, dense materials like aggregates. A bob-style sensor can be used in bins up to 180 feet tall, but are also often used in smaller, active process bins under 40 feet tall.

Properly mounted on a center-fill, centre-discharge bin, bob-style sensors will consistently provide5% to 7% accuracy. They work by releasing a cable with a weighted sensor probe that stops and retracts when the probe comes into contact with material. Redundant measurements are taken when the sensor probe is both descending and retracting to guarantee every measurement is precise. Bob-style sensor networks can be integrated utilizing various communication options.

For example, a control console mounted at ground level can report the data from one up to over 100 bins.

Ultrasonic and Radar These types of measurement devices are popular as they eliminate contamination or interfering with the internal bin structure since the device does not come into contact with the bin material. They are also ideal for liquid applications.

Ultrasonic and radar-based technologies are singlepoint, continuous measurement devices that can be used for on-going level measuring and monitoring of tanks that are up to 100 feet tall. An ultrasonic device generates an ultrasonic pulse that is sent to the surface of the material in the tank. The pulse reflects off the product and returns to the sensor in the form of an echo. The amount of time the echo takes to return to the sensor determines the distance to the material.

PROCESS INDUSTRY INFORMER September 2014

Radar-based devices generate an electromagnetic wave that travels to the material surface being monitored that is reflected off the surface back to the sensor. The calculated distance is based on the length of time it takes the wave to return from the surface.

Ultrasonic and radar may not perform consistently in high dust environments, where their signals can become “confused� and provide inaccurate measurements or no data at all. Since they only measure a single point in the tank, they may offer compromised accuracy in materials like powders that are more prone to bridge or have an irregular surface area. When selecting an ultrasonic or radar device, choose one that is selfcalibrating, or easy to calibrate due to the variability of materials that may be measured.

3D Scanners A 3D scanner is a non-contact, dust-penetrating bin volume measurement system that uses acoustics-based technology to measure bin contents at multiple points within the bin and uses these points to help estimate the volume of material in the bin. Sampling measurements from multiple points when the material surface of the bin is uneven enables the 3D scanner to calculate bin volume for powders and solids with greater precision than any single point measurement device.

A 3D scanner is able to map the topography of the bin and create a computerized profile of the bin contents. This allows for greater accuracy as it detects cone up, cone down, bridging and sidewall build-up and accounts for these variations when it provides the volume estimate. A 3D scanner performs in tanks up to 200 feet tall and in materials with bulk densities greater than 12 pounds per cubic foot. Facilities that install 3D technology are seeking improved inventory accuracy, with a 3D scanner proven to deliver .5% to 3% volume accuracy when mounted in the proper location and used in a bin that is less than 45 feet in diameter.

For bins greater than 45 feet in diameter, a multiple scanner system can record measurement data from multiple devices and combine the data to report volume to a PC and provide a single graphical representation of the bin contents. A 3D scanner is desirable when highly accurate volume inventories are needed to help in optimizing purchasing, delivery logistics, production planning, and financial management. Mapping the contents provides a realistic view of inventory levels.

By detecting build-up, a 3D scanner allows timely preventive maintenance and cleaning. The need for inventory accuracy can vary from one operation or one tank to the next. Getting an accurate measurement for a single point in the tank can be done easily, but it might not give you the volume accuracy you need.

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LEVEL MEASUREMENT

Exciting news from the engineers at UWT Level Controls 2014 has seen the engineers at UWT not only approaching their work with their customary diligence but also with creative flair. In addition to an innovative all-rounder for measuring all types of bulk materials, the RFnivo®, they have developed new, lower-cost Nivotec® software for level monitoring and have worked on the functional safety and safety integrity level SIL2 for rotary paddle switches. Attention has also been given to the interface measurement technology the ever-reliable lot system, Nivobob®.

The new RFnivo® We are often asked whether there is one measurement principle, which works reliably in all bulk solids applications? Is there one sensor that can cope with low bulk density, bridging, caking, abrasiveness, corrosion, high tension and leverage forces, high and low process temperatures and pressures, low and fluctuating dielectric value as well as being able to offer a short reaction time? To date, the answer to this question has been “no”. Therefore, UWT decided to enhance their portfolio with a capacitive sensor that is able to offer a solution for any challenge. The RFnivo® 3000 is the new capacitive level switch for bulk solids and is used as overfill protection as well as a demand or empty detector

in process or storage containers. Call UWT UK Ltd for full specifications on this new addition to the product portfolio of level controls.

SIL2 for UWT rotating paddle series The terms ‘functional safety’ and ‘safety integrity level (SIL)’ have occurred more frequently since the publication of the international standard IEC 61508/ IEC61511. Particularly in hazardous systems such as within chemical plants, the importance of functional safety has become paramount. With this in mind, the UWT engineers redesigned the rotating paddle switch Rotonivo® RN6 series in accordance with SIL2.

Typical safety functions are overfill and dry run protection.

As part of the functional safety issue, the RN6 electronics have been redesigned so that any failure of electrical components leads to a safe switching state of the output.

Clear interface measurement with Nivobob UWT’s Nivobob® NB3300 (rope version) and NB3400 (tape version) are specially modified for interface measurement and have proven themselves under varying process conditions. They are especially designed for continuous measurement of salt or mud levels, used in tanks for contaminated water or silos. In order to continue to provide consistent reliability, the UWT engineers have

further developed the formulation of the Nivobob® technology. All installed parts have been additionally coated and prepared with robust corrosion resistant materials.

Affordable level monitoring with the new Nivotec® NT4500 In order to provide plant operators with a complete solution in the level monitoring of silos, UWT has developed the visualisation software Nivotec® with special focus on the pricing aspect. WebController with Ethernet interface and Modbus RTU as well as standard industrial components of Wago are the basis of Nivotec® system. Any sensors with 4-20mA signal level can be integrated into the system.

Especially convenient when configuring with the UWT Modbus RTU sensors are the low wiring costs. Only one bus cable and a cable for the power supply are wired to the silo where all sensors in the series can be linked. Also any full detector with relay signal can be connected to the Nivobob® sensors in the modbus.

Contact Graeme Hughes at UWT UK Ltd to discuss these latest developments in reliable level control on 0845 4810463 or E-mail: sales@uwtuk.com

HEAT TRANSFER & ENERGY TESTO SAVERIS 2: TEMPERATURE AND HUMIDITY MONITORING RE-INVENTED Thanks to Testo, temperature and humidity monitoring has been simplified.

Monitoring temperature and humidity is important where incorrect climatic conditions can have drastic consequences; too low a temperature in pharmacy refrigerators can negatively influence the effectiveness of vaccines, or excessive air humidity in museums can damage the surfaces of valuable exhibits, and in food production too high a temperature can accelerate the spoiling of sensitive products.

The cost too many businesses that rely on stable temperature management can be excessive should a cooling or heating system malfunction leading to wasted stock, or worse.

Traditionally there have been two methods available for monitoring irregular fluctuations in temperature and humidity; data loggers and data monitoring systems. Data loggers are a very simple solution but a common issue is that information needs to be manually acquired and the logger does not always automatically inform users of excessive temperature fluctuations. The main disadvantage of data monitoring systems is their complexity, i.e. they require time consuming installation and maintenance, and are more often than not complex and expensive.

Cloud based temperature and humidity monitoring The Saveris 2 system was developed by Testo’s measurement technology specialists in Germany’s Black

Forest. They were set one simple task; design a solution so customers can monitor their temperature and humidity levels easily, anytime and anywhere, without needing to compromise security or bother with time consuming software. In the current age this presented a number of challenges but they embraced the situation and have designed a remarkably simple and elegant solution.

Testo’s developers decided to use cloud technology because it allows information to be stored remotely with access to the data as and when needed whilst providing the ability to be on the other side of the world and still be able to monitor and react to issues.

This reduces the pressure on an individual, or team, to be constantly on site to keep measurement values under control. If temperature or humidity levels fluctuate beyond acceptable levels an alert is sent by SMS and e-mail to the parties’ responsible, allowing action to be taken to prevent any loss of product.

Data is extracted and stored wirelessly and can be accessed by simply logging on to the secure cloud location allowing easy viewing of the information. This process simply relies on a standard internet browser, so no special software or

configuration is needed and it can be accessed via a computer, tablet or smartphone. Equally, when on site with Saveris 2 you can scan each Saveris logger’s built in QR code (see image), which will take you to the secure cloud page devoted to the data extracted from the logger in question, allowing speedy assessment of individual loggers.

Using their vast experience with temperature logging, Testo was aware many of their customers’ businesses expand and change over the life of a product. So the Saveris 2 system has been designed with flexible expansion capabilities with customers able to start with a simple setup which can be added to over time and making it easy for the system to grow as their business develops.

Flexibility with security As of autumn 2014, the Testo Saveris 2 will be available in various different versions via www.testolimited.com and from selected specialist dealers. There are five different temperature and humidity probes available, as well as three licensing models for the use of the Cloud.

For more information contact Testo Ltd, Alton, Hampshire. Tel: 01420 544 433 E-mail: info@testo.co.uk or visit Web: www: testolimited.com

AxFlow to distribute industrial sector APV heat exchangers AxFlow has announced that it has taken on the exclusive distribution of APV heat exchangers for industrial markets in the UK. APV heat transfer solution for cooling, heating, condensing and evaporation of process fluids are used across a wide range of industries and AxFlow now becomes the prime source of distribution to the chemical, industrial, oil and gas and power sectors throughout the UK. AxFlow has been involved in supplying industrial heat exchangers for several years, but the decision to take on the distribution of the APV Gasketed Plate range, Brazed Heated range and the APV Hybrid fully-welded, gasketfree product marks a new departure for the company.

Heading up the new operation is Geoff Mahoney, who has joined AxFlow from APV. “APV has a very well established range of plate heat exchangers in the UK, and together with these AxFlow

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will be bringing new innovations to the market,” reports Geoff Mahoney. “These new innovations include plate type hanging, clamping and EasyClip systems. We are also offering the APV Hybrid fully-welded heat exchanger, a system that does not contain gaskets and is fully cleanable. The versatility of the Hybrid is reflected by its ability to be used in almost any type of application, particularly where high temperatures and pressures are encountered.”

AxFlow will be offering the full range of available plates in sizes ranging from 3/4” up to 20” port diameters and plate areas from 0.018 to 3.8m2. The large and extensive plate and gasket materials are capable of withstanding corrosion and ensure processing efficiency.

Announcing the introduction of APV Heat Exchangers to its product portfolio, Managing Director Tony Peters said “This is a significant, yet logical move for the company as

heat exchangers have long been made available for projects where requested. Now they are becoming a mainstream product range in their own right, supported by a dedicated product manager and sales support network. We shall be concentrating on those sectors of industry where AxFlow already has a strong presence for its process pump technologies and APV heat exchangers are already widely used,”.

For more product details and company information please contact AxFlow Ltd, Ealing, London.

Tel: 020 8579 2111 E-mail: info@axflow.co.uk Web: www.axflow.co.uk

PROCESS INDUSTRY INFORMER September 2014

On the subject of knowledge…

As I’m sure you know, we run

NEWS

SEPT 2014

Meet the family the fast way.

All our Eta pumps at a glance.

a series of courses throughout the year but how many of you attend or send your apprentices on them?

It’s not that we are short of attendees but there is always room for more - so why not check out the forthcoming opportunities in the following pages, . it’s never too late to broaden your knowledge and

especially

that

of

your

young engineers…

Always in the news...

Energy saving and working towards “decarbonisation” – hot topics and inseparable and here at the BPMA we are very much alert to the endeavours, that hopefully will in the not too distant future be totally resolved, but for now helping to minimise the situation.

Articles concerning these topics can be found inside the covers.

Stats & Surveys…

If they are your “thing” make a point of take a look at the UKOOG survey for support of natural gas from shale- is the result good or bad, find out for yourself.

Ever wondered about the worth of UK product, export and import

Eta keeps the world on the move Our Eta pump family keeps the world on the move. And there are plenty of big reasons: the highly efficient top-class hydraulic system. Dozens of sizes, materials and drives in almost any combination. And service that puts rivals in the shade. After millions of great pumps, the new generation is here. So discover what Eta can now do for you. www.ksb.com/eta-en

market – now is the time to “figure” it out.

• KSB Limited • 2 Cotton Way • Loughborough • Leicestershire • LE11 5TF • 01509 231872 • www.ksb.co.uk

It’s just a “taster” – there is more to learn inside from both the BPMA and member companies…

Information relating to individual members announcements or advertisements should be made directly to the relevant company or by completing the enquiry form positioned on the back page and faxing it back to the number shown.

Etanorm

Etaline

Etabloc

Etanorm SYT

Our technology. Your success.

Pumps Valves Service n

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1

NEWS BYTES  BPMA

meets with UKOOG

BPMA met with the United Kingdom Onshore Operators Group (UKOOG) in June to discuss the pump supply chain associated with potential UK shale gas developments A new UKOOG commissioned survey shows 57% of Britons support natural gas from shale • 57% of Britons think shale gas production should go ahead; only 16% are opposed • Two thirds believe Britain should be less reliant on gas from other countries • Planned changes to underground land access supported by 42% of the public, with only 16% opposed A new public opinion poll reveals that natural gas production from shale enjoys widespread backing across the country, with more than three times as many supporting production than opposing. The Populus survey of 4,000 adults, commissioned by UK Onshore Oil and Gas (UKOOG), also finds overwhelming support for reducing Britain’s reliance on gas imports from overseas, which are rising rapidly as North Sea production declines.

This survey is one of the largest polls on the issue. The key findings of the research include: • Overall support for shale gas production: 57% support the production of

 Training

– Lecture Based

BPMA Pumping Fundamentals Courses

natural gas from shale in the UK, compared with 16% who oppose and 27% who are undecided.

• Reducing reliance on gas imports: 67% agree that Britain needs to produce its own energy so it isn’t reliant on gas from other countries, compared with just 1% who disagree. National Grid has forecast that without natural gas from shale production, Britain will import up to 91% of its gas by 2035.

• Support for shale gas development alongside renewable energy: 59% would be willing to see natural gas from shale production go ahead as long as it forms part of a mix that includes renewable energy sources, with only 12% disagreeing.

• New infrastructure needed: 47% agree that the UK needs to invest in a whole range of new infrastructure, including housing, roads and railways, airport capacity and new energy sources, with only 5% disagreeing.

• Underground land access: 42% agree with the Government’s planned changes to underground land access, compared with 16% who disagree.

The changes are designed to bring oil and gas and geothermal energy production into line with other essential services that have rights of underground access, including water and sewage pipelines and coal mines.

 Statistics

– UK Pump Market Information

Next courses scheduled for 21/22 October 2014 Venue: National Metalforming Centre (1 minute from J1, M5) Cost: £300.00 + VAT per delegate per course (BPMA member discounts available) Module 001 Part 1 – Pumping Fundamentals

• Introduction • Pumps as machines, liquid properties & definitions • Terminology – definitions • Fluid flow – basic concepts, cavitation & NPSH • Systems performance, pump • Performance, matching pump & system

Module 001 Part 2 – Pump Selection

• Introduction • Recap on part one • General Approach to Selecting A Pump • Defining The Need • Collecting Information From Customer • Grouping The Desired Features • Eliminating unsuitable pump types selecting the pump to meet the hydraulic requirements • Checking the installation requirements • Checking the compatibility requirements • Reviewing the selection • Specifications for other equipment • Contractual issues We are able to offer all of our lecture-based courses “in-house”.

Contact j.page@bpma.org.uk for further details.

Source: European Industrial Forecasting Limited 2014 2

NEWS BYTES   Government publishes CCS scoping document The Government today reaffirmed its commitment to the establishment of a Carbon Capture and Storage (CCS) industry in the UK with the publication on 7 August 2014 of a scoping document which summarises the policies and actions the Government has taken as part of its world leading programme.

The “Next Steps in CCS: Policy Scoping Document” also sets out the Government’s intention to continue engagement with the CCS industry and seeks views and evidence on a possible Phase 2 of CCS deployment, taking forward commitments published in the 2013 Electricity Market Reform Delivery Plan.

Secretary of State Edward Davey said: “The UK is leading the world on CCS and the Government wants to make sure that Britain will be in first place to export this knowledge to a decarbonising global economy.”

“The Government is strongly investing in developing a CCS industry in the UK that can compete on cost with other low carbon technologies. CCS will help us reach our goal of reducing carbon emissions by 50 per cent from 1990 levels more cheaply by while supporting over 15,000 jobs per year.”

The Government is already investing around £100m in the Front End Engineering and Design (FEED) stages of two CCS projects - White Rose and Peterhead, as part of its £1bn CCS Commercialisation Programme.

Taken together, the Peterhead and White Rose projects could provide over 2000 jobs during construction, reduce the UK’s carbon emissions by around 3 million tonnes a year, and provide clean electricity for over 1 million homes.

The White Rose project also recently received e300m in funding from the European Commission under their NER300 programme and was the only CCS project in all of Europe to receive this support.

The document invites views by 23 October 2014.

 Training

– E-learning

BPMA also offer a choice of two on-line courses available.

Introduction to Pumping Technology Level Two (QCF) This provides standardised terminology and a very basic approach to the various pump types. It is targetted at all employees who need to know the language of the pump industry.

Essentials of Pumping Technology Level Four (QCF) For those students who have day-to-day involvement with pumps and pumping systems, this course aims to provide the knowledge needed to cover normal situations. Likely candidates are all personnel who manage or are involved in designing, specifying, sourcing, installing, servicing and maintaining pumping equipment.

Both courses are accredited by the Open College Network and certificated by BPMA. Visit www.bpma-elearning.co.uk for more information and costs.

Buyers

 The Energy Savings

Opportunity Scheme (ESOS) and Pump System Audits

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

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

The scheme’s regulations are published on the government’s legislation website http://www.legislation.gov.uk/uksi/2014/1643/contents/made More information about the Energy Savings Opportunity Scheme can be found on the ESOS webpage https://www.gov.uk/energy-savingsopportunity-scheme-esos Guidance has also been published to help potential participants in the scheme understand their obligations and on page 43 of the full ESOS guidance document you will see that the ISO/14414-Pump System Energy Assessment standard is referenced as an auditing methodology that can be accepted by “Lead Assessors” approved by the Environment Agency. Accordingly it is hoped BPMA CPSA accredited persons (who are trained according to the IS0 14414 standard) will be recommended by Lead Assessors to undertake the pumping system elements of company energy audits.

And bear in mind:• Pumps are the largest consumers of global motive power • Pumping System improvements can deliver up to 40% reduction in energy costs – and therefore improve user bottom line P&L account performance • The fact that BPMA’s CPSA scheme has been designed to help by equipping people with the skills to conduct a Pumping System Audit in accordance with ISO/14414 So when considering auditing your pumping systems, remember the BPMA Certified Pump System Auditor Scheme (http://www.bpma-cpsa. co.uk) has established BPMA as THE body to train and certify personnel who undertake “Pumping System Assessments” as referenced in UK Government Energy Strategy documents.

BPMA are now offering the opportunity to attend a four day residential course culminating in certification and eventual personal ID “Certified Pump System Auditor” status following approved audits.

Guide

2014/15 edition of the BPMA Annual report Directory and Buyers Guide now available!

Contains full guide to pump types, applications and matrix for specifying.

Also contains information on BPMA activities, useful articles, UK pump market data and details of products and services offered by our members.

Request your copy now by emailing j.page@bpma.org.uk

Course Dates: 8-11 December 2014 Course Venue: National Metalforming Centre, West Bromwich, West Midlands (1 min from J1, M5) Course fees: £1,500 + VAT (BPMA Members), £1,750 (non-members).

Fee includes 3 nights (b&b) accommodation Contact j.page@bpma.org.uk for registration form or telephone 0121 601 6691 for more information

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When Pressurised just call Smedegaard the Pressurisation system experts Smedegaard Pumps limited manufacture and supply what is ‘probably’ the largest range of pressurisation equipment for LTHW, MTHW and CWS systems.

The standard ECO and Elite pressurisation units are primarily designed for commercial systems and are used with Expansion Vessels. The units can be free standing or walls mounted, and are Category 5 compliant. Elite units are fitted with system ‘safe fill’ packs allow the units to fill the closed loop system.

For applications such as very large volume, high rise, higher temperature systems or where the final working pressure of the system must be similar to cold fill pressure then the SpillPress units offer the ideal solution.

The compactness of the SpillPress units may also be a great advantage where the available floor space is limited.

SpillPress tanks are designed to accept the full expansion of the system; level control is fitted as standard. All tanks have an overflow and spill over weir to give a WRc Category 5 compliant type AB air gap.

A full digital control panel is fitted to the unit which gives an audible and visual alarm indication with mute, password protection and hours run log and has volt free contacts for BMS connection.

SpillPress are split into three distinct ranges each providing the optimum engineered solution.

SPILLPRESS COMPACT The ‘Compact’ range consists of the pump and control module

mounted together with the spill tank on a common base plate. Peripheral turbine pumps in twin configuration are normally used in the range. However, other pumps can also be offered to suit specific requirements. The spill tanks are available in three sizes to accept 400 litres, 600 litres or 1000 litres of expansion. Solenoid valves are utilised as spill valves on this range.

SPILLPRESS MODULAR

The ‘Modular’ range consists of the pump and control module on a common baseplate and the spill tank supplied loose. Usually two vertical multistage pumps are fitted but there is the option for a third pump. Self acting spill valves are utilised with this range but solenoid valves can also be fitted to this range. ‘Modular’ packages can accept expansion of up to 11875 litres and is suitable for use with boilers of up to 12000 kW at 90°C.

SPILLPRESS BESPOKE The ‘Bespoke’ range is designed and engineered for larger projects which exceed the capability of both the ‘Compact’ and ‘Modular’ packages. The ‘Bespoke’

sets are designed and built to the client’s specific specifications with the aid of our in house expertise. The accompanying picture shows a ‘Bespoke’ custom built pump and control package. Spill tanks with a capacity of 53,000 litres were provided with this package.

High Temperatures Applications When operating the system above 95°C higher pressures will be required to eliminate vaporisation. Additionally intermediate cooling buffer vessels may be necessary.

As the SpillPress for these applications is customised to specific needs, please contact the Smedegaard technical team for assistance when dealing with these system types.

For more information please contact Smedegaard Pumps Limited, Bridgwater, Somerset Tel: 01278 458686 Fax: 01278 452454 E-mail: info@smedegaard.co.uk Web: www.smedegaard.co.uk

Golf @ Glorious Goodwood Player Registration Company......................................................................

The 2015 BPMA Golf Day will take place at one of the UK’s premier sporting venues, ‘Goodwood Park’, Nr. Chichester. A great venue for you to entertain your clients and employees alike.

Thursday 14th May 2015

Goodwood Park Hotel & Kennels (Downs Course) 09:00 - 10:30 Registration - ‘Goodwood Bar & Grill’ 09:00 - 10:30 Coffee and Bacon Rolls - ‘Goodwood Bar & Grill’ 10:30 18 holes Texas Scramble on the Downs Course, 4-Ball with Buggies 16:00 - 18:00 Card return & Bar - ’Goodwood Bar & Grill’ 19:30 Drinks Reception - ‘Cedar Suite’ 20:00 Dinner and prize giving - ‘Cedar Suite’

Friday 15th May 2015 Goodwood Park Hotel Breakfast & Departure

Special Room Rates Available for 13th & 16th Where Required

Amazing value at just

£220.00 per player + VAT

Places are limited so register now to avoid disappointment Please complete the registration form attached.

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I/we would like to reserve .......... places at the 2015 BPMA Golf Day. At a rate of £220.00 + VAT per player. I/we understand that invoicing will take place in January 2015 for immediate payment.

Name............................................................................

Signature.......................................................................

Date..............................................................................

Please return your completed form to Jeanne at the BPMA offices.

Contact: Jeanne Page 0121 601 6691 j.page@bpma.org.uk

Glasgow keeps up the pace With significant medal hauls for all the home nations and huge television audiences, it is acknowledged that Glasgow hosted a very successful games this summer.

Almost as famous as the stars who won medals, many of the venues were also basking in the spotlight of success and were the subject of a lot of media attention as well as much well deserved praise.

One such venue was the Sir Chris Hoy Velodrome and the Emirates Arena that hosted the cycling and badminton respectively. The wide range of energy efficient pump solutions supplied by Grundfos delivered all of the HVAC needs to these venues, as well as ensuring that the all water boosting requirements were met. Grundfos also supplied the fire suppression system that will continue to keep these venues safe and secure for the next generations of athletes who will pass through these sporting portals.

Post games, clever engineering and the integration of hydraulics means this venue can also be transformed into a 200 metre, 6 lane athletes track as well as being capable of playing host to badminton, netball and basketball fixtures. All of which means that this centre will continue to service the local, national and international demands, for many years to come, as will all the supporting Grundfos pumps.

For more information contact Grundfos Pumps Lts, Leighton Buzzard, Bedfordshire. Tel: 01525 850000 E-mail: grundfosuk@grundfos.com Web: www.grundfos.co.uk

GSPX Takes To The (Multi) Stage Why have three pumps when you can have one?

High head performance is now available in a sealless, easy to install, compact package following the launch of the new GSPX pump from Sundyne HMD Kontro.

A multi-stage derivative of HMD’s long established GSP range, the GSPX uses a between bearings design (BB5) for the second and third stage impellers and delivers space and servicing efficiencies plus lower costs than using multiple single stage pumps in series.

Conforming to API 685, the pump produces higher differential pressures than single stage models and is ideal for oil and gas installations, typically refineries, as well as for other chemical and petrochemical applications.

The GSPX is available with two or three in-line stages, two diffuser based hydraulic options and in an end suction configuration, ideal for fitting inducers in very low NPSHA installations. Further efficiencies can be gained via the optional ZeroLoss composite containment shell, which eliminates coupling losses and heating of the process liquid.

Fully draining and self-venting, the GSPX’s commonality with the GSP range delivers maximum convenience with interchangeable components and is available in a range of materials, including bespoke engineered options that allows a multistage pump solution to be tailored to specific requirements.

Sundyne HMD Kontro has more than twenty-five years’ experience in API applications and is continuously developing and extending its range, as improved magnet drive technology enables ever more efficient and powerful pumps to be built, widening the application scope of this versatile pump format.

For more information on the GSPX range please see the website at www.sundyne.com/hmdkontro. Alternatively, please call their head office on +44 (0) 1323 452000 or send an e-mail to info@hmdkontro.com

“Everything I need to know – at my fingertips.”

The Wilo Assistant app supports you in your daily tasks. Quick information on the go: fault signal assistant, replacement guide, product data and savings calculator to name but a few. Even when you‘re offline. Comprehensive information on various pumps all in one app? Wilo makes it easy!

Go to www.wilo.co.uk for further information or e-mail sales@wilo.co.uk

The Wilo Assistant app, the convincing one: ƒ The fault signal assistant provides information on fault signal remedies ƒ Interactive replacement guide for heating and domestic hot water pumps ƒ Online catalogue with quick and easy access to all product information ƒ Savings calculator for potential savings in terms of energy costs and CO2 emissions ƒ Pump configuration with recommendations for suitable Wilo pumps

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E-mail: sales@wilo.co.uk

28.08.2014 17:24:07

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NOV MONO

New Grundfos Product Center – replacement COMPLETES PROJECT made easy TO ENSURE QUALITY There are many benefits to the newly launched Grundfos LEVELS FOR Product Center that has been specifically designed and WELSH WATER developed to make choosing the best pump solution as easy as possible.

One such benefit is a simple to use replacement tool, that on entering basic details about an older pump model from Grundfos or from a wide range of competitor pump suppliers, will deliver a number of alternative.

Simply log onto www.grundfos.co.uk and click onto the Product Center portal, then select the REPLACEMENT option on the home page. You then simply enter the name of the old pump into the Quick Search field. Alternatively, can you enter the pump’s name and other data into the Classic Search field instead.

Where available, the Product Center will display three replacement pump options for you to choose from: • the option with the lowest purchase price • the option with the lowest energy consumption • the option with the lowest total lifecycle costs.

Additional requirements, such as fluid type, lifecycle costs and evaluation criteria provide additional filtering options and will ensure the best pump replacement choice is right there, at your fingertips - 24/7.

For more information contact Grundfos Pumps Lts, Leighton Buzzard, Bedfordshire. Tel: 01525 850000 E-mail: grundfosuk@grundfos.com Web: wwwgrundfos.co.uk

Three Good Reasons To Choose a John Crane A Series Coupling

Booster sets welcomed to Boss range

ZERO MAINTENANCE No relative moving parts hence no lubrication or routine maintenance required

SAFE TO OPERATE Elastomeric insert is retained if failure occurs and there is no metal to metal contact

INSERT REPLACEMENT Can be replaced without moving the associated machines

Rely on John Crane for lower cost of ownership, guaranteed reliability and improved productivity.

To learn more, please contact us at: John Crane UK Ltd, 31 Nash Road, Trafford Park, Manchester, M17 1SS. Tel: 0161-872-2484 Email: enquiries@johncrane.co.uk

®

www.johncrane.com E-mail: enquiries@johncrane.co.uk

6

NOV Mono has delivered a turnkey project to provide an extra level of protection for a major water and waste treatment plant in Pembrokeshire, Wales.

The project centers on an EZstripTM progressing cavity pump which is now being used on sewage transfer duties to ensure that the plant can guarantee the quality of the treated sewage under any flow conditions.

Powered by a 4kW motor and operating at a duty speed of 226 rpm, the EZstripTM pump draws sewagefrom the centre of the final settlement tank at Dwr Cymru’s Crymych treatment plant. It pumps the sewageback up to the head of the treatment system, from where it returns back through the filter bed to the final tank. This ensures that the plant’s biological filters do not dry out and remain effective, even in very low flow conditions. This in turn helps to maintain the quality of the final sewage within the required boundaries, at all times.

MonoTM was approached because of its ability to provide a full turnkey package which covered all the stages, from initial site survey, design and manufacture, through to full mechanical and electrical installation. Working closely with the project’s civils contractor, Mono installed the pump, suction pipe, rising main, control panel, overpressure and high temperature devices and completed the final testing and commissioning. Both the electrical and mechanical work were handled by Mono, who have since completed a very similar project at Dwr Cymru’s Lamphey treatment plant.

The progressing cavity pump at the centre of the Crymych project features Mono’s revolutionary EZstripTM design which allows it to be maintained-in-place.

This provides a quick and easy way to disassemble, de-rag and maintain the pump without the need to disconnect suction and discharge pipework. This reduces a typical day-long maintenance operation down to just 30 minutes. Available in cast iron or stainless steel, and with a choice of rotor and stator materials, the pump requires only basic tools to maintain, and can be retrofitted into existing installations where a Mono Compact C pump has been used previously.

For more information contact Nov Mono Ltd, Audenshaw, Manchester.

Tel: 0161 339 9000 or visit Web: www.mono-pumps.com

BSS Industrial, supplier of heating and pipeline solutions, has added a range of one and two pump BOSS™ Booster Sets to its industry-leading, ownbrand range of products.

The BOSS™ Booster Set range (with WRAS approved pumps and components) are suitable for a wide variety of system requirements, including potable water supplies. Supplied fully-assembled to ensure ease of installation, BOSS™ Booster Sets have a compact design, produce minimal noise and provide constant pressure using an inverter with duty assist and duty stand by modes.

Ed Kendall, Project Category Manager at BSS Industrial, said: “This is a valuable addition to the BOSS range of products. The complete BOSS™ Booster Set range is stocked at our Magna Park National Distribution Centre, meaning we can provide unrivalled availability whilst our AMS Pumps team can commission the set for customers. Combined, this means we can provide a product and service package to make customers lives as simple as possible.”

The range consists of six, one pump variable speed booster sets and six, two pump variable speed sets for duty ranges between 0.4l/s and 7l/s.

For more information on BSS Industrial and to find your nearest trade counter, please visit www.bssindustrial.co.uk or call 0116 262 3232.

Follow BSS on twitter @BSSIndustrial.

APV heat exchangers for the industrial sector to be distributed by AxFlow AxFlow will be offering the full range of available plates in sizes ranging from 3/4” up to 20” port diameters and plate areas from 0.018 to 3.8m2. The large and extensive plate and gasket materials are capable of withstanding corrosion and ensure processing efficiency.

Announcing the intro-duction of APV Heat Exchangers to its product portfolio, Managing Director Tony Peters said “This is a significant, yet logical move for the company as heat exchangers have long been made available for projects where requested. Now they

AxFlow has announced that it has taken on the exclusive distribution of APV heat exchangers for industrial markets in the UK. APV heat transfer solution for cooling, heating, condensing and evaporation of process fluids are used across a wide range of industries and AxFlow now becomes the prime source of distribution to the chemical, industrial, oil and gas and power sectors throughout the UK. AxFlow has been involved in supplying industrial heat exchangers for several years, but the decision to take on the distribution of the APV Gasketed Plate range, Brazed Heated range and the APV Hybrid fully-welded, gasket-free product marks a new departure for the company.

Heading up the new operation is Geoff Mahoney, who has joined AxFlow from APV. “APV has a very well established range of plate heat exchangers in the UK, and together with these AxFlow will be bringing new innovations to the market,” reports Geoff Mahoney. “These new innovations include plate type hanging, clamping and EasyClip systems. We are also offering the APV Hybrid fully-welded heat exchanger, a system that does not contain gaskets and is fully cleanable. The versatility of the Hybrid is reflected by its ability to be used in almost any type of application, particularly where high temperatures and pressures are encountered.”

are becoming a mainstream product range in their own right, supported by a dedicated product manager and sales support network. We shall be concentrating on those sectors of industry where AxFlow already has a strong presence for its process pump technologies and APV heat exchangers are already widely used,”.

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

There’s not much that’s greener and uses less energy than the WEG 22 energy efficient electric motor range.

Save energy, save money, reduce your global footprint.

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To find out more about how to meet new legislation, visit www.weg.net

7

Watson-Marlow pumps replace AOD models at paper bag mill Gloucestershire-based Stonehouse Paper & Bag Mills Ltd has installed three 500 series process pumps from WatsonMarlow Pumps Group in replacement for diaphragm pumps that were proving hard to clean, difficult to maintain and expensive to run. The success of the WatsonMarlow 521VI/R2C peristaltic pumps in recirculating inks on the company’s printing presses, has led Stonehouse to order a further two identical models. In fact, the company plans to replace all of its existing diaphragm pumps with Watson-Marlow models as and when their performance starts to dip.

Cost effective “When we were looking for new pumps, our research revealed that electrically operated pumps would be more economic and easier to use than the air-operated diaphragm pumps with which we had become familiar,” says Jonathan Daniels, the company’s Managing Director. “All compressed air systems have leaks, which basically means you

BPMA News Enquiry Form Sept 2014 For more information about any item in this issue enter the relevant enquiry letters in the boxes below, then add the requested personal and company details and fax back to 01428 751199.

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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 responsibility for the statements, claims or opinions expressed in this Newsletter

BPMA wishes to thank all members who supported this issue of BPMA News

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are using energy even when the pump isn’t running. There are no such worries with an electric pump.

Furthermore, changing the diaphragm and valves in an AOD pump is best done by an octopus, whereas access and tube loading on the WatsonMarlow pump couldn’t be easier.”

On the Watson-Marlow 521VI/ R2C, the pumphead set-up using two-position, sprung-loaded tube clamps and clutched rotor makes tube loading effortless.

Mr Daniels also says that the robust build of the pump helped differentiate it from others on the market. Here, heavy duty construction with impact-proof safeguarding and robust tube clamps ensure grip even in poor operating environments. Furthermore, the 520R2C pumphead features a polyphenlene sulphide (PPS) track and rotor, with stainless steel occlusion rollers to resist chemical attack and abrasive wear.

Ink circulation The pumps at Stonehouse are used to circulate inks on the printing presses, some of which use a ‘chamber blade’ system.

This, in combination with the pump, fills a pot with ink (the pot has an overflow), constantly agitating it to keep the colour consistent “If the pump is running too fast, or the pressure is wrong, there’s a real danger that thinner inks will leak everywhere,” explains Mr Daniels. “However, with the variable speed inverter on the WatsonMarlow 521VI/R2C, we can slow things down to negate this issue.”

In control Mr Daniels says that a further advantage of the WatsonMarlow pump is that it’s possible to ‘back-pump’ using reverse control to extract all of the ink from the tube and save it going all over the floor when changing over.

“In theory we could have a tube for each colour because changeover is so easy,” he says. “In reality, however, we’re running all the colours of the rainbow and every shade in between, so we have to cleandown between print runs. It’s just a case of washing through with water – using the inverter on the Watson-Marlow we can wash through at whatever speed we want.”

In contrast, Mr Daniels says that the diaphragm pumps are hard to keep impeccably clean. They feature their own vessel into which ink is poured – this has to be poured back out at the end of the run, creating downtime.

Further orders The three Watson-Marlow 521VI/R2C pumps have been working at Stonehouse since 2005. Such has been their performance that the company has now placed an order for two more.

“Not only have the pumps proved reliable, but Watson-Marlow are very knowledgeable and have been extremely helpful,” says Mr Daniels. “As and when other diaphragm pumps stop being reliable we will replace them with Watson-Marlow.”

Stonehouse Paper & Bag Mills Ltd is an independent, family run business that was established in 1922 and continues to run from its original location next to the River Frome in the Cotswolds.

The 18-employee company’s main activity is manufacturing from a range of paper substrates from the reel into plain or printed bags measuring from as small as 1” wide x 1” long up to a length of 55” and in volumes of 5,000 upwards. Stonehouse differentiates itself in the market by manufacturing paper bags to exact customer dimensions, rather than having to opt for the nearest size available.

For more information contact Watson-Marlow Pumps Group, Falmouth, Cornwall Tel: 01326 370370 Fax: 01326 376009 E-mail: info@wmpg.co.uk Web: www.wmpg.co.uk E-mail: goulds.axminster@itt.com

Plate Heat Exchangers

Exclusively from

AxFlow Limited are pleased to announce that they have been appointed as the exclusive UK Distributor of APV Industrial Plate Heat Exchangers.

This includes the full range of gasketted Plate Heat Exchangers, Brazed Heat Exchangers and the fully welded, fully cleanable, gasket free Hybrid range.

Please contact us for all new product and spares enquiries.

London 0208 579 2111 - Windsor 01344 886 633 Huddersfield 01484 543 649 - Durham 01325 327 322 - Aberdeen 01224 729 367 www.axflow.co.uk

email: info@axflow.co.uk

INDUSTRIAL FANS & BLOWERS SINGLE/DOUBLE STAGE SIDE CHANNEL BLOWERS/ EXHAUSTERS NOW AVAILABLE ON-LINE Single and double stage side-channel blowers/exhausters added recently to Air Control Industries range of industrial fans and blowers now feature in ACI’s new on-line shop.

As sole distributors for the Italian manufactured units, from italBLOWERS Srl, ACI can offer both 50 and 60Hz products on-line.

The standard 50Hz blowers deliver pressures up to 650hPa(g) and flow rates up to 1615 m3/hr, and the exhausters offer -450 hPa(g) with maximum flow rates

ranging to 1615m3/hr. The 60Hz blowers can deliver pressures up to 600 hPa(g) with flow rates reaching 1938 m3/h, whilst the exhausters achieve -425 hPa(g) and flow rates to 1938 m3/hr.

In addition to the side channel blowers, customers can use the on-line shop to purchase ACI’s standard industrial fans and blowers, impellers, ‘JetBlack’ blowerpowered personnel de-duster plus an extensive range of components/accessories.

For more information contact Air Control Industries Ltd, Axminster, Devon Tel. +44 (0) 1297 529242 E-mail: matthewforknall@ aircontrolindustries.com Web: www.aircontrolindustries.com/ On-line shop: http://www.aci-store.com/

DUST CONTROL

SPIROFLOW TAKES NEW ANGLE WITH EQUIPMENT TO TACKLE DUST Minimising dust contamination when filling and shifting millions of tonnes of powdered ingredients through a factory is challenging for manufacturers, but there is innovative new equipment now available from Spiroflow Ltd. Initially developed for the handling of food and pharmaceutical ingredients, the T2 Angled Bulk Bag (FIBC) Discharger provides an air-tight operation which empties product with the minimum of residue and has angled framework, not horizontal flat surfaces, reducing settlement and saving time on cleaning.

This latest equipment from Spiroflow is suited for a range of materials ranging from baby formula milk, sugar and flour to pharmaceutical powders and granules. Its unique construction stops fine dust sticking to any part of the discharger resulting in improved hygiene.

Unveiled for the first time by Spiroflow to great interest from visitors at this year’s Foodex and Interpack shows, it is probably the first kit of its kind that has been especially designed in the UK to help avoid issues caused by dust residue.

Dust in a factory environment can prove hazardous so manufacturers must have systems and equipment in place that adhere to the European Union’s ATEX Directive 1999/92/E, which has been implemented by the Dangerous Substances and Explosive Atmosphere Regulations 2002 (DSEAR) act in the UK. These regulations require that employers classify places where explosive atmospheres are likely to occur - such as in the form of combustible dust generated by processes such as flour milling and sugar grinding – and must implement protective measures and select appropriate equipment for use in those environments.

Spiroflow’s world-leading products for conveying and bulk handling are designed and built to USDA standard

and meet regulatory requirements for transporting and handling powders and other materials in potentially hazardous conditions. The company offers the food and pharmaceutical sectors innovative equipment that will help to eliminate material flow problems and dust contamination that can also lead to potentially dangerous blockages in factory piping or tubing applications.

In addition to bulk bag dischargers, Spiroflow manufacturers bin activators, Flexible Screw Conveyors, Aero Mechanical Conveyors, Tubular Cable and Chain Drag Conveyors, Vacuum Conveyors, Bulk Bag Fillers, Ingredients Handling and Weighing Systems. The company’s technical and engineering expertise has led to it developing an international reputation for an unrivalled range of products with state-of-the-art control systems.

For more information on Spiroflow’s products and services visit http://www.spiroflow.com/or call +44 (0)1200 422525

COMPRESSED AIR LINE EQUIPMENT

Hi-line range of filter housings extended

New all-in-one compressed air solution for high-quality surface technology

The extensive range of compressed airline equipment manufactured by Hi-line Industries Ltd has been extended to include filter element housings with 1/4” BSP connections. These products complement their existing wide range of aluminium filter housing with connection sizes now covering from 1/4” up to 4” BSP, offering a throughput flow range from 20 up to 1700 cfm. For larger flow rate patterns, then a range of flanged steel filter housings can also be supplied for flow rates up to 15,000 cfm.

The latest 1/4” BSP additions, designated as part numbers HF20 and HF22 feature a robust die cast construction in high grade aluminium. They also incorporate an overall Alu-Chrome treatment which provides corrosion protection against aggressive condensates. The outer surface is also subject to a tough baked-on epoxy coating in RAL 5015 Compressed Air Blue. For OEM requirements, this final coating can also be undertaken in any colour. The cost of Hi-line housings and filter element assemblies are claimed to be competitive, often being less than replacement filter elements only when sourced from other supplies.

Compressed air specialist BOGE has launched a new all-in-one compressed air solution for users operating in the surface technology sector. Paintline enables users to generate extremely pure, oil-free compressed air that is precisely tailored to meet their needs. It combines the most important components for generating and filtering ultra clean compressed air and covers a performance spectrum ranging from 5.5 to 22 kW. BOGE Paintline is based on an oil-injection cooled screw compressor with special filter technology. This results in extremely pure, oil-free compressed air being produced that meets the specific requirements of surface finishers and attains class 1 purity where solid impurities and residual oil content are concerned, and class 4 purity where water content is concerned. As it is an all-in-one solution, including compressed air generation, compressed air treatment and condensate disposal, maintenance costs are kept at an absolute minimum while efficiency is maximised.

The various components featured work together so effectively that the only system configuration that is needed is to state the free air delivery required. BOGE offers all components as an all-in-one turnkey solution. This saves both the time and expense of fitting pipework and cabling at the user’s site..

These innovative product designs also mean that the BOGE DUOTHERM heat recovery system and a frequency controller can be integrated in order to operate BOGE Paintline even more efficiently.

For more information contact Hi-line Industries Ltd, Burton on Trent, Staffs.

Tel: 01283 533377 Fax: 01283 533367 E-mail: enquiries@hilineindustries.com Web: www.hilineindustries.com

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For more information contact BOGE Compressors Ltd, Brighouse, West Yorkshire.

Tel: +44 (0) 1484 719921 Fax: +44 (0) 1484 712516 Web: www.boge.co.uk

PROCESS INDUSTRY INFORMER September 2014

Make it safety first with compressed air

By Ben Rickards, Product Technical Manager, Norgren Limited, Lichfield

Maintaining a safe working environment is vital for all manufacturers and is an area subject to increasingly stringent legislation such as the Machinery Directive, the Pressure Systems legislation and the Provision and Use of Work Equipment Regulations (PUWER).

All of these focus on the need to address issues such as overpressure, sudden movement of parts, and treatment of exhaust air.

Overpressure protection (Legislation Reference: 2006/42/EC which replaces BS EN 983 Machinery Directive) Components in pneumatic systems often have a pressure rating which is lower than that generated at the compressor. To ensure that systems run at safe and efficient levels, pressure regulators are normally used, which reduce high generation pressures to lower levels.

Components in pneumatic systems exposed to excess pressures often result in malfunction, or even extreme failure of the pressure-containing envelope should the upstream regulator fail or malfunction.

The relief valve is the most popular option to combat overpressure conditions. In selecting the right valve manufacturers should consider the criteria specific to individual systems. All components and equipment within a pneumatic system should have a Safe Working Pressure (SWP) and an overpressure limit of 10%. Regulators can be designed into a system to run it at pressures up to or below SWP. The additional 10% safety factor is the maximum overpressure allowed for the system with the relief valve in operation.

A relief valve is a control valve with its outlet connected to a pressure system to enable the system pressure to be held at a constant level. This level should be above the required system operating pressure, which may be above or below the stated SWP. Avoid setting the valve too close to the system operating pressure, as the valve’s operating characteristics can cause it to open and vent air during normal system operation - a costly waste of air.

To ensure the relief valve can maintain the correct pressure, the relief device should have a flow capacity in excess of the compressor’s free air delivery capacity in systems where no receiver exists. Alternatively, the device should have a capacity in excess of the flow through the smallest flow passageway of the equipment being protected when exposed to the highest possible pressure (usually the generated pressure at the compressor).

The smallest bore acts as a restriction to the flow downstream. This is important because, even if the distribution system is a mains system consisting of very large volume with large bore pipes and high capacity compressors, the device being protected might be fed by 1/8” nominal bore tubing and it is this that will limit the flow capacity. As long as the relief valve can match or exceed these flows,

then a constant, acceptable overpressure level can be achieved.

Types of relief valves To achieve different levels of performance of flow capacity and overpressure limitations, a number of types of relief valves are available. The one most commonly used is the pop type, followed by the diaphragm type, which is more accurate and repeatable. It is recommended that, for optimum performance, pilot operated valves are used. Of these, the integral pilot operated type is the most compact and cost effective.

An ‘in-line’ type is particularly popular with machine builders, where all the control equipment/protection devices are in one discreet position, usually in an assembly – aiding both installation and scheduled servicing.

This device has a relief port at 90° to the direction of flow and, under normal operating conditions, flow passes through the body of the device to the downstream system unaffected .Only when the set relief pressure is exceeded will the relief port operate. The ‘in-line’ device differs from the pop or diaphragm types which are connected into the system on a teepiece. Flow through these pop or diaphragm relief valves only occurs when venting air to atmosphere. In-line and diaphragm valve types can have the exhaust flow piped away to an area where the noise and flow will not cause disruption or harm to the environment or the operators.

fully open position at a condition known as the snap point, allowing full flow to proceed through the unrestricted passageways of the valve and rapidly fill the system to full line pressure.

For most devices this snap point will be within the range of 40 to 70% of full line pressure. It is important to locate these devices close to the piece of equipment they are used to protect.

The devices deal with pressure build-up as a result of the system volume. Fitting a larger valve to a complete distribution system can often result in the system taking many minutes to fully pressurise.

It is extremely common to couple the slow start with a dump or exhaust function valve within one body for compactness. The ‘dump’ valve is designed to quickly exhaust the pressure from the downstream system. It can have solenoid or air pilot operators and often an override or emergency dump function.

Furthermore, a limit switch can be introduced to the device’s valve spool. This can give a spool open or closed signal, thus providing a monitoring function which, in conjunction with other valves and relays – plus suitable system redundancy – can help comply with legislation to make machines safer.

Exhaust air In order to reduce noise and oil mist, and to minimise danger to personnel, exhaust air has to be treated correctly. Where a dump valve is employed, large volumes of air can be released at high speed creating high noise levels. Simple silencers can often solve the problem but more heavy duty silencers might be required in more demanding applications.

Soft start/dump valves (Legislation Reference: 2006/42/EC which replaces BS EN 983 Machinery Directive)

Silencers are normally rated on their noise reduction and associated back pressure, the most cost effective choice of silencer would be based on the flow rate and duty required of the device.

Protection within the area of moving parts of the system is paramount, both in terms of protecting the parts themselves against excessive wear, due to loading on start-up, or danger to personnel from sudden movement of parts.

Oil is the next major pollutant, particularly in incorrectly lubricated systems or those which require high levels of lubrication. In such instances, use of a coalescing exhaust silencer should be considered. Similar to those used for oil removal filters, this device results in small airborne particles in the form of mists merging into larger droplets and falling into a container for removal as liquid oil. Since these devices are on the exhaust side of the pneumatic system, they are exposed to sudden shock loading, meaning their oil removal capabilities are not as good as those using coalescing filters. A good exhaust silencer, however, should remove oil to around typically 2 ppm under average usage conditions.

PROCESS INDUSTRY INFORMER September 2014

This is where the use of ‘soft start’ (‘slow start’) valves is desirable. During normal operation, air is allowed to pass to a pneumatic system or device in a gradual manner.

The rate of pressure build-up into the system can be adjusted through a restricted passageway in the valve, which is generally an internal poppet spring-operated device. The poppet operates when the gradual pressure buildup produces a force in excess of that holding it closed. The poppet then moves to the

Other products In addition to the products and devices described above, there are a number of other products that can help increase safety in pneumatic systems, including preset pressure regulators, lockable shut-off valves, and tamperresistant kits.

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Five ways to improve Food Processing efficiency with thermal imaging

By Mike Murley – Product Manager, Thermal Imaging at Testo Limited

The food and drink processing industry is the fourth highest industrial energy user in the UK, according to The Carbon Trust. In 2010, it consumed nearly 37TWh, which is enough energy to power 125,000 homes for nearly 15 years and up to 3 times as much energy per square foot as the average commercial building. With this in mind, the importance of successfully managing the energy efficiency and running costs of any food processing facility becomes immediately obvious. vessels easy and efficient. The ability to perform these inspections is particularly important for safety purposes, checking fill capacity or temperature maintenance purposes.

This coupled with the continuous production pressures of the industry means that an emphasis must be put on keeping production machines running at optimum capacity. Maintenance downtime costs almost every production line at least 5% of its productive capacity, and many lose up to 20%. Maximising efficiency and minimising downtime then, is a clear challenge faced by any production team.

Thermal Imaging Cameras can help drastically reduce downtime and improve energy efficiency in the food processing sector; it is a mature technology and already often used in food processing facilities both for maintenance and monitoring food product temperature and levels.

Making the most of versatility…

Thermal imaging cameras employ a versatile technology and the latest hand-held devices are increasingly affordable and provide considerable benefits. The primary benefit is that all tests can be performed quickly and without any contact with the equipment, minimising any disruption to production.

Testo thermal electrical

The ideal strategy for using thermal imaging in a preventative maintenance schedule is the comprehensive understanding of the operating environment and the conditions components are under in everyday operation.

Component wear, and subsequent failure, is one of the biggest causes of unplanned downtime and any increase in operating temperature is an early indicator of potential problems. Using a hand-held thermal imaging camera as part of a preventative maintenance programme can quickly and easily identify failing components (without interrupting production) before an incident occurs.

Thermal Imaging Cameras can also be used to identify opportunities for energy saving measures, which not only reduce carbon emissions but also operating costs for businesses. Wasted energy, in the form of thermal leaks and inefficiencies, can be easily identified using a thermal imaging camera to visually inspect oven temperature spreads, door seals on refrigerated areas, pipework, ventilation and any other thermal processes on site.

So what are the main areas in which modern thermal imaging cameras can benefit a food processing facility?

1. Energy savings – use the camera to check the seals on cool stores and ovens to stop wasting energy and potentially spoiling product. Typically, a refrigerator with a split door seal uses up to 11% more energy than an efficiently operating refrigerator and a split door seal on an oven can lose 20% of its heat.

2. Mechanical wear – maintenance staff can check mechanical components for wear so that preventative maintenance can be scheduled to replace components that have degraded over time (such as bearings) before they cause catastrophic failure and loss of production.

3. Insulation surveys – check the integrity of pipe insulation to save energy. A 2” hot water pipe

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A thermal imaging camera can be used to capture and log the process and its components. Thermal survey reports can be created as a reference showing temperature profiles in normal operation and subsequent anomalies can be compared with the reference reports to aid decision making in a conditionbased assessment.

Testo thermal mechanical with 4” of insulation, which has suffered just 1/2” of damage, would require 7% more energy to maintain temperature. A thermal imaging camera lets engineers locate the heat signature of damaged pipe insulation in need of repair.

4. Electrical surveys – identify failing electrical circuits which left unchecked could cause unscheduled downtime or even electrical fires. Fuse clips will start to lose their spring tension at approximately 200°C and when this happens the fuses become loose, small gaps develop and more power is needed to jump across that gap, generating heat.

These tell-tale hot spots and heat signatures allow easy identification of necessary replacements and maintenance requirements using a thermal imaging camera.

5. Vessel checks – save time and gain access to difficult locations to check the fill level of vital liquids. Make monitoring the surface temperatures or contents of large containers, such as tanks or

Similarly in a predictive maintenance schedule which involves the monitoring of wear conditions and equipment characteristics against a predetermined tolerance to predict possible failures. The regular use of thermal imaging can highlight when certain tasks are needed, rather than wait for the allotted time on a fixed schedule. If a bearing begins to show signs of operating at a hotter than expected temperature, lubrication can be applied to remedy the situation.

Gaining the benefits…

The key to the successful use of thermal imaging is in determining basic parameters so that when abnormal conditions are encountered they can be easily detected, analysed and remedied. This means establishing operation criteria as part of the original acceptance inspection or following a planned maintenance overhaul when everything is operating within expected tolerances. By reviewing these images against the reference images, more effective decisions can be made about repairing or replacing components.

The adoption of increasingly accessible thermal imaging technology (as described) will lead to cost savings through reduced maintenance hours, increased plant operating efficiency and allow the more effective operation of maintenance engineers.

PROCESS INDUSTRY INFORMER September 2014

THERMAL IMAGING CAMERAS

FLIR INTRODUCES OPTICAL GAS IMAGING CAMERAS FOR CONTINUOUS MONITORING FLIR Systems, Inc. has announced the introduction of three new thermal cameras for optical gas detection: the FLIR G300a, G300pt and A6604. These cameras provide vital new tools for monitoring gas pipelines and installations from safe distances.

Optical gas imaging (OGI) cameras are widely used in industrial settings, such as oil refineries, natural gas processing plants, offshore platforms, chemical/ petrochemical facilities, and biogas and power generation plants. They improve efficiency by allowing inspectors to scan wide areas quickly, without interrupting normal operations.

These new infrared cameras can also play a major role in minimizing environmental damage by detecting the unintended emissions of dozens of volatile organic and inorganic compounds. Each model contains a cooled Indium Antimonide (InSb) detector, which enhances the sensitivity of each camera to detect even

the smallest gas emissions. The G300a and G300pt cameras have a resolution of 320 x 240 pixels, while the A6604 has a resolution of 640 x 512 pixels. Each camera can be controlled via Ethernet, or integrated into any TCP/IP network. They are also GEV/Genicamcompatible.

The G300a and A6604 cameras require an additional housing while the G300pt comes with its own housing mounted on a pan/tilt mechanism.

The housing can rotate the camera 360° continuously and tilt +/- 90°. It also enables users to monitor different areas with the same system. The G300pt is equipped with a long range daylight/low light camera, and the video output of the thermal and daylight/low light cameras are simultaneously available. Users can

WELDING SERVICES

Axium’s welders have their fingers on the pulse Thin wall, light weight, precision engineered components, such as those associated with aerospace and laboratory applications require specialist skills and Axium’s welder fabricators have developed their expertise over a number of years producing lightweight tube and sheet fabrications, as well as the manufacture and design of high end, high value pharmaceutical processing equipment.

With the aid of the company’s latest micro pulse welding equipment, Axium Process can now provide customers with a bespoke service for sheet metal and tube fabrications below 0.7mm wall thickness.

Its Procedures and Welders are Notified Body approved to ASME IX/BE EN287 and certified to CAA BCAR A8-10 which combined with the company’s stringent processes, procedures for testing, inspection and validation, and its ability to provide a complete traceability dossier, enables Axium to fully meet almost any level of requirement specified by companies operating in the pharmaceutical, aerospace and nuclear industries. Its traceability dossiers typically include weld maps and logs, full materials traceability and testing certification such as radiography, dye penetrant, ferroxyl and surface finishing.

A comprehensive range of stainless steel surface finishes are available and Axium specialises in the level of finish required by the pharmaceutical industry which is typically welds removed both internally and externally and polished to <0.4µm Ra. Axium Process has earned a reputation as one of the UK’s leading hygienic stainless steel engineering fabricators with a proven track record in its ability to understand what the customer really needs and prides itself on delivering engineering solutions and expertise that meets, if not exceeds, its customers’ expectations.

For further information please contact: Axium Process Ltd, Hendy, Swansea Tel: +44 (0) 1792 883 882 Fax: +44 (0) 1792 886 049 E-mail: info@axiumprocess.com Web: www.axiumprocess.com

PROCESS INDUSTRY INFORMER September 2014

monitor electrical substations or other equipment that is in the same field-of-view.

“As the World’s Sixth Sense, FLIR continues to save lives, increase energy efficiency, and protect the environment through the use of our innovative products and technology.” said Andy Teich, FLIR’s President and CEO. “FLIR’s industry leading Optical Gas Imaging cameras are game-changing tools in the effort to reduce fugitive gas emissions globally through improved detection and mediation programs.”

The three new FLIR cameras detect the following gases: Benzene, Ethanol, Ethylbenzene, Heptane, Hexane, Isoprene, Methanol, MEK, MIBK, Octane, Pentane, 1-Pentene, Toluene, Xylene, Butane, Ethane, Methane, Propane, Ethylene and Propylene.

To learn more, visit www.flir.com/gas or contact FLIR Systems on telephone +32-3665-5100 / email gasimaging@flir.com

CALIBRATION

An efficient calibration process is automated and paperless Every plant has a process on site for performing and managing calibrations, but there can be many different types of calibration processes and they vary in terms of quality, efficiency and productiveness.

The calibration process starts from the planning and scheduling of the calibration work and includes performing of calibrations as well as documentation of results. An efficient calibration process saves time, automates procedures, is cost-efficient and assures that the results are reliable. The best-in-class calibration processes are integrated, automated and paperless. This is the key message in Beamex’s global “Calibrations under Control” marketing campaign. Jan-Henrik Svensson, VP Marketing & Sales of Beamex Group explains, “We are not just offering a product or even a set of products and services – what we are actually offering is a new process of performing and managing calibrations in a way that provides efficiency and quality improvements as well as cost-savings”.

Beamex ICS, the integrated calibration solution, which constitutes the heart of this marketing campaign, is unique compared to any other calibration system due to its seamless communication between calibrators and calibration software, the possibility to integrate it into a maintenance management system (ERP/CMMS), the multifunctional calibrators that can perform automated calibrations fast and efficiently as well as the calibration software that allows smart analysis and management of all calibration data.

The microsite beamex.com/calibrations under control explains the benefits of an automated and paperless calibration process as well as includes an online test for testing the efficiency of a plant’s current calibration process.

BEAMEX is a leading, worldwide provider of calibration solutions that meet even the most demanding requirements of process instrumentation. For more information, visit www.beamex.com or call 01455 821920.

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PROCESS CONTROL & AUTOMATION TECHNOLOGY CAN HELP KEEP OPERATIONS HEALTHY Mike Charles, Operational Intelligence Product Manager at industrial IT provider, SolutionsPT, looks at how process control and automation technology is key to improving efficiency, productivity, safety, and availability in manufacturing environments.

Today, more than ever, manufacturing productivity depends upon seamless data communication and intelligent automation systems. The penalties for high operating costs, delivering products late to market, or delivering products with quality issues are severe and can cripple your business. Best-in-Class manufacturers are addressing these issues by implementing process control and automation tools to manage and monitor manufacturing operations and, among other things, improve product quality and inventory flow.

Whilst the UK’s manufacturing industry is said to be leading the country’s recovery from the recent financial downturn, keeping a close eye on operational costs is still a major focus for many businesses, with the emphasis still centred on lean operations. This can often cause strains on businesses as they push to increase throughput without significantly increasing operational expenditure. It can often be the case that businesses have higher demand than their capacity can meet, resulting in lost sales or delayed orders.

Similarly energy efficiency and waste reduction are top priorities from both a cost and ethical perspective, with businesses now being fined for non-compliance. With both raw materials and energy prices continuing to rise, ensuring that unnecessary usage is eliminated is imperitive.

A further worry for business leaders is being confident they are investing correctly in skills and training to plug the skills shortage left by an ever ageing skilled workforce and a lack of replacements from the younger generation. With this predicted to continue for years to come, the shortfall in key roles being filled will soon result in businesses not having the manpower to meet demand, resulting in unnecessary but unavoidable down time.

In implementing process control and automation, businesses can develop a stronger and more insightful understanding of the health of their operations. This can be identified easily through a real-time view of whether manufacturing Key Performance Indicators are being met. Any changes that need to be made can then be immediately implemented, allowing users to speed up the manufacturing process or increase throughput capacity with ease.

Automation and process control can also allow manufacturing to interact and coordinate better with other elements of the business.

Whilst better understanding of throughput capacity can give insight in terms of fulfilment capability, the ability to align the manufacturing process directly to sales and orders means customer’s expectations on delivery can be managed.

Saving data is fine – to analyse it is what matters…

Across the UK, process plants, factories and power plants are using process control and automation technology to discover significant opportunities to cut per-unit-production energy costs, reduce emissions and reduce product rejects. One such business is Syngenta, one of the world’s leading producers of insecticides and herbicides. The processes at Syngenta’s Huddersfield site were capable of producing huge amounts of valuable data, but it was not being stored for analysis, leaving the Syngenta team to react to issues rather than proactively solve them.

Like all other companies with multiple manufacturing locations, Syngenta kept a close eye on production performance across the board and wanted the Huddersfield site to remain one of the leading manufacturing sites. The company turned to process control and automation technology, in the shape of a high-performance process

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historian tool, capable of storing huge volumes of data and securely delivering information to desktop or mobile devices.

Ewan McAslan, Site Production Manager at Syngenta, said: “The historian tool, combined with the dashboards we developed ourselves, presents everyone within the business with a single version of the reality. Prior to its use, we were spending 80% of the time collecting data and only 20% of the time was spent driving improvement. Now, with real-time data at our fingertips, we have been able to rapidly speed up how we improve.”

As with all technology, process control and automation is constantly evolving, responding to new demands of business and implementing the latest developments. The emergence of a clear need for better analytical capabilities and ways of working with data in order to make smart decisions has become paramount in modern business.

The ability to have a ‘holistic view’ of operations from a single pane of glass, rather than multi-page reports or employee feedback, is now highly sort after in the fast-paced and competitive manufacturing world where the slightest of permutations can result in the largest of variations in output. This is being driven by advancements in mainstream IT such as the move to HTML5 and ‘slice-and-dice’ data mining tools. However, whilst these tools are commonly seen at boardroom level, they have taken a little longer to permeate down to operations where they can be analysed to provide real insight, which is sometimes referred to as Operational Intelligence.

It is predicted that Operational Intelligence will continue to develop at pace as senior decision makers become aware of what is now possible with the latest tools and how valuable they are to their businesses. It will become common practice that CEOs and the like will expect to be able to get high level insight into operational Key Performance Indicators in the same way they do for systems such as Customer Relations Management and Enterprise Resource Planning.

The next step for the industry will see data from various niche manufacturing systems such as Manufacturing Execution Systems, Supervisory Control and Data Acquisitions, Maintenance Management Systems and Laboratory Information Management Systems aggregated together. This can then be manipulated and analysed using accessible browser based, slice-and-dice enabled technologies such as Wonderware Intelligence. This will become common place and allow those running businesses to directly see the impact of issues on the manufacturing shop floor and how they track back to the bottom line.

The word is out…

Speaking with senior decision makers, it is clear to see that this is exactly the kind of tools they need to allow them to drill down and see data which can assist them in making real and beneficial changes in their companies. As more and more key figures hear about the technology and the benefits it offers, it wouldn’t be surprising to see adoption rapidly Manufacturers need to realise the value that is hidden in their operational data and find out more about the tools available to help them extract and analyse it. The answers to many questions such as: ‘how can I increase throughput?’, ‘how do I reduce downtime?’ and ‘why is my energy usage higher on line A rather than line B?’ can be found using automation tools and software, and finding the answers to these questions can be the difference between being successful or not.

PROCESS INDUSTRY INFORMER September 2014

NETWORK & COMMUNICATIONS

Connectors meet intrinsic safety requirements for use in potentially explosive areas The new Han® Ex range of connectors from HARTING meet all the requirements for the implementation of high-quality connectivity solutions in application areas with explosion protection requirements. This includes applications in mining and the chemical and process automation industries.

The connectors are designed to meet the intrinsic safety requirements for ignition protection class in explosion hazard areas classed as 1 and 2. In intrinsically safe circuits, energy is limited in such a manner that even a potential spark cannot ignite an explosive environment.

The Han® Ex product portfolio offers complete connector systems consisting of housings and inserts, including housings made from an alloy that can be used in pulverised methane-coal dust atmospheres. They also offer ignition protection class 65 in the mated condition.

The housing’s blue colour indicates that an intrinsically safe circuit is present. The contact inserts provide a high number of pins and meet the standards of the ignition protection class even in the tightest of spaces.

The termination technology used in the Han® Ex is based on HARTING’s patented HanQuick Lock® technology. This allows time-saving and easy assembly without the need for special tools, and provides a reliable and vibration-proof contact for maximum safety in the most demanding applications. HARTING’s proven crimp technology can also be selected as the termination method, allowing the connection of wires with crosssections from 0.14 to 2.5 mm2.

To view the data sheet: www.harting.com/en/ethernet-switches/ For more information contact HARTING Ltd, Northampton NN4 7PW Tel: +44 (0) 1604 827500 Fax: +44 (0) 1604 706777 E-mail: gb@harting.com Web: www.harting.co.uk

PROCESS CONTROL

NEW GENERATION MOTOR CONTROL PLATFORM OFFERS GREATER SPEED AND TORQUE CONTROL The motor control platform, direct torque control (DTC) - used extensively in ABB’s variable-speed drives since 1996 – has been greatly improved to bring even higher accuracy in motor speed and torque control, as well as the ability to control more motor types.

This fourth generation DTC provides enhanced performance in open and closed loop and a higher switching frequency. Speed and torque control accuracy have been improved, for both dynamic and static values.

Support for high speed motors up to 500 Hz and absolute encoder and resolver support are provided, while other improvements include more choice of identification (ID) set-up runs. These include highly accurate standstill ID runs, allowing the drive to identify the motor from its performance characteristics without the need to uncouple the motor from the load.

DTC lets users of the latest ABB industrial drives, ACS880, control any motor type without a change to the firmware.

For more information contact: ABB Ltd, Discrete Automation & Motion Tel: 01925 741 111 Fax: 01925 741 212 E-mail: energy@gb.abb.com Web: www.abb.co.uk/energy

PROCESS INDUSTRY INFORMER September 2014

Q1245 - PII Sept Thermal.indd 1

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8/6/2014 2:26:37 PM

PROCESS MEASUREMENT & INSTRUMENTATION

Non-intrusive flow measurement in harsh, corrosive environments The FLUXUS F705 and G705 ultrasonic liquid and gas clamp-on flow meters allow for an inherently precise bi-directional, highly dynamic flow measurement of volume and mass flow rates of virtually any gaseous and liquid media – even at wet gas applications (up to a Liquid Volume Fraction of 5%) or liquid media carrying high contents of solids.

With the transmitter being ATEX, IECEx Zone 2 and FM Class I, Div. 2 certified – transducers for ATEX, IECEX Zone 1 FLUXUS F/G705 ultrasonic clamp-on and FM Class I, Div. 1 are available - it is gas and liquid flow me also the ideal flow meter for hazardous areas. Moreover, with its stainless steel enclosure (316L / 1.4404) it is highly corrosion resistant and especially suited for applications Offshore.

For more information contact FLEXIM Instruments Asia Pte Ltd, TT International Tradepark, Singapore.

Tel: +65 67 94 53 25 Fax: +65 68 62 28 36 E-mail: salessg@flexim.com Web: www.flexim.com

dBi Intelligent Transducer Range has choice of HART or Profibus PA on board Non-contacting ultrasonic measurement specialists Pulsar Process Measurement of Malvern have launched a new range of self-contained two-wire powered transducers, which feature a choice of either HART Version 7 or Profibus PA version 3.0.2 Fieldbus protocols. The dBi Intelligent Transducer range are both available in three sizes, covering a measurement range from 125mm through to 15m.

Pulsar’s dBi Series Transducers feature Pulsar’s world-leading DATEM echo processing system for robust and reliable measurement. Integration with plant systems and other equipment is straightforward, dBi Transducers supporting a full range of industry standards. It is easy to configure and calibrate the devices using standard PLC/HMI industry protocols, Pulsar’s own software or on site multi-drop set up, with options to program the transducers using either a standard interface or using Pulsar’s programming parameters. A standard HART or Profibus modem allows the units to be set up from a PC if required, or proprietary hand held calibrators will also perform the function.

The dBi range is low-power, with rapid response times that make them perfect for wide scale monitoring or overflow, such as CSO, applications. Powerful crystal arrays make the dBi series suitable for use in either solids or liquids applications, and can be specified with a full range of options; PTFE coating for corrosive chemical applications; flange options, front threads or brackets for ease of mounting; submergence shields to keep the transducer face dry in applications where it may be covered from time to time and more. For solids applications the dBi transducer can be fitted with a foam face for more power and mounted on an aiming kit.

The transducers feature, in each case, the latest version of the digital protocol. In particular, Pulsar are early adopters of the Profibus PA 3.0.2 system.

For more information please contact Pulsar Process Measurement Ltd, Malvern, Worcestershire. Tel: +44 (0) 1684 891371 Fax: +44 (0) 1684 575985 E-mail: keithf@pulsar-pm.com Web: www.pulsar-pm.com

CO2 TRANSMITTERS WITH INSENSITIVE INFRARED MEASUREMENT PRINCIPLE Clean measurements even in polluted environments The new CO2 transmitter series EE850 and EE820 from E+E Elektronik allow highly accurate and reliable measurements of CO2 concentrations up to 10,000 ppm. The applied infrared measurement principle (dual wavelength NDIR* procedure) is particularly insensitive to pollution. The transmitter’s autocalibration function automatically compensates for aging effects.

The multi-point CO2 and temperature factory adjustment procedure leads to excellent CO2 measurement accuracy over the entire working temperature range. The measured values are available as either analog current or voltage outputs. An optional kit facilitates easy configuration and adjustment of the transmitters.

The EE850 CO2 and temperature transmitter for duct mounting is ideal for applications in building management or process control. A mounting flange enables easy installation of the sensing probe directly into the ventilation duct. The CO2sensing cell is well protected inside the transmitter. For CO2 measurement, a small amount of air flows through the divided probe, into the transmitter housing, and back into the duct. The temperature sensor is located inside the probe. The EE850 offers an additional option for a passive temperature sensor output with a 2-wire connection.

The EE820 CO2 transmitter is designed for particularly demanding applications. *) non-dispersive infrared technology Downloads for this Information DE CO2-Messumformer mit unempfindlichem Infrarot-Messprinzip EN CO2 transmitters with insensitive infrared measurement principle For more information contact E+E Elektronik Ges.mbH, Engerwitzdorf, Austria Tel: +43 (0) 7235 605-217 Fax: +43 (0) 7235 605-8 E-mail: johannes.fraundorfer@epluse.at Web: www.epluse.com

DISCOVER HART 7 IN A 6 MM DEVICE With selected devices featuring HART 7 technology, the entire 3000 series of compact best-in-class temperature transmitters and converters provides high accuracy, fast response time and low temperature drift – without compromise.

Temperature transmitters and converters have been PR electronics’ core business for four decades, and now this expertise extends to the 6 mm wide 3000 series. Never seen before in a 6 mm device, the HART 7 technology featured in the 3113 and 3337 gives future temperature applications more design and system flexibility in programming, monitoring and maintenance for both analog and digital signal outputs.

An entire range with top performance In addition to temperature transmitters and converters, the 3000 series includes a complete range of high performance signal devices for all standard applications. Both temperature and signal devices can be used in a wide range of industries, such as energy, water/wastewater and chemical/petrochemical with a much lower total cost of ownership.

Unlike the competing devices, the 3000 series excels on all parameters – accuracy, response time and temperature drift – without compromise. It simply delivers precise measurement of rapidly changing signals, in any environment with high energy efficiency.

Compact and reliable At just 6 mm, the 3000 series includes many advanced features in each compact device. Up to 50 units or 100 channels can be mounted vertically or horizontally on a 30 cm standard DIN rail or power rail with no air gap separation. All of the devices are individually validated to exceed the most demanding failure rate assessments and are backed by comprehensive technical documentation and a 5-year warranty.

For further information, please contact: Thony Bruun Jensen, PR Electronics Tel: +45 8637 2677 E-mail: tje@prelectronics.com

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PROCESS INDUSTRY INFORMER September 2014

PROCESS MEASUREMENT & INSTRUMENTATION

Realising the flexibility of electronic differential pressure Electronic DP has lots of advantages for the user, particularly over conventional ‘Remote capillary’ based DP systems; faster, easier installation and excellent accuracy, no oil-filled capillaries, better performance with changing temperature, faster measuring response, lower costs and easier maintenance. It is especially useful in lower range differential applications such as pressurised vessel levels and across low pressure filters. To date all electronic differential pressure (e-DP) systems have been ‘hybrid’ configurations requiring specialist secondary electronics, field or cabinet signal conditioners (3-piece systems) and/ or with limited housings and sensor options. There have also been limitations on cable types, separation distance and the issue of ‘thermal shock’ – where rapid temperature change affects one cell - can still result in large errors. The latest generation of e-DP systems, which are from a full-range pressure supplier, removes these constrictions.

The VEGABAR 80 series of pressure transmitters offers a solution for all pressure measurements, gauge absolute or differential: simple, reliable and flexible.

Another ace up their sleeve: they can convert to e-DP with no special field electronics, only a slave electronics module in one of the sensors, simply connect them together and you have your e-DP system. The standard electronics in one recognises the connection of a ‘slave’ sensor in the other. This capability minimises

cost and complexity, it includes virtually any combination of sensors so you get optimum performance and sensor longevity. Any housing combination can be used; for example, a submersible IP68 housing for the bottom of a pressurised tank in a bund area liable to flooding, with a standard IP66/7 sensor housing on the top. Any diaphragm combination can be selected – a flush ceramic one in an abrasive slurry before a filter system and a recessed metal diaphragm after it. There are even suspended submersible pressure sensors for ‘open water’ level differential, to monitor across intake screens or weirs for example. If the 25m recommended interconnecting distance needs to be longer, there is the opportunity to use remote housings, which can extend to provide another 100m or so - more than enough for most applications.

Thermal shock is overcome with a world first patented fast thermal reaction system. A temperature sensor is mounted directly on the diaphragm, it immediately measures the smallest change in temperature and compensates for it just as fast - virtually eliminating thermal shock errors. Especially useful on flushmounted sensors and great for e-DP systems, this is an ideal innovation for the food, beverage and pharmaceutical industries, where high temperature cleaning can be followed by a chilled product. Fast

thermal reaction keeps the outputs stable, accurate and most importantly, the production moving smoothly.

VEGABAR 80 uses the plics concept, now over 10 years old, which has resulted in a proven, tried and trusted instrument system. It is designed to offer users easy selection, flexible configurations and simple operating system, to get you up and running fast and it has low life-time costs. With a 5-day build time on the majority of sensors, it also means you get the delivery speed you need. VEGABAR 80 has SIL2/3 and ATEX are standard too, so what’s stopping you change the way you measure pressure?

For more information contact VEGA Controls Ltd, Burgess Hill, West Sussex. Tel: 01444 87005 E-mail: info.uk@vega.com or visit www.vega.co.uk

Coriolis Flow Control

Precise Direct Mass Flow Control of Pump Systems gives proven COST Savings u With On Board PID Electronics ensures control of virtually any pump technology u Optional: ATEX Rated for Zones 1 & 2 u Independent of Fluid Properties

u On Board CORI-FILLTM firmware eliminates need for a Batch Controller u Alarm Functionality to Protect both the Process & Pump u Self Learning with Fast Response and Stable Control

Innovation - Experience - Responsibility

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

PROCESS INDUSTRY INFORMER September 2014

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Achieving excellence in energy and utilities management

By Maura Argiolas, Consultant, AspenTech

Companies face constant pressures to make effective capital planning decisions. Running a refinery, chemical plant or power station is a complex business. Therefore, being able to see the bigger economic picture is vital in effectively managing operational maintenance, regulatory requirements, energy efficiency and sustainability goals.

Minimising costs and optimising the operation is a priority in the battle to remain profitable and competitive. However, when global energy markets fluctuate, businesses need to improve the way they source, trade and use energy while considering everchanging environmental, organisational and technical constraints. So, how can companies achieve overall excellence with their energy and utility management on a daily and weekly basis?

Energy is the single largest operating expense after raw materials for the process industry. Cutting-edge utilities software allows manufacturers to manage and optimise the way they use and source energy across an entire production site. It enables companies to ensure that all their processes receive reliable supplies, while minimising running costs by reducing overall consumption and identify the most economical sources of supply. Crucially, utility planning software defines and improves the energy business processes that are important to the overall economic performance of the site.

Reducing Production Costs Minimising energy costs and maximising operational reliability of the utilities system can be achieved simultaneously through the implementation of an integrated energy management and optimisation system, which links business and operational objectives. In turn, this enables companies to make more profitable decisions about how to use and source energy across an entire production site.

Utilities are integral to the functionality of a plant and provide the heating and cooling, electricity and fuel used by vital machinery to ensure that product quality standards are consistently met and produced to optimum operational effectiveness. It is common for fuel, power, steam production and consumption networks to be modelled in high level detail to build a customised model, which helps users understand how to reduce site energy costs within a short timeframe.

Many plant decision-makers have adopted utility planning software in an effort to improve their weekly and daily planning. This includes forecasting plans and demands based on current results and the provision of future assets, recommending how to operate the plant, eliminating or reducing fuel and steam venting and performing ‘whatif’ analysis of future investments while operating and optimising current assets. From a defined model they can expect fully optimised assets based on economic evaluations to obtain specific recommendations for fuel exchange, proposals to operate steam turbines or information on boiler loads.

Companies have options to purchase or import utilities from outside sources, while some plants may choose to produce their own solutions. The key to choosing an optimum schedule is establishing the blend between purchasing and producing utilities in order to minimise cost. Cutting-edge utilities planning software can model the required utilities system for a process and help specify the quantity and timeframe of when utilities are needed. From a designated utility purchasing contract, the software will optimise around the utility’s needs to establish the cheapest method of acquirement (i.e. through in-plant production or outside purchase).

A complete operational overview From a business perspective utilities software considers all aspects of the operation of a utilities system (e.g. reliable supply of energy or energy sourced at the lowest overall cost that meets reliability and environmental goals). Companies can achieve both technical and commercial excellence in energy and utilities management by embracing the adoption of software applications for different types of users - ranging from plant

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operators to utilities contract managers up to senior company management.

Process manufacturers are increasingly migrating to the latest breed of integrated utilities software solutions that allow them to optimise and manage energy usage and sourcing across an entire production site. Not only can such solutions enable companies to ensure all their processes receive reliable supplies, they can also at the same time minimise running costs by reducing overall consumption and identifying the most economical sources of supply.

Another crucial benefit of utilities software is that it can integrate with existing plant and business systems, allowing information to be automatically extracted (i.e. planning and scheduling systems, Best practice approaches in this area are based on defining and improving the energy business processes that are important to the economic performance of the site.

By considering all site utilities systems within a single environment, the best of the latest breed of utilities solutions can capture all relevant data and provide clear and consistent recommendations on how to achieve the lowest cost operation. Systems can be used both offline, such as for ‘what-if’ analysis, and also online to provide real-time recommendations to operations personnel.

Utilities planning software can be deployed to improve weekly and daily planning, forecasting plans and demands based on current and future asset results. In addition, it eliminates or reduces fuel and steam venting and investigates likely imbalances. Utilities planning software calculates a utilities forecast based on actual and future production demand while considering penalties, peak demand charges and load factor contract clauses. The optimum utilities production plan accounts for operational, economic and environmental constraints. The benefits of using these tools are significant. Energy optimisation software solutions improve energy management to enable users to reduce site energy costs by up to 5% with a project payback in less than one year.

Energy optimisation tools have three main areas of application: • Online operational advice system for operators to optimise the utilities plant operation • Tactical and strategic advice system to improve utilities plant planning, including utilities nomination, CO2 trading, power trading, maintenance scheduling, as well as contract negotiations and investment analysis • ‘Plan versus Actual’ management system for utilities consumers to allow the tracking and evaluation of actual performance compared to target performance

Achieving operational excellence The process industry is experiencing dramatic market changes as it endeavours to meet energy requirements while maintaining competitive rates. Those executive decisionmakers who embrace more robust project planning methodologies and implement thorough plans to gain greater visibility of the overall operation will deliver a better financial return to the business, while meeting the needs of their customers.

By establishing a two-way link between production and energy scheduling, companies can ensure continuous energy supply for production plants and avoid unnecessary costs. With leading utilities planning software, decision-makers will achieve more informed evaluation of assets, the lowest cost operation, better choice of fuels, accurate demand forecasts and profitable trading - the ultimate achievement in energy management and utility optimisation.

PROCESS INDUSTRY INFORMER September 2014

GAS DETECTION

POWER CONVERSION

CROWCON ANNOUNCES NEW PORTABLE GAS BUMP TESTER FOR REMOTE TESTING OF PERSONAL GAS DETECTORS

Transphorm Spurs Adoption of GaN for Power Conversion

Key Facts: • Easy-to-use, portable spray canister for remote bump testing • Eliminates need for gas regulator and docking station • Spray canister subject to lighter regulations Crowcon, the gas detection specialist, has today announced the availability of a new portable gas solution for bump testing. The new method eliminates the need to carry around cumbersome gas bottles and docking stations or return to base to test handheld gas detectors.

Resulting from an innovative reapplication of existing technology, the Crowcon Bump Test Gas Spray performs bump tests on handheld gas detectors, either on site or on-the-road, using a 12 litre spray canister. The gas is simply applied through a straw on the canister nozzle and a small amount of gas is sprayed into a calibration cap placed over the sensor.

“Having a fully portable 12 litre spray can and straw is just the ticket to test and calibrate on site. It could not be easier,” stated Richard Dunn, Portable Product Manager, Crowcon. “With no regulator, no heavy gas bottle and no docking station, it’s a no brainer for bump testing.”

“We have listened to our customer concerns and found a novel way to satisfy their requirements,” Richard Dunn added. “The gas cans can be bought in a range of gases or combination of gases to suit. The kit comes with a canister of chosen gas, nozzle, straw and an MSDS sheet.”

Crowcon is offering this solution as the most cost-effective and easiest way to bump test when mobile. Less equipment means less weight to carry and more room for storing productive equipment. Spray canisters are also covered by less demanding regulation (directives UN1950), helping keep costs down further.

For more information contact: Crowcon Detection Instruments Ltd, Abingdon, Oxon.

Tel: +44 1235 557700 E-mail: fiona.macrae@crowcon.com Web: www.crowcon.com

CODING UNITS RITTAL COOLING UNITS FOR QUIET ENVIRONMENTS Rittal’s ‘Blue e’ cooling units are usually found controlling the temperature within enclosures in workshops or on shop floors in the industrial sector where noise level is largely irrelevant as they cannot be heard above other equipment in these noisy environments.

In situations such as laboratories, offices or other more peaceful areas where cooling is required, Rittal’s TopTherm ‘Blue e’ roofmounted cooling unit range successfully provide cooling where excessive noise would be an irritant to personnel working close to an enclosure.

With nominal outputs of 1.1 kW, Rittal roof-mounted cooling units for office applications offer viable solutions when it may have been assumed they would simply be too noisy.

Rittal’s ‘Blue e’ cooling units benefit from the intelligent and targeted use of energy, electronically commutated (EC) fan technology and are proven to achieve energy savings of up to 45%. Nano-coated condenser coils negate the need for filters and an integrated electric condensate evaporator maintains an efficient supply of cooling for longer periods of time extending maintenance intervals.

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

PROCESS INDUSTRY INFORMER September 2014

Transphorm Inc. designs and delivers cost-competitive and easy-to-embed Gallium Nitride (GaN) power devices and modules that reduce costly energy loss by more than 50%.

By establishing the industry’s first and only qualified 600V GaN device platform with its TPH Series portfolio, Transphorm is enabling the broad adoption of dramatically more compact and efficient GaN-based power electronics.

Transphorm’s EZ-GaNTM technology simplifies the design and manufacturing of PV inverters, power supplies and adapters, motor drives, and converters/inverters for electric vehicles.

With more than 450 independent patents/patent applications and more than 1,100 world-wide patents/patent applications, Transphorm offers the most extensive IP portfolio in the GaN power arena.

Transphorm was recently awarded landmark patents based on its TRANSPHORM DIODE-FREETM GaN solution. By helping to eliminate diode components, this approach results in more compact, higher efficiency systems and is widely applicable in a variety of bridge circuits that are typically used in over 60% of high-voltage power conversion topologies.

For more information contact please Primit Parikh, Transphorm Inc, Goleta, California, USA. Tel: 001 805 456 E-mail: pparikh@transphormusa.com Web: www.transphormusa.com

FILTRATION & SEPARATION

NEW SIEVING MACHINE AIR SIZER 200 For most efficient particle sizing in the micron range The new Air Sizer 200 is ideal for sieving very fine dry particles, which require efficient dispersion and desagglomeration via air jet technology (e.g. electrostatic material). It is also the perfect instrument to quickly provide a sieve cut of powdered materials.

Most sieving operations on the Air Sizer take only a matter of minutes. Useful functions including the ability to regulate the level of vacuum, and constant or timed operation help to achieve optimum performance. The Air Sizer 200 is easy to use, extremely efficient and provides accurate and reproducible results.

The new sieving machine Air Sizer 200 is available as of September 2014.

NEW FEATURES:

• Advanced air jet technology for fine particles, usable for dry material 20 µm upwards • Digital controls for easy and reliable operation • Suitable for 203 mm (8’’) and 200 mm premium air-jet sieves • Adjustable nozzle speed, 5 - 55 rpm • Pre filter unit & vacuum cleaner available as accessories • Ideal for fine electrostatic powders • Maintenance-free • Voltage-independent For more Information contact Endecotts Ltd, London Tel: +44 (0) 208 542 8121 Fax: +44 (0) 208 543 6629 E-mail: sales@endecotts.com Web: www.endecotts.com/products/sieve-shakers/air-sizer-200/product-specifications/

41

FLUIDS & LIQUIDS HANDLING INC. PUMPS & VALVES

MAG-DRIVE PUMPS ENABLE UPGRADE TO SEALLESS, LEAK-FREE PUMPING The benefits of using sealless, magnetic-

and the Viking Universal Mag Drive Series

and reliable Universal Mag Drive

drive pumps as opposed to conventionally

of Internal Gear Pumps, is a good example

series comprises nine sizes of pump

sealed pumps for transferring hazardous

of this type of pump. Available from

providing flows up to 114m?/hr at

and reactive fluids are well documented,

MICHAEL SMITH ENGINEERS the proven

pressures up to 14 Bar. Reducing maintenance costs and minimising environmental impact are important, for many fluid transfer applications and Viking Universal Mag Drive pumps help achieve these.

The absence of a pump shaft seal means significant potential savings in maintenance and downtime and with only two moving parts the simple design ensures durability and reliability even in tough applications.

The

pumps

are

interchangeable

dimensionally with

Vikingâ&#x20AC;&#x2122;s

Universal Seal and easy to retrofit with similar sized sealed pumps. And the design also enables short-term dry-run capability and bi-directional operation, without the need for modification or disassembly allowing filling or emptying using one pump helping to minimise system costs.

Other features include, dual thrust control washers and an externally adjustable relief valve which can be adjusted while in service when process conditions change.

An adjustable rotor end clearance allows the pump to be adjusted for different viscosities and temperatures if

process

conditions

change.

Available in cast iron, steel and stainless steel these tough, durable pumps provide the highest level of liquid containment available and are suitable for handling a wide range of liquids. For example, transferring hard to seal liquids such as isocyanates, sodium hydroxide, adhesives and epoxy resins, reactive liquids such as volatile organic chemicals, LPG and ammonia. Typical applications include 24/7 operation in refineries, chemical and polymer plants, paper mills or wherever sealless, leak-free and low maintenance pumping is required.

Further details are available from: Mr Sam Smith, Michael Smith Engineers Ltd, Woking, Surrey.

Tel: FREEPHONE: 0800 316 7891 E-mail: Info@michael-smith-engineers.co.uk Web: http://www.michael-smithengineers.co.uk/products/viking/ internal-gear-pumps

42

PROCESS INDUSTRY INFORMER September 2014

VIRTUALISATION: THE FUTURE IS HERE Steve Leech, Product Manager – Process Automation at Siemens Industry takes a look at an emerging trend within the process sector virtualisation - and assesses the arguments for and against its adoption by industrial users seeking operational and cost efficiencies.

The subject of virtualisation has come increasingly to the fore in recent years as technology advancement has helped drive both its capability and growth.

You cannot appreciate the current status and potential benefits of a virtualised solution in the industrial world without first understanding how hardware and software technology has developed over recent years, in particular, physical hardware, operating systems and applications.

Historically, the demand from operating systems and associated applications has always been greater than could be provided by hardware. Typically, users were faced with a situation where the RAM, the processing power and the hard disk requirements were often insufficient to deliver the required performance of the operating system and applications. Achieving significantly improved hardware performance came at a cost, and was, in many cases, a difficult investment case to make.

As technology has developed over recent years, hardware performance has improved and corresponding costs to obtain the required standards markedly reduced. Hardware has evolved to allow more available resource to run demanding operating systems and applications and presently can outstrip system and application needs. Crucially, alongside this, costs have come down bringing such solutions within reach of the wider industrial community. RAM is now available in multi gigabyte sizes, multi core processing power is standard and hard disk storage is now in terabytes. With operating systems and applications able to exist within the hardware platform with minimal impact on resources, the ability to run numerous operating system environments and applications from a single hardware platform is now a reality for many.

• •

Demand Grows as Costs Recede Users are creating the demand to utilise multiple operating systems and varied applications and there is a natural reluctance to compromise on choice or performance. While in personal use the internet and cloud-based operating systems and applications can be run seamlessly on our chosen hardware, in the industrial world the potential scenario where a number of hardware platforms are required is commonplace. This is where the virtualised approach allows for a multi operating system and multi-application environment to be run on a host system removing the issue of multiple hardware platforms.

It is clear to see that the explosion of applications and operating environments has led to an increased thirst for data. Data centres used in the banking sector or for hosting consumer cloud based services such as iCloud and Google Drive are now the norm and their optimisation has been pivotal in the drive for virtualised systems.

Momentum for the take-up has been cost reduction benefits. These can be achieved simply through the reduced space requirements to house a virtualised system when compared to a conventional one. Cost is also slashed in fixed expenditure areas such as heating and energy bills as a result of centralising the IT infrastructure into a virtualised server environment. Figures of up to 80% in energy savings have been estimated as a direct result of data centres adopting this approach. The other area of cost reduction is in system management as a consequence of a standardised, centrally co-ordinated approach to IT. It means simple, low cost terminals can be used as the main tools to operate the data centre.

•

•

•

Pros and Cons Like all technology solutions, virtualisation has its advantages and drawbacks. It will be for individual industrial users to determine whether or not its adoption is the correct strategic decision for them.

In terms of arguments for its selection, six key areas are worthy of consideration.

•

Security – a virtualised system can provide greater security and reduce the risks associated with industrial IT security. Through the use of remote access with centralised rights management, the chances of cyber-attack are minimised

PROCESS INDUSTRY INFORMER September 2014

•

Flexibility – by using a single host system to run a number of different applications, flexibility is increased Long-term stability – with the typical life cycle of a traditional approach including computer hardware, the operating system and the version of the control system (in a process control environment), the decoupling of these life cycles contributes to the creation of a more stable and longer-term solution Total cost of ownership (TCO) reductions – TCO can be reduced by adopting a focused approach to administrative work on a virtual system through centrally performed activities such as updates and backups. As a result, the system only requires very simple PCs to operate the front end System Upgrade and Update – the effective deployment of new software using prepared templates and images provides an operational efficiency opportunity to simplify the upgrade and update process. By pre-testing the updates in a controlled environment, the impact of a change is significantly reduced Standardisation – a prime benefit of a virtualised system is the ability to clone an environment. This enables fast and easy cloning of key elements such as servers and clients.

They can be tested and further developed before deployment as a standardised system for a companywide roll out. While the benefits above are clear, nonetheless there is also a counter argument for rejecting the virtualised approach. Some of these issues include: Higher initial IT investment – while the TCO can be seen as lower, the trade-off for this is the initial higher cost of investment into a suitable level of IT infrastructure. As well as the hardware platform, additional elements such as cooling and air conditioning have to be factored in. Thought also needs to be given to the cost

•

•

•

•

•

of the virtualisation software and requirements such as maintenance contracts Discontinued support – in a virtual environment, legacy systems including patches and virus scanners are still capable of running long after products are discontinued. This could result in a plant being operated based upon technology that is no longer supported by the vendor Data security – if the decision is taken to adopt an offsite, virtualised solution, managed by a third party, attention needs to be given to where vital data is held and who has access to it Distributed responsibility – in a virtualised system running for example a process plant, there exists a triangular relationship between the host system supplier, the virtualisation software provider and the process control system provider. Responsibility if an issue occurs or if costs are incurred can become a problem. This is not an area of concern in the more traditional approach as the responsibility in this case lies solely with the process control system vendor Skills – with an increase in system complexity, the requirement for highly trained IT specialists is increased both to understand their own area as well as an industrial production environment so that any decisions do not adversely affect production New chances and sources of error – the opportunity exists to introduce new chances and new sources of error into the system driven by an increase in the overall complexity and shifting of functionality to an IT environment

Industrial users need to weigh up the ‘pros and cons’ for their particular organisation and assess whether the virtualisation route is the right one for them. What is clear is that thanks to technology advancement and cost reduction, the concept of a virtualised operating environment can now become a reality for many organisations who thought the benefits it delivers were previously beyond reach.

43

ISO 55000 – Taking Asset Management into the

Boardroom

Maintenance managers know that proactive asset management can cut costs and improve lifetime value. Yet making that shift towards best practice has been an uphill battle... until now. With the launch earlier this year of the new ISO 55000 standard, asset management is now on the boardroom agenda.

ISO 55000 provides a framework to enable organisations to use asset insight and good process to improve operational effectiveness. It is about reducing costs but also about understanding the business risk and cost associated with individual asset failure. It is about improving planning and providing individuals across the organisation – from finance to production and senior management – with visibility into the end to end spend on asset maintenance. In effect, ISO 55000 will change asset management from tactical to strategic.

Karen Conneely, Group Commercial Manager, Real Asset Management, outlines the way ISO 55000 is set to change corporate attitudes to asset maintenance and explains the fundamental importance of a good Computerised Maintenance Management System in delivering critical asset information and enabling process change.

44

Best Practice The introduction of the ISO 55000 standard for asset management is the beginning of a significant seachange in corporate attitudes to asset value. Despite the long term awareness that strong proactive policies for asset maintenance can reduce costs and extend an asset’s lifetime value, far too many organisations still retain a highly tactical approach to asset management.

Jobs are primarily reactive and there is no understanding of the business cost associated with individual asset failure or downtime. Any information that is recorded is often extremely sketchy and only retained as some way of keeping track of the reactive maintenance activity and providing a basic schedule.

Yet reactive maintenance is three to five times more expensive than planned maintenance. Scheduling stock, parts, trades and engineers in advance as part of a proactive maintenance strategy can deliver astonishing cost savings. There is no time wasted waiting for the right resources; and individual workloads can be scheduled more proactively. Critically, assets that are maintained on a regular basis are less likely to break or stop working.

And it is for this latter reason that ISO 55000 is set to fundamentally change the perception of asset management for good. Rather than just cutting asset maintenance cost through better practice and day to day management, the ISO standard is designed to enable organisations to understand the strategic value of individual assets and the entire asset lifecycle value – including the impact of asset downtime. Assets are no longer the sole preserve of the maintenance department but of core strategic value and interest to the business as a whole.

Detailed Asset Insight Fundamentally, ISO 55000 is about making the most effective use of assets to generate the most profit for the business. So what does that mean in practice? At the heart of the new model is a strategic understanding of the role each asset plays within the business and the associated risk of asset failure.

The first step – planning – requires the business to record detailed information about assets, costs, procurement and resource utilisation. Armed with this insight the business can then determine clear corporate objectives which can then be reflected within the asset management strategy. Is the focus on decreasing maintenance costs; minimising resources by reducing reactive maintenance; or prioritising the uptime of key asset classes? How is contingency planning addressed within the maintenance plan? Organisations also need to understand how asset performance can affect business continuity and determine the strategic response to outage/problems.

It is clear that good, accurate and detailed asset information is at the heart of successful ISO 55000 accreditation. With a robust Computerised Maintenance Management System (CMMS) an organisation can quickly collate the depth of information required. For example, how many jobs occur each day/week or month? What is the fix time? Which skills – and subcontractors – are required to complete the job?

What items were requested from stores? Was there a delay in attaining spare parts? And what are the associated costs in terms of business performance?

In depth analysis of asset performance information – from purchase through repairs – in tandem with the business impact of the failure of individual assets is key to understanding business cost and risk.

Quantifiable Value With this strategic understanding of asset value, status and related business risk for the first time, the business can then use a CMMS to support the next phase of the ISO 55000 framework – namely delivering more effective asset maintenance. From improving scheduling to tracking staff performance and delivering appropriate training, the ‘Action’ phase of the standard framework delivers immediate, measurable improvement in resource utilisation and the quality of the assets.

The ability to assign a risk level to each asset enables far better risk management and ensures maintenance activity can be prioritised for critical assets. With good understanding of every aspect of the maintenance process – from ordering parts to accessing skills organisations can run ‘What If?’ scenarios to accurately assess the impact of increasing proactive maintenance and determine in which areas this would be most successful and valuable.

Indeed, ISO 55000 also provides a clear framework for enabling efficient, improved performance that will also help those organisations with mandated safety standards (such as the NHS) to achieve the required levels of performance and audit.

Conclusion While ISO 55000 is not mandated, over the next few years it is likely that growing numbers of organisations will stipulate that suppliers and business partners achieve accreditation to demonstrate a level of excellence and competence in asset management and utilisation. ISO 55000 will not only provide commercial benefits in areas such as better performing assets, reduced costs and improved asset lifetime value but accreditation will increasingly offer a chance for competitive differentiation.

ISO 55000 places assets under the corporate spotlight.

It is time for organisations across the board to recognise the new strategic imperative of asset management.

PROCESS INDUSTRY INFORMER September 2014

FLUIDS & LIQUIDS HANDLING INC. PUMPS & VALVES

GRIP COUPLINGTM FOR Higher pressure HydraALL METAL PIPES Cell pumps available

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, Reading, Berks Tel: 0118 9503707 Fax: 0118 9504066 E-mail: straub@mvfh.co.uk Web: www.straub.co.uk

In response to customer requests and following extensive testing, Hydra-Cell® G35 high pressure, diaphragm pumps are now rated to 100 bar pressure.

Conventionally the G35 has been rated with a maximum pressure of 83 bar and a maximum flow rate of 140 litres per minute.

The new version, is now rated with a maximum pressure of 100 bar at a maximum flow of 67 Ipm, which should open up new applications for this popular and economical Hydra-Cell model.

This very versatile, workhorse of a pump is available with a wide variety of liquid head materials, including brass, cast iron, duplex 2205, super duplex 2207, nickel alloy (Hastelloy®) and 316L stainless and variety of flange types is available on request.

Capable of pumping both hot and cold liquids, in a wide range of viscosities, Hydra-Cell pumps are characterized by their complete lack of dynamic seals, making them ideal for transfer pumping, dosing, injection and metering applications where complete liquid containment is essential.

Having no dynamic seals also enables Hydra-Cell to pump abrasives and dirty fluids that may contain abrasive particles, situations that would eventually cause problems for other pumping technologies.

The multi-diaphragm design produces a low pulsation flow ideal for a range of dosing applications.

For more information contact Wanner International, Fleet, Hants.

Tel +44 (0)1252 816847 E-mail: NHerrington@wannerint.com Web: www.hydra-cell.eu

20% 20% More performance

NEW

Lower maintenance Longer hose life Higher flow rates Heavy duty design

Verderflex Dura 55 Flow: max. 15.3 m3/h Pmax: 16 bar Verderflex Tel.: +44(0)1924 221020 info@verderflex.com

www.verderflex.com

PROCESS INDUSTRY INFORMER September 2014

45

FLUIDS & LIQUIDS HANDLING

TorkDrive –

a torque limiting device which prevents valve damage Smith Flow Control’s TorkDrive is a unique device which prevents manual valves from being damaged due to excessive torque application during valve operation. It can be customised to suit most manufacturer’s handwheel operated valves (Ball, Gear, Gate & Globe, etc) where valves require a torque monitoring of over 80Nm. The device is set to a predetermined maximum torque and if, during the operation of the valve, the operating torque increases above the pre-set limit, the TorkDrive will slip, indicating an irregular valve condition. Following over-torque, the TorkDrive unit will automatically reset to the predetermined torque.

TorkDrive is a customisable add-on tool which minimises the risk associated with unavoidable plant/process shutdown and unnecessary repair costs through valve over-torque. It can be specified as a simple, standalone unit mounted on either the valve input handwheel or directly to the valve input shaft; or it can be used in conjunction with SFC’s EasiDrive portable valve actuator, a non-impacting, air driven power tool designed to simplify valve operations.

In most circumstances, manual adjustment of the power source (air or electric) restricts or limits the output torque and speed (RPM) of the EasiDrive. However, if the use of the portable actuator is not restricted to larger valves and is used on a wide range of valves with differing sizes and operating torques, the TorkDrive would be the ideal solution. TorkDrive limits or restricts the operator from applying excessive force and protects the valve and valve seat from the over-torque that could be generated via the tool.

For more information about the TorkDrive and how it can be used, please contact Smith Flow Control, Witham, Essex Tel: +44 (0)1376 517901 or E-mail: enquiries@smithflowcontrol.com Web: www.smithflowcontrol.com

SEE YOU AT THE HUB? With a loyal following of new, and more importantly, returning visitors each month the Grundfos website is a popular communication hub for those seeking information on new and/or replacement pump solutions.

There are many good reasons for this popularity, including that it is now easier to find a specific product, locate support data as well as there being a quick link to a wide range of campaign specific sites.

Not surprisingly - as it is estimated that pumps consume 10% of the world’s electricity consumption - there is a major emphasis on the significant amounts of energy that can be saved simply by fitting the correct pumps.

The Meet the energy challenge NOW section of the web site will give a lot of information on pump selection as well as where and how energy can be saved. There is also the opportunity to sign up for eNewsletters and to view a range of information and movies.

In addition there is a section towards the bottom of the home page that provides information on case stories, product updates, industry news and other relevant updates all of which mainly relate to the UK market. This communication hub - that is updated regularly - has become one of the most popular areas of the site.

But it doesn’t end there, by accessing www.grundfos.co.uk you can also be among the first people to find out about product innovations, get access to a range of literature and pump selection tools, as well as getting access to background information such as the Grundfos approach to the environment.

So pay a visit and see for yourself why visitor numbers are continuing to increase and then save the Grundfos site as one of your ‘favourites’. We think you’ll be glad you did.

For more information or to request literature please contact Grundfos Pumps Ltd Leighton Buzzard, Beds. Tel: 01525 850000 E-mail: grundfosuk@grundfos.com Web: www.grundfos.co.uk

46

Stainless Steel housed Ultrasonic Clamp-On Flowmeter

FLUXUS® F/G 705 for Liquids and Gases p Highly accurate and reliable bidirectional gas and liquid flow measurement over a wide turndown ratio p Extremly rugged and corrosion resistant stainless steel housing for the harshest environments - including Offshore (ATEX / IECEx and FM approved) p Very cost efficient: - No pipe work - No process shut-downs - Virtually no maintenance p Highly zero point stable, drift free and independent of pipe size, material, line pressure and the medium Oil & Gas exploration and processing Refineries (up to 400 °C and beyond) Oil & Gas Storage & Transport Chemical industries

www.flexim.com

PROCESS INDUSTRY INFORMER September 2014

FLUIDS & LIQUIDS HANDLING INC. PUMPS & VALVES

New Verderflex Dura 55 Industrial hose pump for medium flow applications Following the highly successful, class leading Verderflex Dura 45 hose pump, Verderflex are proud to announce an expansion to the range, the Verderflex Dura 55. This innovative, superbly engineered pump is designed to deliver over 20% more flow, increasing the Dura Hose pump family’s flow range.

The Verderflex Dura 55 is the class leader for this size of peristaltic pump, significantly outperforming its competitors in both continuous and intermittent duty applications. The addition of the Verderflex Dura 55 expands the Dura range’s flow rates from <1 l/hr to 15.3 m3/hr at pressures up to 16 bar.

The Verderflex Dura 55 meets growing market demands for a pump that can reduce life cycle costs, maximise plant uptime and incorporate special design features for arduous heavy duty applications. The Verderflex Dura 55 solves pumping problems associated with dry running liquid streams, shear sensitive polymers, high viscosity sludge and pastes, variable speed dosing, abrasive solids in suspension and off-gassing fluids. This makes the Verderflex Dura 55 ideal for use in a wide variety of applications including; biogas production, brewing, fly ash recirculation, chemical manufacturing, industrial processing, mining and water treatment.

Low life cycle costs The Verderflex Dura 55 delivers more flow per revolution. This significantly increases hose life by decreasing the number of revolutions to pump a given volume for longer hose life and expanded maintenance intervals.

A key attribute behind lowering user’s life cycle costs is the renowned, premium quality Verderflex hose. Like all Verderflex hoses, the Dura 55 hose has the optimum design to maximise strength and longevity.

Available on iPhone and Android devices

Maximise plant uptime The Verderflex Dura 55 has a unique, patent pending port flange that totally encloses the hose.

This unique flange design also includes an innovative quarter turn lock system, halving hose change times to maximise plant uptime. Normally, supplied in 316 Stainless Steel, this flange design also has optional PP & PVDF inserts for aggressive chemical duty options.

• Single operator • NO tools required • 4 Minute change-over • Easy access “external” seals

Heavy duty design

1” to 100” Blinds 150 to 2500 ANSI

The Verderflex Dura 55 heavy duty design guards against blockages and chokes with its advanced stalled rotor protection technology, including visible slippage indicators. This advance eliminates potential rotor, rotor shoe or gearbox damage when the pumped liquid settles out or a line chokes, reducing both maintenance costs and production downtime. This key design feature enhances the Verderflex Dura 55’s suitability for pumping sludge, slurries and all kinds of vicious and waste liquids.

Reinforcing the heavy duty design is the pump’s casing and rotor, made from high tensile strength SG iron unlike the lower specification GG iron used by many competing products. The Verderflex Dura 55 pump’s rotor shoes are fully supported, eliminating potential stress weak points.

Marven House, 1 Field Road, Reading RG1 6AP England Tel: (0118) 950 3707 Fax: (0118) 950 4066 International Dialling: (44-118 + Tel/Fax No.) Email: info@mvfh.co.uk • www.mvfh.co.uk

ONIS “Quick-Action” Lineblind

Why use a peristaltic pump?

- Abrasion resistant - Can run dry - Self-priming - Pumps high SG, low water content slurries - Superior Secondary Containment, eliminating any risk of workplace contamination - No seals - Low cost of ownership - No moving parts in the liquid stream Here is a link to the Product Launch Video https://www.youtube.com/watch?v=Xqa4Tonj_tM For more information contact Verderflex, Verder Ltd, Castleford, West Yorkshire. Tel: +44 (0) 1924 221020 E-mail: info@verderflex.com or visit www.verderflex.com

PROCESS INDUSTRY INFORMER September 2014

Making light work of a heavy maintenance process...

47

HEALTH & SAFETY

Clean-In-Place, Actuated New hose Valves… and Keeping coupling Things Flowing interlock safeguards silo deliveries RGV now lighter, more resilient and easy to use SERV Trayvou Interverrouillage (STI) has improved its RGV range of hose coupling safety products, which are fitted to silo inlet pipes, to ensure tanker drivers deliver their load to the correct silo.

Companies need to consider the risk of a tanker driver accidently delivering their load to the wrong storage silo. Such processes have to be optimized to satisfy increasingly tough legal requirements, as well as to prevent the risk of accidents caused mainly by human error.

Now lighter, more resilient and easy to use, the latest version of the RGV enables the safe transfer of goods via trapped-key interlocking technology. The RGV range requires operators to receive authorization from the control room before the process can begin. Depending on the type of product being used, this authorization is given either by the hose coupling being unlocked remotely or through the use of an interlocking safety key. The addition of an inductive proximity sensor indicates that a tanker driver is transferring their load.

Mechanical RGV To connect this product to the silo, the operator must obtain the dedicated coded key from the loading manager.

Each silo has a corresponding key to avoid load transfer errors.

This solution can be used in conjunction with STI’s RFID key management panel, Smart Key Manager, to ensure optimum safety and traceability.

Electromechanical RGV To connect this product to the silo, the operator has to liaise with the loading manager and wait for authorization from the control room before coupling the hose and starting to unload. Access to the coupling is granted directly from the control room.

Electrical contacts can be added to either version of the RGV to enable monitoring from the control room.

Supervisors can see which RGVs have been made available to tanker drivers and those that have hose couplings attached.

The RGV system has been designed in accordance with French silo legislation DEVP0750104A. For more information contact, SERV Trayvou Interverrouillage S.A.S. 1 Ter rue du Marais, 93106 Montreuil CEDEX, France Tel: +33 (0)1 48 48 15 15 Fax: +33 (0)1 48 59 68 50 E-mail: pr@servtrayvou.com Web: www.servtrayvou.com

48

Smith Flow Control’s IML lock is a safety device that prevents injury or product loss in the food and beverage processing industries. Specifically designed to replace an actuator mounting kit, it locks the actuator in a desired position, both remotely and locally.

Under normal conditions in the food and beverage industries, actuated valves respond to process commands in a largely automated, predetermined way. During planned maintenance or clean-in-place, however, the system managing the valves may still need to be live while work is carried out. It may therefore be necessary that a valve is deliberately held, so even if a remote signal requests the valve to change position, it will remain in a locked condition to enable work to be done safely.

The IML Lock covers F05 to F16 ISO 5211 actuator mounting dimensions and can be operated up to a maximum torque of 1500Nm.

For more information contact Smith Flow Control Ltd, Witham, Essex Tel: +44 (0)1376 517901 Fax: +44 (0)1376 519720 E-mail: enquiries@smithflowcontrol.com Web: www.smithflowcontrol.com

PREVENTION RATHER THAN CURE IS THE KEY TO SAFETY Rob Lewis, Managing Director at Fortress Interlocks, explains the revised EN ISO 14119 standard and looks at a preventative alternative. release is sited) and by that time it is What is an Escape Release? highly likely an accident will occur.

EN ISO 14119 defines “By adopting a safety key system, Escape Release as the people entering a dangerous area ‘possibility to release are 100% protected from an manually without aids the unexpected start-up, preventing an guard locking from inside incident in the first place, whereas the safeguarded area to an Escape Release system seeks leave the area’. It sets out the following requirements: to minimise the effect after an • Deliberate unlocking of unexpected start-up has occurred.” the guard locking from Prevention is better than cure inside of the safeguarded Safety keys stop the accident area shall be easily occurring in the first place by possible without auxiliary blocking the interlock once the door means and regardless of is opened. Once all safety criteria are the operating conditions met, the door will still not open until Safety keys work by blocking the • The unlocking means an employee removes the safety key. interlock once a door has opened shall be manually operIn reverse, the door will not relock ated and act directly on until the safety key is returned. The the principle of the locking mechanism operator is therefore kept completely safe while the • The unlocking shall generate a stop command safety key is in their pocket.

• The unlocking means for the escape release shall Many people liken a safety key system to a padlock only be accessible from inside the safeguarded area in a lockout procedure – and given that you can’t In summary, an Escape Release allows someone restart until the key is returned, this is true. However trapped inside a safeguarded area to leave the safety keys have two major advantages over a area and, in doing so, send a stop command to lockout procedure: the controller.

• Firstly, the safety key is always at the door, so you When is an Escape Release needed? can’t forget it and be tempted to nip inside for a EN ISO 14119 is much less prescriptive about minute this, merely stating ‘Depending on the application • Secondly, unlike a lockout procedure, if you don’t supplementary methods of release can be necessary’. remove the safety key the door won’t open, so In practice the risk assessment for the safeguarded operators are forced to follow the procedure area should consider the risk of a person becoming In summary, by adopting a safety key system, people trapped inside the area. Factors to consider when entering a dangerous area are 100% protected from making a risk assessment are: an unexpected start-up, preventing an incident in the • Is the access full body access (i.e. can you walk into first place, whereas an Escape Release system seeks the area or is it just a hatch)? to minimise the effect after an unexpected start-up • Is the safeguarded area small or large (i.e. can you has occurred. easily see if someone is in the cell)?

• In the safeguarded area, are there blind spots where For more information contact, Fortress Interlocks Ltd, Wolverhampton a person could be hidden from sight?

But this doesn’t appear to stop an accident occurring? Tel: +44 (0)1902 349 000 No it doesn’t. An Escape Release will allow someone Fax: +44 (0)1902 349 090 trapped to get out, but the machine won’t stop until E-mail: sales@fortressinterlocks.com the employee is already at the door (where the escape Web: www.fortressinterlocks.com

PROCESS INDUSTRY INFORMER September 2014

HEALTH & SAFETY Seeing is SUPPORTING believing with new ENGINEERS WORKING WITHIN ROCOL® stainless steel cleaner SIL RATED Request your FREE sample today PROCESSES - Greater process reliability for high integrity hazardous applications The IEC industry standards detailing the safety performance requirements for hazardous operations have been widely adopted by many industries (IEC 61508 and IEC 61511). However, the requirement within high integrity industries, like the Oil and Gas and Pharmaceutical sectors, to further quantify levels of compliance within these standards has led to the implementation of the Safety Integrity Level (SIL). SIL is another measurement of the reliability of protection systems in hazardous processes.

Elfab rupture discs and burst detection assemblies make a valuable contribution to these systems. Rupture discs have become an increasingly popular method of pressure relief in modern process plants with ever-increasing safety standards and environmental considerations. The need for reliable yet cost-effective detection systems to indicate when a disc has functioned has also become a pressing requirement.

This has led disc manufacturers and customers alike to seek increasingly advanced systems that provide reliable protection. In response to customer requirements Elfab is now able to assist engineers working within stringent SIL rated conditions.

Knowing suppliers comply with such requirements enables users to specify more suitable pressure relief and associated detection devices into their high-risk installations, where the reliability of the safety system is paramount. Using generally recognised models for risk assessment and risk reduction, engineers are now finding this an effective way to improve a systems overall safety.

If you would like to know more about SIL, or need advice on how Elfab can support you in your safetycritical processes please contact the company on +44 (0)191 293 1234 or E-mail: pr@elfab.com Web: www.elfab.com

STATIC GROUNDING FOR PROCESS PLANT & EQUIPMENT

A new stainless steel cleaner from ROCOL is delivering superior smear-free, no-residue cleaning results in a wide range of production environments, including food, beverage and clean industries.

The new cleaner and polishing spray, which removes grease, oil and general grime from metal surfaces and is particularly suitable for use on stainless steel, is receiving widespread praise from customers following its launch.

ROCOL says, “The feedback we are getting from customers is that we’ve succeeded in developing a cleaning product which surpasses their expectations – we’ve looked at other stainless steel cleaners in the market and produced an outstanding cleaner that doesn’t leave any residue.”

“In addition, it offers a range of food safety, hygiene and traceability benefits, which make it ideal for use throughout food, pharmaceutical and clean industries.”

As well as leaving surfaces polished, and residue and smearfree, the STAINLESS STEEL CLEANER Spray from ROCOL is 100% food safe. Manufactured from only FDA listed ingredients, it carries NSF registration, making it ideal for use in food processing areas.

The product’s food safe credentials are further enhanced through the use of the ROCOL patented DETEX™ caps and actuators, which are manufactured from x-ray and metal detectable plastic components to help food processing plants meet HACCP requirements.

ROCOL is offering customers the opportunity to experience the benefits of the new STAINLESS STEEL CLEANER Spray by giving away a limited number of free samples.

Newson Gale has launched its next generation static grounding relay, the Earth-Rite® OMEGA II. Featuring ATEX, IECEx and cCSAus Intrinsically Safe certified circuits for the highest gas, vapour and dust groups the Earth-Rite® OMEGA II monitors the resistance of circuits designed to ground equipment that are subjected to electrostatic charging.

The new DIN rail mountable relay caters for installations where dedicated grounding systems like the Earth-Rite® RTR or Earth-Rite® PLUS would not normally form part of an electrical contractor’s turnkey control panel project for an EX hazardous area installation.

The Earth-Rite® OMEGA II features four adjustable resistance monitoring settings that can cater for the specific requirements of a wide range of static grounding applications. The resistance monitoring settings available for selection are 2 ohms, 4 ohms, 10 ohms and 600 ohms. By ensuring the grounding circuit has a low resistance path to a verified earth ground, the risk of an ignition caused by an electrostatic discharge is controlled to safe levels.

The Earth-Rite® OMEGA II relay has a certified operating temperature range of -40° C to +60° C (-40° F to +140° F) and carries SIL 2 certification in accordance with the requirements of IEC 61508. It requires a 24 V DC power supply with up to four relays powered simultaneously by a single power supply. The relays are normally mounted in the non-hazardous area but can be mounted in a suitably certified Ex(d) flameproof enclosure located in the hazardous area.

To be in with a chance of receiving a free 400ml sample, E-mail customer.service@rocol.com and for more information about the new product, visit www.rocol.com.

For more information please contact Newson Gale Ltd, Colwick Nottingham Tel: 0115 940 7500 Fax: 0115 940 7501 E-mail: groundit@newson-gale.co.uk Web: www.newson-gale.com

KEY INTERLOCK COMMISSIONING MADE SIMPLE Installing mechanical key interlocks is often one of the last tasks before commissioning and handover of a project. Occasionally, interlocks can impede this process by preventing the valve settings needed to create the process conditions (hydro-testing) for commissioning of piping systems.

One solution is to defer fitting the interlocks until all mechanical commissioning tasks are concluded. This is not ideal as there may be a number of different contractors involved in the final commissioning programme. Commissioning of interlock systems should ideally be done and completed by one responsible party – particularly when it comes to management of the operating keys.

Smith Flow Control’s ComKey is a simple, effective solution to this problem. It defers the need to fit the interlocks until all mechanical commissioning tasks are accomplished, saving time and simplifying operational logistics.

PROCESS INDUSTRY INFORMER September 2014

SFC Interlocks are usually supplied with one key trapped and one key free as standard. However, in situations where any of the above issues are relevant, they can be supplied with a factory-fitted ComKey that allows random operation of the installed interlock irrespective of the coded logic of the interlock system.

The ComKey is a ‘one-time-only’ product – once the key is removed after all testing/ commissioning tasks are completed, it can’t be re-used. The installed interlock will only then accept its dedicated coded key for normal operations.

Commissioning is complicated enough without having to worry about interlocks – ComKey simplifies the process.

For more information contact Smith Flow Control Ltd, Witham, Essex Tel: +44 (0)1376 517901 Fax: +44 (0)1376 519720 E-mail: enquiries@smithflowcontrol.com Web: www.smithflowcontrol.com

49

PRODUCT AND SERVICES DIRECTORY ABRASIVE RESISTANT LININGS

EXPLOSION PROTECTION

CONSULTING

The Wolfson Centre for Bulk Solids Handling Technology

Bulk Solids Short courses and consultancy for handling

Solutions Contact the experts +44 (0)20 8331 8646 bulksolids.com

AUTOMATED IRIS VALVES

LIQUID RING VACUUM PUMPS

Total Process Protection ■ Conventional Bursting Discs ■ Engineered Bursting Discs ■ Explosion Venting

One Thousand Pumps, One Distributor.

■ Flameless Venting ■ Explosion Suppression ■ Explosion Isolation

www.tomlinson-hall.co.uk Tel: +44 (0)1642 379500 Email: enquiries@tomlinson-hall.co.uk

Fike UK, 35 Earl Street, Maidstone, Kent, ME14 1PF, United Kingdom T: +44 (0) 1622 677081 E: info@fike.co.uk W: www.fike.co.uk

Tomlinson Hall & Co Ltd, TS23 4JA

MIXERS & BLENDERS

CONTINUOUS PARTICULATE EMISSION MONITORING FOR REGULATORY COMPLIANCE AND PROCESS CONTROL

MIXERS & CRUSHERS

FEEDERS

GENESIS

BIG BAG HANDLING

Spiroflow Wall Planner Ads_Layout 1 19/10/2011 09:11 Page 1

WHAT’S IN YOUR BULK BAGS IS YOUR BUSINESS...

PROCESS SOLUTIONS Providing solutions for the Plastics, Food, Chemical & Pharmaceutical industries including:

DISCHARGE AIDS

How you put it in or get it out is ours!

Bulk Bag Fillers

• Feeders - Screw, Belt, Vibratory • Volumetric & Gravimetric Systems • Fabric Internal Silos & Storage Hoppers • Refill Systems Unit 5, Springvale Business Centre, Sandbach, Cheshire CW11 3HY Tel: 01270 766300 Fax: 01270 766302 E-mail: phil@genesisps.co.uk www.genesisps.co.uk

Bulk Bag Dischargers

MOTION SENSORS INDUSTRIAL DATACOMMS

www.spiroflow.com Tel: 01200 422525

BUTTERFLY VALVES

INDUSTRIAL DATACOMMS SOLUTIONS

KD420 Modbus Sensor Interface 4-20mA and DC voltage inputs Modbus RTU Slave registers with multiple data formats Modbus Master feature can write data to a Modbus Slave device

Modbus RS422 / 485

Modbus RS485 Slave

Master

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DUST CONTROL

DUSTECH ENGINEERING LTD 162 Chiltern Drive, Surbiton, Surrey KT5 8LS Tel: 0208 399 9991 Fax: 0208 390 2004 www.dustechengineering.com explosionhazards_6x6b.pdf 1 30/10/2012 11:55:26

CONSULTING

EXPLOSION PROTECTION

C

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KK Systems Ltd

01273 857185 01273 857186

Visit us online

www.kksystems.com

LEVEL MEASUREMENT

NYLON SCREENS & WEDGE WIRE BASKETS

PRODUCT AND SERVICES DIRECTORY PARTICLE ANALYSERS

PROCESS MEASUREMENT

Worldwide Level and Flow Solutions SM

A preferred partner in the global supply of level and flow control solutions

TEMPERATURE MEASUREMENT

VACUUM CONVEYING

- Optris PI Series - Thermal Imaging - From Just £2,690 - Industrial Process & R&D Applications - Fast Moving Processes - Compact & IP67 Rated www.processparameters.co.uk/ thermal-imaging-camera

01628 778688

magnetrol.com • (0)1444 871313 • sales@magnetrol.co.uk

Hosokawa Wall Plan ad 55 x 60_Layout 1 17/10/20

PARTICLE SIZE REDUCTION

QUICK CONNECTOR SOLUTIONS

TRADE ASSOCIATIONS

» WEH® QUICK CONNECTOR SOLUTIONS

WEIGHING SOLUTIONS

PRECIA-MOLEN UK LIMITED

Pressure-tight connections in SECONDS

Unit 30, Walkers Road, North Moons Moat Industrial Estate, Redditch, Worcs B98 9HE Tel: 01527 590300 Fax: 01527 590310 E-mail: sales@preciamolen.co.uk Web: preciamolen.com

» Simplified workflows » Reduced operating times » Increased productivity

s • Systems icroniser ills • M Delivering accurate and M s sher repeatable particle size reduction.

• Cru Wet or dry milling equipment and systems for coarse grinding, medium and fine grinding and nano-milling.

www.hosokawa.co.uk • info@hmluk.hosokawa.com

PIPE COUPLINGS

WEH UK T: 01564-825100

enquiries@wehuk.co.uk

» www.weh.com

RISK ASSESSMENT

GexCon has a staff of highly qualified personnel, which can offer safety services for all types of installations.

Including: · Expert Witness · Advanced CFD modelling · Hazardous area classifications and DSEAR risk assessments/compliance in accordance with DSEAR / ATEX 137

Tuf-Lok (UK) +44 (0) 1706 822512

www.tuflok.com

www.gexcon.com

01695 726565

TRAINING PIPEWORK SYSTEMS

SERVICE & MAINTENANCE

The Wolfson Centre for Bulk Solids Handling Technology

Bulk Solids Short courses and consultancy for handling

Solutions Contact the experts +44 (0)20 8331 8646 bulksolids.com

PROCESS COOLING

NEED PROCESS COOLING? Chillers · Dry Coolers Cooling Towers · Chilled Air UK distributor for the new JACIR TOPAZ “Dry Cooler on Steroids”

0845 057 3097 appliedthermodynamics.co.uk

SLIDE GATE VALVES

ULTRASONIC FLOWMETERS

To advertise here or within our editorial pages or on our website please call Peter or Guy on 01428 751188

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