Process Industry Informer September 2017

www.processindustryinformer.com

SEPTEMBER 2017 Volume 13 No.5

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

the new piimag.com has launched

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

CONTENTS

FEATURED ARTICLES

PRODUCT SECTIONS 4-5 News & Events

TOP TIPS FOR SELECTING THE RIGHT PRESSURE TRANSMITTER

6-8 Applications

13

9 Health & Safety 12 Bearings

PREPARING FOR HAZARDOUS CHEMICAL EXPOSURE IN THE WORKPLACE

12 Heat Transfer & Energy 15 Process Control

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17 BPMA NEWS 33 Data Acquisition

THE COMPASS TO NAVIGATE INDUSTRY 4.0: INDUSTRIAL ANALYTICS

33 Enclosures

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(incl. Pumps & Valves) 37 Light Curtains 37 Lubrication 40 Sensors

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45 Recycled Polymers

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

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

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TIPS FOR EXTENDING YOUR ELECTRIC MOTOR’S LIFE

DO PLANT MANAGERS MAKE THE BEST OF THEIR DOWNTIME?

45 Weighing

34

GAMBICA - A BRIEF HISTORY & FUTURE OF INSTRUMENTATION

WASTEWATER ISSUES SOLVED

41-44 Process Measurement

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THE INDUSTRY PIPELINE: THE EVOLVING WORKFORCE, TECHNOLOGY & OPERATIONS

33 Ethernet Connectivity 35-36 Fluids & Liquids

10

IMPROVING THE EFFICIENCY OF COMPRESSED AIR SYSTEMS

12 Filtration & Separation

& Instrumentation

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

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whatsoever and however arising, whether due to inaccuracy, error, omission or any other cause, and whether on the part of the publishers of Process Industry Informer, or their servants or agents, or any other person.

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NEWS & EVENTS HOSOKAWA AGREE SERVICE & SPARES PROVISION FOR IIT LTD EQUIPMENT Leaders in powder and particle processing, Hosokawa Micron Ltd have today announced it has signed an agreement with Hippisley Ltd to acquire the Intellectual Property Rights of International Innovative Technologies Ltd. (IIT).

The acquisition assigns Hosokawa Micron Ltd the rights to provide maintenance services and spare parts for the range of comminution/size reduction equipment known as the m-series of mills (M350 and M600), the c-series of classifiers and the s-series of cyclone separators.

Owners of m-series, c-series and s-series equipment should contact either Dave Lyon dlyon@hmluk.hosokawa.com or Keith Sanderson ksanderson@ hmluk.hosokawa.com at Hosokawa Micron Ltd to discuss options for continued equipment after care and spare parts support.

For further information/reader enquiries, please contact: Hosokawa Micron Ltd, Runcorn, Cheshire.

Tel: +44 (0) 1928 755100 | Email:info@hmluk.hosokawa.com | www.hosokawa.co.uk

ADVANCED VALVE SOLUTIONS (UK) LTD ANNOUNCE HP AND IP WORKSHOP/SEMINAR

EXPORT GROWTH DRIVES UK MANUFACTURING GROWTH FOR HANSFORD SENSORS

At their new training facility in Cheshire, AVS has provided Valve Workshops that concentrate on concerns within the power industry, drawing on the expertise of their engineers as well attendees. The next ‘one-day’ workshop will be on the 8th November 2017.

Advanced Valve Solutions (UK) Ltd has been instrumental in the provision of reliable and robust valves into Power Stations across Europe. Their approach to business, they claim, is one of consultation and innovation.

Solutions offered is a custom ‘fit for purpose’ one that ensured increased product/process life cycle and significant improvements in plant efficiency. In many cases the increased efficiency has saved many hundreds of thousands of pounds per year.

Lunch and refreshments are free of charge.

Please contact our UK office in Crewe and ask for Sadie Beavis if you need any more information.

Tel: 01270 586944.

A rapid increase in export orders is driving continued expansion at Hansford Sensors, the leading manufacturer of high performance industrial vibration sensors and systems.

The company’s overseas sales are growing at over 20% year on year, leading to a further increase in the company’s production facilities at its UK headquarters in High Wycombe.

Hansford Sensors recently celebrated its tenth anniversary with a record year, with revenues and production volumes reaching an all-time high. This rapid growth has led to the expansion of the company’s production facilities, with the sales and administration offices being relocated to a new build area and the space converted to production areas. These include extended test and development, quality control and assembly departments, totalling an additional 2,000 square feet of space.

For more information please contact Hansford Sensors Ltd, Tel: 0845 680 1957 | E-mail: sales@hansfordsensors.com Web: www.hansfordsensors.com.

OPTIMISE VIBRATION MONITORING DATA IN PHARMACEUTICAL MANUFACTURE WITH NEW WHITE PAPER A white paper is helping pharmaceutical manufacturers to optimise vibration monitoring data – enabling production and performance to be maximised.

The white paper, which has been published by vibration monitoring experts Hansford Sensors and is available as a free download, provides a comprehensive explanation of the vibration monitoring process and the technologies available to enhance it.

Engineers responsible for overseeing the operation and maintenance of machinery in the manufacture of pharmaceuticalswill gain an understanding of how to correctly specify, select and install different types of vibration sensors for online and offline systems, in addition to valuable information on the process itself. It also provides an in-depth example of the process in action in an air handling unit, detailing the equipment used for best results.

“Accurate data capture is essential as part of a predictive maintenance plan in today’s pharmaceutical manufacturing.

Vibration monitoring techniques and technology play a critical role in gathering this data, and, therefore, maximising performance,” explains Chris Hansford, Managing Director of Hansford Sensors.

“Our new white paper explains how to achieve this, using a real world example, so engineers can put theory into practice – and truly optimise data collection. Only with this data can the right decisions be made about what action to take to prevent equipment downtime and, where possible, extend the operating life beyond recommended maintenance intervals.”

For more information contact Hansford Sensors, Tel: 0845 680 1957 E-mail: sales@hansfordsensors.com Web: www.hansfordsensors.com

NEW GUIDE EXPLAINS HOW TO ACHIEVE A HEALTHY MEASUREMENT SYSTEM Top tips for accurate and reliable measurement revealed by new ‘How to’ guide ABB has released a new guide explaining how to keep your instruments and analysers in top working condition. Titled ‘How to check whether your installed instrumentation is in need of a health check’, the guide covers the key factors to consider when assessing the operational performance of measurement equipment.

Available on request from enquiries.mp.uk@gb.abb.com, the guide covers a range of topics, including why, how and when instruments should be calibrated to ensure they are delivering accurate measurement. Many users mistakenly assume that the calibrated accuracy of an instrument will endure throughout its operational life, potentially resulting in incorrect measurements that could have a major impact on production and profitability. The section explains how to create an effective calibration regime and how to spot when an instrument may need recalibration.

The guide also provides advice on the new possibilities being unlocked by advances in instrument technology, particularly when it comes to the availability of diagnostic data. The latest generation of smart digital instruments, coupled with developments in communication technology such as WirelessHART, have helped to unlock new possibilities for gaining quick and easy access to an expanded range of instrument data.

Foremost amongst these is the ability to obtain a clearer picture of what is happening in a process. The ability to convey a greater range of data from a device at faster speeds over a digital network enables real or near real-time data to be obtained on process conditions, which can then be used to identify areas for possible improvement.

Other topics covered include guidance on inspecting instruments to check for deteriorating performance and tips for designing and implementing safety instrumented systems in critical safety applications.

“The scale and complexity of many industrial sites means that many companies may be unsure about the age, condition or even location of some of their installed instruments,” says Wayne Deeks for ABB UK Measurement & Analytics Service. “Our new guide aims to provide an easy to use point of reference for anyone looking to improve the performance of their process through more effective measurement.”

To obtain a copy of the guide, email enquiries.mp.uk@gb.abb.com quoting reference ‘Health check guide’.

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PROCESS INDUSTRY INFORMER - SEPTEMBER 2017

NEWS & EVENTS 4D PRODUCTS DRIVES NEW DESIGNS FOR MOTOR SALES WORLD-WIDE Award winning product design company 4D Products is working with Invertek Drives to supply development services on a range of its industrial electronics enclosures.

Invertek Drives is a global manufacturer of Variable Frequency Drives (VFDs / AC Drives) for energy efficient control of variable speed electric motors. North West based 4D Products developed the enclosures with a quick turnaround for a trade show at which Invertek wanted to test reaction to the new product concepts.

“Growth Hubs nationwide are offering grants towards product consultancy services at the moment. Grants between £1,000 and £6,000 can be available to businesses to support business investment and expansion and can make up to a 40% cost contribution towards the cost of expert advice, coaching or consultancy.” Iain McCall, Co-Founder and Design Director for 4D Products Glyn Jones, technical director at Invertek had researched design companies on the internet based on previous work experience and quality and selected 4D Products to help the team take their products to a new level of design and functionality. Always focused on enhancing products, 4D Products’ Co-Founder and Design Director Iain McCall and his colleagues completed CAD work on existing enclosures for Invertek before being asked to support work for the exhibition.

Iain said; “The deadlines, two to three weeks, were very tight and although 3D visuals would have done, a prototype was ideal to show the new product enclosure variant and test reaction at the show.”

Glyn Jones, technical director at Invertek said: “The model arrived on time and it looked great especially considering how short the time was that 4D Products had it for. The design was spot on and after exhibiting at the show there were product improvements suggested to add to the design.” He added; “The fast turnaround and success of this project has now moved on to Invertek working with 4D on three new projects.”

Iain continued; “The challenges were to deliver a new, purpose built casing with multiple inputs and outputs, a circuit board, fan and displays all of which needs isolating and styling. We’ve also designed the casing to be snap fit for easy production and for heat dispersion, with minimum cost and maximum flexibility. For example, a simple change to part of the front panel will allow additional revenue streams for the product. Working with Invertek’s design team and the suggestions from potential customers at the show we will be creating a family of parts and products in Invertek’s brand colours for world-wide sales and world-class products.”

For more information on the project and the process of design please visit: www.4dproducts.co.uk For information on the products please visit: www.invertekdrives.com

THE GRUNDFOS ECADEMY IS NOW EVEN BIGGER The popular on-line Grundfos Ecademy has been around for over 10 years. Until recently the content was mainly aimed at plumbers/installers and merchants who predominately worked within the domestic pump arena.

This situation changed, when earlier this year we launched this flexible learning platform to a new audience whose focus is on larger commercial applications. This now means that consultants/specifiers, as well as relevant distribution partners who work on larger types of projects and applications, can get access 24/7 to a range of on-line modules covering the following topics: - Commercial heating - MAGNA1 - MAGNA3 - Water boosting - Air conditioning - Life Cycle Costing.

Each topic is broken down in bite-sized modules and a small gift is on offer for the successful completion of four modules (there is a short quiz at the end of each one). New subjects are added regularly, so there is always a reason to visit.

Why not join the many people who have already signed-up and start your learning journey today by logging onto www.grundfos.co.uk

NEW PARTNERSHIP WITH GLOBAL STEAM SPECIALIST WILL GROW SUPPORT SERVICES Industrial services provider ERIKS UK & Ireland has formed a strategic partnership with steam specialist TLV to expand its asset management, condition monitoring and support services.

The partnership will allow ERIKS customers to benefit from TLV’s experience, as well as its portfolio of steam products. The company, which is headquartered in Japan, has been working with steam for over half a century and has acquired over 3,700 patents to date.

TLV’s main priority is providing a holistic approach to steam system integration for its clients. ERIKS’ customers will now also be able to take full advantage of the company’s Steam System Optimisation Programme (SSOP), a three-phase evaluation of an entire system to improve safety, efficiency and productivity.

ERIKS will also be able to recommend products from TLV’s extensive portfolio, such as the Cospect, which provides a compact, all-in-one solution for steam systems. The Cospect is one of the few products available in the steam market that combines solid particle removal, steam separation, condensate removal and pressure reduction.

ERIKS has a number of partnerships with specialist providers of industrial products and services, from sealing technology through to power transmission, gaskets and flow control. The new partnership with TLV will expand its support capabilities for the flow control portion of ERIKS’ business, providing customers with access to TLV’s risk-based analysis and Lloyd’s-approved testing systems.

For more information on ERIKS UK & Ireland, please visit www.eriks.co.uk.

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APPLICATIONS CALCULATING THE VALUE OF AUTOMATION When it comes to processing panels, CNC machining centres, such as Perforex from Rittal Automation Systems, are light years ahead of the alternative, manual approach when it comes to productivity and efficiency.

In fact, machining centres speed up processing by as much as 66 percent compared to the traditional hand-tooled method.

Now, a new web-based Return on Investment (ROI) Calculator helps customers accurately gauge how quickly a Perforex will take to pay for itself before they place the order – and they may be pleasantly surprised by what they find!

Perforex machining centres from Rittal Automation Systems are tailored to the challenges of switchgear manufacturing. They are ideal for the automated production of bore holes, cut-outs and threads in mounting plates, enclosure doors and side panels.

All the mechanical processing steps in the preparation of enclosures for population – including drilling, thread cutting, and milling of cut-outs – which are so timeconsuming, cost-intensive, and error prone, can be accomplished in a single work step.

Programming a job into the machining centre takes just minutes, and is either on the basis of simple, component-oriented workshop programming, or using imported CAD data from either Rittal’s software system Eplan or DXF imports from any other CAD platforms. Any programme setting can be saved for future, identical jobs, speeding up work-flow even more.

Furthermore, once done, engineers are free to work on other tasks, maximising team efficiency and business output.

Perforex systems are suitable for all materials typically found in switchgear, including steel, aluminium, copper and plastics.

Moreover, an automatic tool changer allows multiple tasks to be performed in a single operation, without the need for human intervention.

Work Out Your ROI – at the Click of a Mouse The new Rittal online calculator demonstrates how a Perforex system can deliver a rapid and tangible return on investment even for low production volumes.

Customers simply enter the typical manufacturing quantity, current machining cycle time, and labour rates per hours, and the webbased tool computes the corresponding payback period for a variety of Perforex models.

Proven efficiency gains under real-world conditions When the directors of Peterborough-based panel builders Pneumatechnique Ltd were looking at ways to improve efficiency and offer better production consistency they turned to Rittal and its automation systems for switchgear construction. Pneumatechnique’s aim was to find ways to lower both overheads and operational costs.

Following a detailed assessment and recommendations made by Rittal’s expert team, the decision was taken by Pneumatechnique to install a Rittal Automation Perforex CNC machine. It was quickly identified that the capital expenditure could clearly be outweighed by the cost savings and the Perforex installation became a “no-brainer” as part of the investment project.

Adam Wilson, production manager at Pneumatechnique advises: “This project has seen a lot of investment not only in money but in time; it has involved a great deal of hard work. The final result is an excellent fit for us and we are now offering customers something they can’t do.”

Going forward, Adam advises that, “the Perforex system has opened up a number of new routes to market. What’s more this system looks like it will offer us the opportunity go way beyond the targets we have set for it.”

Thanks to their new, higher levels of productivity, the team expects the machining system to pay for itself in just 12 months.

To find out more, go to www.youtube.com/watch?v=OoOQf-O7G3A. Web: www.rittal.com/roi-calculator. | Tel: 01709 704000 | E-mail: information@rittal.co.uk

PLANNED SERVICING IS A VITAL COMPONENT AT KEMIRA CHEMICALS Kemira Chemicals in Bradford is part of a global chemicals company renowned for a wide range of different products for the water treatment industries. In Bradford, up to 230 tonnes of dried polyacrylamide is manufactured and packaged daily and then sold across the world to companies in the water treatment, paper and pulp, mining and oil recovery industries.

Some years ago, Production Managers at Kemira Chemicals took the decision to work with single suppliers of ancillary equipment used throughout the manufacturing process. Rotary valves came under the spotlight.

Up to this point Kemira Chemicals used rotary valves from three manufacturers. Keeping spares, manuals and servicing complicated an otherwise smooth-running operation.

Meetings with suppliers took place and the decision was taken to work with DMN Westinghouse.

Today, there are over sixty DMN Westinghouse 200mm and 250mm rotary valves together with some 175mm and 300mm versions throughout the factory with around twenty more held in stores. However, what has really helped to confirm that the decision to work with one supplier was the right decision is the DMN Westinghouse Servicing Plan.

The production area at Kemira Chemicals consists of four sections. Every six months, one section is shut down for three days for general maintenance. During this three day period, two engineers from DMN Westinghouse strip, clean and replace any damaged or worn components in every valve in the section.

This means that every valve in the factory is maintained every two years.

Dave McDonald is the Maintenance Manager at Kemira Chemicals says: “Since the introduction of the DMN Westinghouse Service Plan, downtime has been drastically reduced to the point where if there is a problem it rarely involves a rotary valve.”

For more information please contact Bob Rogers on Tel: 01249 818401 or E-mail b.rogers@dmnuk.com

MODEL GLOVEBOX TO STIMULATE CAREERS IN NUCLEAR INDUSTRIES A demonstration/educational glovebox, commissioned by the National Nuclear Laboratory to enhance public understanding and recruitment and training of young people for emerging job vacancies in the nuclear industry, is proving a hit at science events and government departments in Whitehall. says Adrian Bull, NNL’s Director of External Relations ‘We were very pleased with both the excellent service we received from Hosokawa and with the glovebox itself. We have already used it at a number of events, including the “Amazed by Science” festival in Cheshire, a demonstration of NNL’s work at the head offices of the Government’s Business, Energy and Industrial Strategy Department in Whitehall, and our own annual Science and Technology Conference in Manchester. On each occasion it has proved an excellent way to discuss the work we do and to engage people of all ages in conversation and practical experiments,’ The compact, portable unit can be used by all ages to demonstrate tasks common within the scientific fields of nuclear, chemicals, pharmaceuticals and healthcare. In these industries tasks such as material analysis, sampling, operational engineering and waste management are all carried out within a protected glovebox environment. The acrylic glovebox replicates a full size working glovebox and students using it can see for themselves the specialist skills required to complete tasks with the challenges of working in a protective environment with limited access and when using protective gloves.

Design engineer, Adam Harper, Hosokawa Micron says, ‘Whether used in schools, educational fairs or science events we hope this interactive model glovebox will be the catalyst for learning and hopefully the stimulus for a new STEM career path for many of today’s students. We hope people will ‘have a go’ at different interactive tests and challenges to share an insight into the practical processing tasks typically carried out within a protective, contamination controlled environment and will see their future in the diversity of engineering opportunities open to them.’

As nuclear power continues its resurgence as an alternative energy source offering reduced carbon emissions, the need for exceptional and skilled workers increases. With nuclear build in the UK now confirmed, public perception and understanding of nuclear power, particularly at secondary and tertiary education level is a key issue in engaging with job seekers and the community and it is hoped that the demonstration glovebox can play its part in stimulating interest about the career prospects in all sectors of the nuclear and other science based industries.

For more information/reader enquiries, please contact: Hosokawa Micron Ltd, Tel: +44 (0) 1928 755100 | Email: info@hmluk.hosokawa.com | Web: www.hosokawa.co.uk

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PROCESS INDUSTRY INFORMER - SEPTEMBER 2017

APPLICATIONS BREDEL PUMPS PROVIDE HYGIENIC SOLUTIONS AT RUSSIAN FOOD PLANT Watson-Marlow Fluid Technology Group (WMFTG) has supplied Bredel CIP (clean-in-place) pumps to a global brand sauce and condiments manufacturing plant in Russia. Replacing pumps that were proving difficult to clean and maintain, Bredel CIP 50 models are being used to pump products that include cheese sauce, tomato ketchup and mayonnaise.

Hygiene is paramount in food industry applications, where any failures can have a devastating impact on brand reputation. For this reason, Bredel CIP 50 pumps are available with the option of externally-operated retracting shoes that release the hose so that the line is open and unobstructed for cleaning. Pumps featuring this option are used at the Russian plant with a food-approved hose and food grade lubricant, both from WMFTG, while stainless steel sanitary connectors include DIN, ASA and JIS types.

Daily CIP Hygiene and sterility are crucial at the plant where, depending on the production plan, CIP is often scheduled daily.

The process takes place at full velocity using food industry standard cleaning agents such as Tarmo (1.0%) and ET (0.30.5%).

Bredel CIP 50 pumps have been installed on two filling lines to transfer cheese sauce, which is heated to 75°C. Here, the sauce needs to be pumped quickly from the hoppers to the filling line at flow rates of up to 7000 l/h. If the sauce cools

SEPTEMBER 2017 - PROCESS INDUSTRY INFORMER

in the pump hose or in the transfer lines, it will solidify, which would cause huge cleaning issues because hot water and stronger cleaning agents would be needed to break down the starch and fats.

Ketchup and mayonnaise Elsewhere on site, Bredel CIP pumps transfer ketchup through 20 metre-long pipework with 7 metre delivery. The pumps dose ketchup with a viscosity of 50,000 cP (at 3040°C) from the hoppers to a line that fills plastic single serving sachets for fast food outlets. On the same line, plastic sachets are also filled with mayonnaise (5,000 cP), again for fast food outlets.

Aside from ease-of-cleaning, there were several important factors to consider before selecting the Bredel pumps, not least the shear thinning of these thixotropic sauces. Further

factors included the avoidance of air entrainment which could lead the sachets to burst upon filling, and the need for sterility. Sachets are in high demand in the Russian market, where glass bottles are deemed unacceptable. The same is true in Africa, which is a major export market for the plant.

Gentle handling Ultimately, the gentle, low-shear capability of Bredel pumps was put forward by the contractor that supplied the Rossi and Catelli filling system.

The recommendation was supported by referencing the use of Bredel pumps at other group plants outside of Russia.

“WMFTG has a very strong competitive advantage in the quality and performance parameters of its pumps,” says the customer’s purchasing manager “As a result, we are now standardising on Bredel pumps as the most reliable, efficient and minimal maintenance solution. This will have further site-wide benefits in terms of spares management and operator knowledge.”

The customer is now planning to upgrade another site in Russia, where Bredel pump technology will again be deployed.

For more information contact Watson-Marlow Fluid Technology Group, Tel: 01326 370370 E-mail: info@wmftg.co.uk | Web: www.wmftg.com

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APPLICATIONS ALICAT MASS FLOW CONTROLLERS POWERS MDC’S XPRESSSTICK GAS DELIVERY MODULE Gas connection module benefits from Alicat’s MCE’s high precision flow control Alicat Scientific’s MCE mass flow controllers have been integrated into MDC Vacuum Products’ XpressStick™ MFC Gas Stick. With precision control of gas flows of up to 20SLPM and onboard display, Alicat’s MCE provides gas programming functionality to the gas connection module, which links pressurized gas inputs to vacuum chambers.

The all-in-one design of the XpressStick MFC gas stick eliminates complex hardware specification in processes which include a combination of specialty gases, pressure, precise regulation, and vacuum.

Its easy programming and precise gas control system allows users to go from bottle to process in one simple step. Designed to meet ultra-high purity process requirements, the XpressStick is also offered in a stainless steel model for corrosive environments.

“Fast response time, accuracy, and reliability were all key criteria in choosing an MFC instrument for our XpressStick,” explained James Moore, MDC Vice President, Engineering & Technology. “Based on past experience with Alicat, we knew that they could deliver all three, with an integrated display that enables our all-in-one design.” With the MCE’s zero warm up time, the XpressStick is ready to control process flows in just one second, with real time mass flow, volumetric flow, absolute pressure and temperature data, fully compensated for temperature and pressure. The gas module is programmed directly through the MCE’s integrated display, with easy changes to gas type using the on-board gas calibrations.

The standard gas calibration list includes 98 gases, with an additional 32 corrosive gases on the stainless steel model. Alicat’s built-in COMPOSER™ gas mixing software can be used to compose up to twenty additional custom blends using the standard gas list. Accuracy is virtually unaffected by change in gas type, and full-scale valve range is automatically recalibrated to maintain throughput ranges.

For more information contact Alicat Scientific, Tucson, USA Tel: +1 520 290 6060 | E-mail: info@alicat.com or Europe@alicat.com or contact Tel: 01223 472804 | Web: www.alicat.com

COMPRESSOR PACKAGE SLASHES MANUFACTURER’S ENERGY COSTS BY 90% A leading manufacturer of drive train technology in the wind energy sector is saving almost £44,000 a year thanks to the installation of a BOGE compressor and pipework.

The customer’s 110kW compressor was predominantly used in air beds for lifting and shifting components, air tools and punch presses feeding the manufacturing plant.

However, three other unused factories also remain on the site due to downsizing of the UK manufacturing operation.

All three redundant factories were fully pressurised, but suffered from leaks and this cost the company £47,385 a year in power consumption.

By decommissioning the pipework feeding the three unused factories and installing the high efficiency BOGE EasyFit aluminium pipework system, BOGE platinum partner Airflow Compressors & Pneumatics was able to exchange the 110kW compressor for a 15kW package, bringing the power consumption down dramatically to just £3,450 per annum For more information contact: BOGE Compressors Ltd. Tel: +44 (0) 1484 719921 | Web: www.boge.co.uk

BELOVED BRITISH POTTERY MAKER OPTIMISES COMPRESSED AIR SYSTEMS WITH BOGE A state-of-the-art BOGE variable speed air compressed air system is saving money and energy at celebrated pottery manufacturer Emma Bridgewater’s busy Stoke-on-Trent factory.

The BOGE C25F frequency-controlled compressor and standalone refrigerant compressed air dryer with associated filtration are also helping to cut maintenance requirements dramatically and future-proofing the factory, which produces 1.3 million pieces of hand-decorated pottery annually.

A critical challenge on the project was to avoid disruption to production. BOGE distributor Aroplus installed all equipment without losing production time, or causing a disturbance.

John Nash of Aroplus explains “We used our speciallydesigned service vehicle that allows us to supply customers with an independent, clean, dry compressed air supply while their machines are being serviced or a new machine is being installed. We connected our vehicle to Emma Bridgewater’s compressed air system, isolated their plant both pneumatically and electrically so it is safe to work on, and then installed the compressed air system,” For further information contact: BOGE Compressors Ltd. Tel: +44 14 84-71992 | Web: www.boge.co.uk

HYDRA-CELL, THE PUMP FOR DE-SCALING When a major producer of heavy-duty industrial cleaning machines and jet washers was commissioned to design and manufacture a high-pressure cleaner/de-scaler for an agricultural equipment manufacturer, they turned immediately to Hydra-Cell Seal-less pumps.

The biggest pumping problem with such heat treatment de-scaling installations is the solid scale particles that invariably bypass filtration stages to some extent in such re-circulating, closed loop systems. Such abrasive particles cause severe damage to pumps that rely on close internal tolerances for efficiency. Seal wear, caused by the finest particles can be expensive and at worst catastrophic for these types of pumps.

Hydra-Cell diaphragm pumps have no dynamic seals to wear and no tight internal tolerances, ensuring long-term efficiency and reliability with no seal maintenance.

The Company had good past experience of using Hydra-Cell leak-free, low maintenance pumps but for this particular application the liquid flow requirements were substantially higher than previously encountered.

The answer was to use four Hydra-Cell T100K triplex pumps in parallel in order to achieve a flow of 681 lpm at 193 bar pressure. The pumps handle the solid abrasive particles with ease and have proved to be an exceptionally reliable solution.

Further information contact Nick Herrington, Wanner International.

Tel +44 (0)1252 816847 Email: NHerrington@wannerint.com www.hydra-cell.eu 08

PROCESS INDUSTRY INFORMER - SEPTEMBER 2017

HEALTH & SAFETY VEOLIA WATER TECHNOLOGIES UK LAUNCHES AN ENHANCED ACTIFLO® PACK RANGE FOR MUNICIPAL AND INDUSTRIAL WATER TREATMENT Veolia’s newly launched, fully standardised, Actiflo® clarifier package plant offers a compact high rate water clarification process that is used across both municipal and industrial markets for the production of drinking water and industrial process water, wastewater treatment and reuse.

The range is based on the existing Actiflo® process developed by Veolia Water Technologies (Veolia) that uses microsand and polymer in the flocculation tank to increase settling velocity and produce water free from suspended solids and other contaminants. The Actiflo® process has shown consistent and unparalleled results in handling fluctuating flows and contaminant concentrations.

Three new models have been added to the range which, along with several performance design improvements, make the process more efficient, reducing energy and chemical usage and delivering a single prefabricated Actiflo® stream flow rate up to 1440m3/hr (application specific).

With over 1,800 Actiflo® units installed worldwide, including more than 900 package plants, Veolia guarantees a high level of local services based on reliable, efficient and modular solutions and cost effective products.

Visit www.veoliawatertechnologies. co.uk/products/actiflo for full details of the Actiflo® Pack product range.

BLAST RESISTANT, NATURAL VENTILATION IS POSSIBLE Windows from Crittall-Fendor that can be left open for natural ventilation but which slam shut automatically in the event of a blast can enhance the working environment in hazardous sites without compromising safety.

The company’s BlastLine SlamShut window has a restricted opening that allows natural ventilation and also features as standard thermally enhanced glass that contributes towards energy efficiency. The reinforced steel or stainless steel frame is narrow so as to maximise natural light, ventilation and increased airflow.

In the event of an explosion the opening vent is slammed closed by blast pressure. The window is designed to be low maintenance, is finished in an anti-corrosive paint system, and features an integrated water drainage system.

Because it is openable it reduces the need for air conditioning in petrochemical facilities, offices and modular buildings. It is fitted with the SlamShut latch and locking system for security and can be supplied with an energy efficient coating.

Different fire rated options (to EN1654 and EN1560) are available and glazing can be single, double, triple, security or acoustic. It is available in a full RAL/BS powder colour range or with a bespoke finish.

The BlastLine SlamShut window has been tested to GN04-105, ASCE Design of Blast Resistant Buildings and GSA Standard.

For more information contact E-mail: jason.davidson@crittall-fendor.co.uk

THE

PRESSURE IS ON!

26-28

September

INTERPLAS UK STAND # D52

High Pressure Rotary Valve The DMN-WESTINGHOUSE HP valve with specially designed inlet is very suitable for handling granular formed products under a high pressure of maximum 3.5 bar g.

The valve has a very important advantage in air leakage: the special configuration of body, rotor and seals does not only protect product against degradation, it also does not allow any axial air leakage.

DMN-WESTINGHOUSE T +44 1249 818 400 | dmn@dmnuk.com

SEPTEMBER 2017 - PROCESS INDUSTRY INFORMER

max 3.5 bar g

Features: • Special inlet for maximum protection against product degradation • High filling efficiency • Lowest air leakage through special seals • Robust construction • Easy assembly and disassembly

www.dmnwestinghouse.uk 09

FEATURED ARTICLE

TOP TIPS

FOR SELECTING THE RIGHT PRESSURE TRANSMITTER FOR YOUR APPLICATION The variety of potential applications a n d installation locations for pressure measurement means it is difficult to set any hard and fast rules.

In this article, David Bowers, Product Manager for Pressure and Process Flow for ABB Measurement and Analytics in the UK, advises on some basic guidelines that will help to shape and narrow down the eventual choice of pressure measurement device for your application.

1. TRANSDUCERS OR TRANSMITTERS? The first stage is whether to opt for a transducer or a transmitter. Although the terms are often confused, there are several differences between transducer and transmitter devices.

A transducer creates a low-level electronic signal in response to changes in applied or differential pressure. As with transmitters, transducers feature an internal sensor that converts the applied force into an electrical signal, from which the measurement is derived.

Transducers are generally unsuitable for the harsh environments typical of many industrial applications. The transducer body is usually small and cannot easily be fitted to standard industrial piping. In contrast to transmitters, which are designed for use in industrial applications, most pressure transducers are either for niche applications or for use in laboratories.

Transducers have a number of drawbacks that make them generally unsuitable for widespread use in industrial environments. They are generally most suited to very contained environments where there is no risk of water or dust ingress, for example. They are also commonly poorly protected against the effects of overpressure or damage caused by sudden variations in process conditions.

As well as being much less rugged, transducers lack 10

include square root extraction for flow applications, totalizers, and reverse flow output function.

This minimises unwanted measurement errors and gives the transmitter a very stable output.

Operators can also calibrate the transmitter over a range of input pressures, enabling one unit to be used to measure a range of spans.

2. CONSIDER YOUR OPERATING ENVIRONMENT Modern pressure transmitters should be able to comfortably handle adverse temperatures, humidity and vibration conditions provided Multivariable pressure transmitters offer significantly lower installation costs through the need for fewer devices and a reduction in the amount they are within design specification limits. of cabling and I/O devices required Minimising the effects of such conditions will help to maximise the sufficient energy to transmit a signal over the same distance that transmitters can. There is also a much wider range of transmitter’s operational life. temperature transmitters certified and available for use in a. Temperature hazardous areas and areas with extremes of temperature Most electronic transmitters are suitable for ambient conditions ranging from lows of –20°C to –40°C to highs and humidity.

Compared to transmitters, most transducers also have offer of 60°C to 85°C, although this may not always be the case a very limited amount of adjustability and have inferior for certain types, for example where special filling materials stability and measurement accuracy. They offer limited have been specified for the transmitter. compensation for variations in process or ambient conditions An application’s ambient temperature conditions can such as temperature and are often fixed range devices, which significantly affect transmitter accuracy. This can include not just the inherent background temperature of the installation can only measure within a set span.

Transmitters for measuring pressure or differential pressure, location, but also heat generated from a process or radiated on the other hand, comprise two basic parts. A primary from surrounding process equipment and piping. element directly or indirectly in contact with the process High temperatures can have a detrimental effect, potentially collects the measurement, while a secondary electronics causing premature component failure. Exceeding the device’s package translates the output from the primary element into parameters can have a significant effect on performance. Low a communications signal enabling it to relay information temperatures, for example, can cause fill fluids to become either via a fieldbus protocol such as Foundation Fieldbus or more viscous, whilst high temperatures can cause them to vaporise. Variations in ambient temperature and pressure Profibus, or a standard 4-20mA dc output signal.

These secondary electronics are highly sophisticated and can also have an impact, particularly if the transmitter’s perform many functions that transducers cannot. Variations calibrated span is a small proportion of its upper range limit. in process or ambient conditions measured by the primary To overcome these problems, the temperature of the sensor, for example, can be automatically compensated for transmitter should ideally be kept as close to room before being converted into a 4-20mA signal. Other functions temperature as possible for maximum life expectancy.

PROCESS INDUSTRY INFORMER - SEPTEMBER 2017

Careful consideration also needs to be exercised when installing a transmitter outdoors.

Atmospheric conditions such as direct sunlight or high winds can cause heating or cooling of transmitters, which can adversely affect their operation. b. Humidity Vapour caused by humid conditions can sometimes penetrate the transmitter housing and attack sensitive components. Prolonged exposure to high humidity can also result in corrosion of the transmitter housing and mountings. Transmitter housings are designed to protect electrical components against the ingress of moisture caused by humidity. However, even housings with an IP rating for moisture or hosedown applications can encounter problems if the housing cover is removed during commissioning, operation or maintenance.

Some manufacturers employ various methods such as using potting material to protect transmitter electronics against humidity. Whilst they can delay humidity problems, these methods do not provide a long-term solution. The only true prevention against humidity is for the transmitter housing to be hermetically sealed. c. Vibration Avoid installing a transmitter in an area subject to prolonged or unnecessary levels of vibration, as this can reduce the service life of the transmitter. To protect against potential damage or bmalfunction caused by vibration, transmitters should be mounted in a location that will be unaffected by vibration when a process is in operation.

ideal for a range of

3. TWO WIRE, DIGITAL OR WIRELESS?

solution in applications

There are many different types of transmitters, each of which use different techniques to transmit a signal. The role of the transmitter is to amplify and condition the signal so that it can be relayed over long distances to the control room or to localised devices such as indicators, recorders and controllers without deterioration or interference.

For the majority of applications where power is readily available, the two-wire transmitter, which uses a 4-20mA current both to operate its circuitry and to relay a signal, is often the most practical choice. Because the current is protected against the effects of changing resistance along the line, signals can be relayed over long distances.

Where transmission of accurate data or large volumes of data (such as diagnostic information) is essential, the best choice may be to opt for digital transmitters. Digital signal transmission allows much more data to be relayed between the instrument and the control room. Fieldbus technology such as Foundation Fieldbus and Profibus PA (for process automation) and DP (for discrete or factory automation), enable data to be quickly relayed to the control room, where it can be used by the control system to make informed and immediate operational and management decisions.

Depending on the application, a WirelessHART enabled device may provide an alternative solution.

WirelessHART provides the ideal solution for any application where it is either uneconomical or impractical to have a wired device. The ability to remotely interrogate a wireless device from up to 200 metres away also eliminates the need for operators and maintenance staff to have to visit potentially unsafe areas, such as high up on a column, for example.

With wiring and installation costs accounting for almost 50 percent of the total cost of a device, it makes both financial and technological sense to use wireless devices wherever possible.

Wireless devices used to be largely confined to specialist applications in remote installations, such as water distribution or oil and gas. However, the arrival of the WirelessHART protocol means industry now has an international standard that enables wireless instruments to communicate a wealth of standardised information throughout plant networks.

Reliability is crucial, and the meshed architecture of WirelessHART networks provides a robust solution that can reroute information to bypass malfunctioning nodes and provide a secure service.

4. IS THE APPLICATION HAZARDOUS? Any electronic instrument either stores electrical energy or is a source of electrical energy.

In certain conditions, this energy, if discharged, could ignite any accumulated mixtures of flammable gases, combustible dusts and ignitable fibres that may be present.

Caution needs to be exercised when locating any electronic pressure transmitter in a hazardous or potentially hazardous location. There needs to be careful analysis of the conditions that might arise under normal operating conditions and/or fault conditions. Attention also needs to be given to preventing ignition of any hazardous atmospheres that might be present.

Various international standards, such as ATEX, FM, IEC, INMETRO, GOST, NEPSI and SAA set out various measures for assessing the risk posed by hazardous environments and the steps that need to be taken to minimise the risk of ignition.

5. DO YOU NEED A REMOTE SEAL? Remote seals are used to isolate pressure transmitters from conditions that will either shorten their operational life or dramatically affect their performance.

Comprising a transmitter body, a capillary and a seal element incorporating a liquid filled diaphragm, remote seals can be tailored to the application at hand. As such, they are SEPTEMBER 2017 - PROCESS INDUSTRY INFORMER

pressure measurement applications involving process fluids which are: - Highly corrosive - Dirty, viscous or laden with solids that can block or foul the impulse lines - Likely to solidify in the impulse lines or the transmitter body -

Extremes

of

temperature They also present a where

process

wetted materials are required, such as PTFE anti- stick coating, or materials for highly

Using remote seals helps protect the performance of pressure transmitters by isolating them from arduous or potentially destructive process conditions

corrosive fluids, such as Hastelloy. To have an entire pressure transmitter manufactured from such materials would be prohibitively expensive. Since only the parts that are in contact with the process need to be made from such materials, remote seals can help to greatly reduce this cost.

Remote seal transmitters can also provide an ideal solution for hygienic processes, such as in the pharmaceutical and food and beverage industries, where it may be undesirable to have a pressure measurement device in direct contact with the product.

6. WHAT ELSE DO YOU WANT TO MEASURE? For certain applications involving the measurement of gases or fluids subject to rapid density changes, it may be advantageous to use a multivariable pressure transmitter device. These devices offer a combined solution for the measurement of flows of liquids, steam or gas with absolute pressure and temperature compensation, ideal for calculating changes in flow density.

Previously, the main method of calculating flow density involved deriving measurements against known standard conditions. Though fine for applications with constant or relatively minor deviations in process conditions, this approach is less effective for installations where high accuracy measurement is required or where fluctuations in the flow medium are likely to occur.

For example ABB’s multivariable transmitter, the combination of multiple measurements into one device enables users to select appropriate accuracies for their applications ranging from 0.04% to 0.075%.

Incorporating multiple forms of measurement into one unit, as well as the ability to use the signal converter as a flow computer, can also significantly reduce installation costs savings on installation through the need for fewer devices and a reduction in the amount of cabling and I/O devices required.

SUMMARY When it comes to pressure measurement, choosing the right equipment from the outset can have a major impact on accuracy and performance. ABB has wide experience in the manufacture and supply of pressure measurement solutions derived from a host of industrial applications worldwide.

11

BEARINGS

FILTRATION & SEPARATION

PRECISION BEARING MANUFACTURER ANNOUNCES NEW WEBSITE Precision ball bearing manufacturer, HQW GmbH, is pleased to announce the launch of its newly developed website, hqwbearing.de . With a simple to navigate structure and detailed information about the company, products and application sectors, the new site has been designed to offer a user-friendly experience for visitors wanting to know more about HQW’s

range of high precision miniature ball bearings.

The new website includes a wealth of information on the company’s range of miniature bearings, which are available in both angular contact and deep groove configuration in sizes between 1mm and 42mm outer diameter (OD). As the foundation of the HQW product range, miniature bearings are found in application areas as diverse as aerospace, automation and Food Beverage, Flow Meters through to dental handpiece turbines and precision electric motors. A full breakdown of these market sectors can be found on the website, with each page listing the technology features and benefits that HQW miniature bearings offer.

HQW plans to continually enhance and evolve the website so visitors are always provided with the most current and relevant information. Future plans include the provision of German language pages, social media links and a news & events page which will outline current company information and opportunities to meet with the team.

We encourage visitors to explore the website at www.hqwbearing.de

PLASTIC BEARINGS MAKE THE GRADE SPECIALIST BEARINGS PROVIDER LAUNCHES PLASTIC BEARINGS RANGE Miniature and specialist bearings and relubrication provider, SMB Bearings, has launched a range of plastic bearings that provide nonmagnetic, chemical resistant options to a variety of industries and manufacturers.

The bearings provide a costeffective solution to a range of niche markets, where traditional bearings would not be appropriate.

Bearings are available in a variety of materials, the most common being chrome steel and stainless steel. However, these materials are not always appropriate for applications across industries like the food and beverage or pharmaceutical sectors.

For instance, bearings used across the food and beverage industry need to be able to handle regular wash-downs and steam cleaning as well as potentially corrosive fluids and materials, yet they must also meet the industry’s hygiene standards.

Our range of plastic bearings are ideal for these types of applications,” Chris Johnson, managing director at SMB Bearings said. “Plastic bearings are non-corrosive and are usually unlubricated which makes them ideal for commercial food equipment. Acetal resin is the standard material but alternatives are available for greater corrosion resistance in aggressive environments such as the chemical industry.

“While plastic bearings are suitable for a wide array of applications, they do have limitations,” Johnson explained. “As the material is much softer than steel, plastic bearings should only be used in low load applications. However, many manufacturers don’t realise that the bearings can be paired together to increase their overall load capacity.”

The SMB Bearings plastic bearing range is available in a range of popular metric and imperial sizes, starting at 3mm.

To discuss your bearing application requirements, contact the SMB Bearings sales team on Tel: +44 (0)1993 842555 or email sales@smbbearings.com.

12

RANSOM NATURALS CHOOSE AXIUM PROCESS TO DESIGN AND BUILD A MOBILE ATEX ZONE ONE RATED MEMBRANE FILTRATION SYSTEM

Ransom Naturals Ltd (RNL), part of the OBG Pharmaceuticals Group and a leading developer and manufacturer of natural products and extracts to the Pharmaceutical, Healthcare, Cosmetic, Food and Drinks industries has been working closely with membrane filtration specialists, Axium Process, to develop a system that would process an aqueous or solvent based extraction process to reliably remove suspended solids and bioburden from raw plant extracts to meet product specifications.

Following previous experience with extraction technology involving membranes, Ransom Naturals Ltd commissioned Axium Process to design and build a mobile ATEX Zone One rated membrane filtration plant able to move to a number of positions in their factory.

Membrane technology provides excellent results for the removal of bacteria, yeasts and moulds from extracts and Ransom Naturals chose Axium Process as their preferred supplier due to their experience of natural extract separation from a wide range of products utilising membrane filtration technologies and its ability to design and build ATEX rated systems. The system which is manually operated for batch operations with safety cut outs for level and temperature was designed to EudraLex (Vol 4, chapter 3 Equipment) and ASME BPE standards and was certified by an ATEX Notified Body. The plant which was finished to pharmaceutical standards was designed and built in house; the system fully installed, commissioned and operator training carried out by Axium’s specialist engineers in a very short window.

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

HEAT TRANSFER & ENERGY BALTUR BRINGS IT’S MOST POWERFUL BURNER TO THE UK Italian burner manufacturer Baltur has recently announced the launch of its most powerful packaged monoblock gas burner ever developed, available exclusively in the UK through EOGB Energy Products Ltd. The TBG 2000 ME modulating burner has a maximum thermal output of 20MW and offers an impressive turndown ratio (range between maximum and minimum output) of 1:7, which is one of the best performances recorded in an industrial application.

Additional benefits include easy maintenance, a compact and lightweight frame, better control, low electrical consumption, and reduced noise emissions.

EOGB has been Baltur’s sole UK distributor since 2000 and stocks the entire range of oil, gas and dual-fuel burners for commercial and industrial applications alongside its own XSeries domestic oil burner range and new low NOx modulating burner – Sapphire.

Martin Cooke, Technical Director at EOGB, said: “We’re delighted to bring the Baltur TBG 2000 ME to the UK market. Not only is the technology at the very forefront of burner innovation, it will provide a cost-effective and highly energy-efficient solution for any industrial or commercial heating system.”

EOGB is one of the UK’s leading manufacturers and distributors of one stage, two stage and fully modulating burners for domestic, commercial and industrial applications.

For further information on EOGB visit: www.eogb.co.uk PROCESS INDUSTRY INFORMER - SEPTEMBER 2017

FEATURED ARTICLE

IMPROVING THE EFFICIENCY OF COMPRESSED AIR SYSTEMS

There is no doubting the costs involved in running an energy intensive compressed air system.

However, it is possible to reduce a compressor’s energy consumption – and therefore its running costs while at the same time boosting its productivity by applying sensible control measures. BOGE’s Mark Whitmore explains.

I

t is all too easy to be drawn into a belief that compressed air is free. It is a site commodity after all, and thanks to modern compressor technology, air is always available to power tools, actuators or other process equipment. Of course, it is not free, and may indeed be a significant factor in overall site utility costs. What many plant managers fail to understand is that there is huge potential to improve the efficiency of compressed air production and delivery. As well as saving energy, reducing compressed air wastage by tightening up on control measures not only cuts costs, but also improves reliability and boosts productivity. Indeed, the efficiency of compressed air systems is largely determined by the effectiveness of their controls.

But what do we mean by ‘effective controls’? Effective compressed air system controls match the compressed air supply with system demand, and compressor manufacturers have developed a number of control measures to achieve this. At its simplest, the compressor motor is turned on or off in response to the discharge pressure of the machine. Typically, a simple pressure switch provides the necessary motor start/stop signal.

A marginally more sophisticated approach called load/unload (also known as constant speed control) allows the motor to run continuously, but unloads the compressor when the discharge pressure is adequate. Modulating controls can also be used to throttle the inlet control, varying the compressor output according to demand.

Variable speed drives (VSDs), on the other hand, provide closer control of motor speed (and therefore energy consumption) to deliver a more constant supply pressure; they also avoid the large inrush currents experienced when starting up large ac motors.

But the control of compressed air systems is not the only issue affecting costs; downtime can also have a catastrophic impact on production schedules. The reliability of a compressed air system is

SEPTEMBER 2017 - PROCESS INDUSTRY INFORMER

largely determined by its age and state of maintenance. Depending on frequency of use and machine type, a typical compressor life cycle is ten to 15 years before it is no longer economically viable to repair and requires replacement.

Some oil-free models will run for 20 years or more, but the performance of all compressors will eventually degrade over time. A major overhaul involving a motor rewind and refurbished compressor element might keep things running, but the unit’s efficiency will be reduced, leading to higher running costs. A new compressor is likely to be more reliable and efficient, and the use of VSDs will ensure greater energy efficiency. A VSD controlled compressor can provide significant energy savings - up to 50 per cent may be possible in some cases.

Modern compressors are more reliable and can run for extended hours between maintenance interventions. Moreover, they deliver cleaner air, thanks to advances in air filtration that will also extend the lifespan of downstream, air-powered equipment. Retaining older plant assets beyond their useful life – that all too frequent ‘make do and mend’ mentality - does not make good economic sense, particularly at a time of soaring energy costs.

MEASURING COMPRESSOR PERFORMANCE There is a well-worn management maxim that states: ‘you cannot manage that which you do not measure’. There are many ways to measure the performance of a compressed air system; for example, a data monitoring device might be deployed to track compressor and pipework performance, including upcoming servicing requirements based on actual usage. This would provide an early warning of potential compressor or air delivery system problems, as well as arecord of the unit’s energy consumption over a period of time, plus an analysis of its energy efficiency performance.

Here at BOGE, for example, we offer an air compressor monitoring system called ‘airstatus’, which includes a fault and maintenance indicator, remote data polling and server-based data retention for up to 24 months. Offering remote viewing via an internet connection, air status measurements include hours run, indicated faults, and both air and electrical power consumption. And for those maintenance personnel on the move, there’s an app for IOS and Android operating systems that provides system status and alarm indications on a smartphone screen via email and/or SMS. Most compressor manufacturers and consultants offer a one-week audit service involving a site visit and installation of monitoring equipment to measure parameters such as air flow, air pressure and air quality, and provide a report at the end of the period. Some also offer a fixed, remote monitoring system, which will form a permanent part of their compressor installation.

Anyone conducting a compressed air energy assessment should follow the procedures outlined in ISO 11011:2013. This international

standard sets requirements for conducting and reporting the results of a compressed air system assessment that considers the entire system, from energy inputs to the work performed as a result of these inputs. The standard sees compressed air systems as three functional subsystems: • supply, which includes the conversion of the primary energy resource to compressed air energy; • transmission, which includes movement of compressed air energy from where it is generated to where it is used; • demand, which includes the total of all compressed air consumers, including productive end-use applications and various forms of compressed air waste.

The standard also outlines requirements for analysing the data from the assessment, reporting and documentation of assessment findings, and identification of an estimate of energy saving resulting from the assessment process. It also identifies the roles and responsibilities of those involved in the assessment activity.

THE IMPORTANCE OF MAINTENANCE Unless it is periodically and properly maintained, the performance of a compressed air system will rapidly degrade; it will also become less energy efficient and therefore more expensive to operate. Properly conducted periodic maintenance will ensure that the system continues to coperate reliably and at peak efficiency. Poor maintenance, on the other hand, is likely to result in increased energy consumption due to lower compression efficiency, air leakage or pressure variability, and may also lead to higher operating temperatures, contaminated air streams and poor moisture control.

On a typical industrial site, air-powered production systems derive their energy from high pressure air stored in the air delivery and distribution system; air compressors simply replenish this system as air is consumed. In other words, the energy needed to perform tasks involving compressed air comes from air already stored in the site’s air delivery pipework. The efficiency of a compressed air system is thus affected as much by how air escapes the system as by how it is generated in the compressor itself.

Matching supply with demand requires that both air generation and storage are properly maintained. That means fixing leaks in pipework as well as servicing the compressor itself – a task that can be undertaken either in-house or carried out by experts capable of maintaining and servicing all makes of compressor, as well as their ancillary equipment on a 24/7 basis.

The Chartered Institution of Building Services Engineers sums up the whole maintenance issue rather well: “It is a false economy to ignore maintenance on any type of compressor. It is recommended that manufacturers, or their accredited agents, are used for service work and that genuine spare parts are used.”

We couldn’t agree more!

13

FEATURED ARTICLE

PREPARING FOR HAZARDOUS

CHEMICAL EXPOSURE IN THE WORKPLACE

By Paul Thorn, the MD of Safety Eyewash

If you work with hazardous, corrosive chemicals, it’s essential to take steps to ensure that you employees and colleagues can be kept safe during an emergency.

With any luck, you’ll go your entire career without having to deal with an emergency situation; however, it’s important to be well prepared should the unthinkable happen.

In this article, we’ll take a look at emergency eyewash and shower facilities and talk about the importance of staff training. First, here’s a rundown of some of the most common hazardous chemicals.

CORROSIVE SUBSTANCES IN THE WORKPLACE The following materials are considered harmful, corrosive substances. While this list is not exhaustive, it should give you an indication of the sorts of chemicals that are included: - Oxidizing agents (e.g. hydrogen peroxide) - Strong acids - Strong bases - Dehydrating substances (e.g. quicklime) - Alkylating agents (e.g. dimethyl sulphate) - Organic acid halides (e.g. acetyl iodide) - Organic halides (e.g. chloroform) - Certain halogens (e.g. iodine, chlorine, bromine, and fluorine) - Molten metal - Petrol - Certain organic compounds (e.g. carbolic acid) - Battery acid - Anhydrous ammonia - Pesticides, herbicides, insecticides etc.

- Chlorine (bleach) - Formaldehyde If you use these substances (or substances like them) in your workplace, then you need to ensure that your workforce have access to emergency decontamination equipment.

Workplaces that benefit from the installation of emergency decontamination equipment include the following: - Garages - Warehouses - Industrial laboratories 14

- University laboratories - Petrol stations - Universities, schools and colleges - Processing plants - Factories - Foundries - Workshops - Chemical plants - Agricultural sites and farms

THE RIGHT EQUIPMENT When it comes to protecting your workforce from hazardous chemical spills, there are two essential pieces of equipment: drench showers and eye wash stations. While emergency washing facilities cannot prevent accidents from happening, they can mitigate the damage that occurs as a result - reducing the risk of scarring and permanent disability, and potentially saving lives.

Drench showers - also known as safety showers, decontamination showers or emergency showers - are much like the shower you use at home. They are designed to discharge water at a specified rate and for a specified amount of time in order to thoroughly drench the user and remove as much of the harmful substance from their body as possible.

Emergency eye wash stations look a little like water fountains. Each unit normally comes with a drainage bowl and two spray nozzles - one for each eye. Once activated, the unit will discharge tepid water into the user’s eyes in an effort to flush out any harmful material and prevent further injury.

Most of these fixtures are permanently plumbed in, although portable units are also available for businesses that undertake site work, especially in locations with no access to clean running water.

Many units can also be supplied with optional drench hoses. These deliver a targeted stream of water that can be used to sluice injured workers who are incapacitated, or to hone in on specific areas of contamination.

PROCESS INDUSTRY INFORMER - SEPTEMBER 2017

LOCATION, LOCATION, LOCATION In an emergency situation that involves exposure to hazardous chemicals, time is truly of the essence. Once an injurious substance comes into contact with skin, the harm it causes becomes more serious with each passing second; that’s why it’s essential that your emergency equipment is easy to locate during an emergency.

The ANSI Z358.1 regulations, which cover the manufacture, installation and use of safety eye wash equipment and drench showers, state that decontamination must be installed on the same floor as, and no more than a ten-second walk from, the hazardous area. The equipment must also be clearly signposted, and the surrounding area well lit.

THE IMPORTANCE OF TRAINING Of course, safety equipment is all well and good - but if your staff don’t know how to use it, then it’s as good as useless. Adequate staff training is also mandated in the ANSI regulations.

Training should be provided when a new item of equipment is installed, and also whenever a new employee joins your workforce. Training new employees is also an excellent opportunity to provide ‘top-up’ training to the rest of your workforce.

At the outset of training, you should show your employees where the safety equipment islocated before walking them along the route they would take to reach it.

Next, ask one worker to lie on the floor close to the hazardous area and shout for help; two others can then come to the aid of their ‘injured’ colleague and help them to the decontamination shower or eye wash unit.

When training your employees on the use of safety eye wash units, it can be useful to have an employee wear a blindfold and attempt to make their way to the eye wash station with the assistance of a colleague; this will help your employees prepare for an emergency situation where the eyesight of the injured party has been compromised.

EMBARRASSING BODIES One major issue surrounding the use of emergency decontamination showers is that the user must remove all of their clothing in order for the treatment to work properly - and yet, the taboo against public nudity can be so powerful that injured workers will remain clothed and risk severe injury rather than strip off in front of their co-workers.

Even if the contamination is mild, the injured party’s clothing can become saturated with the harmful substance and keep it in close contact with their skin - and as we’ve discussed, the damage inflicted by corrosive substances increases substantially over time.

Similarly, many people are averse to ‘making a fuss’ in the workplace. Activating emergency equipment - especially drench showers - can attract a great deal of attention; you’d be surprised at how many people would rather put their lives in danger than risk ‘losing face’ in front of their colleagues.

During training, you should impress upon your workforce the importance of removing hazardous chemicals from the surface of the skin and remind them of the dire consequences of prolonged exposure. These consequences include permanent scarring, disfigurement, damage to nerves, muscle and tendons, severe pain, and even death.

SHOULD I BOTHER? If all of this sounds like a lot of effort - and expense - then consider this: according to the Health & Safety Executive, some 621,000 British workers suffered an injury in the workplace, and of these, around 200,00 led to three days of absence from work. A further 152,000 led to seven days of absence.

Employee injuries can also lead to court costs, fines and workplace injury compensation, all of which can be extremely costly. Installing emergency decontamination equipment in your workplace doesn’t just fulfil your ethical obligation to your employees - it also makes good economic sense.

PREVENTION Prevention, as they say, is better than cure. Accordingly, you should ensure that your staff are well trained in the handling of hazardous chemicals and all associated machinery and equipment.

Hopefully, they’ll never have to use a drench shower or eye wash station at all.

SEPTEMBER 2017 - PROCESS INDUSTRY INFORMER

PROCESS CONTROL NEW RANGE OF PASSIVE GAUGES & CONTROLLERS FOR SPECIALIZED HIGH VACUUM APPLICATIONS Edwards is introducing a new range of passive gauges and controllers to meet the needs of those customers with specialized applications across the high energy physics and ultra-high vacuum sectors. The new range of gauges and controllers are ideal in a wide range of applications, from UHV systems to process industries, or wherever the use of an active gauge is not possible.

This new range comprises Pirani, Penning and both Bayard-Alpert and Extractor Ion gauge heads. These are used in conjunction with a passive gauge controller to display pressure and offer an interface for the user. Pressure ranges of 10-9 to 1000 mbar are covered by the PGC201 controller together with Pirani and Penning gauge, and for pressure ranges of 10-12 to 1000 mbar are covered by the PGC202 controller together with Pirani and Ion gauge.

Full details can be found at www.edwardsvacuum.com

THE NEW SLD FUNCTIONAL SAFETY PROGRAMMABLE LOOP DISPLAY Moore Industries announces the release of the SIL 3 capable SLD Functional Safety Programmable Loop Display for use in Safety Instrumented Systems (SIS). The SLD has been certified by exida ® with full Functional Safety approval after rigorous evaluation to ensure conformance with strict IEC 61508 standards for safety-related applications.

The SLD is part of the FS Functional Safety Series family and the loop-powered SLD provides reliable and accurate display of real-time process status in mA, percent, or any designated 5-character Engineering U n i t s (EGU). Built for Safety Instrumented Functions (SIF), the SLD can be taken out of the loop with the –LMD option (Loop Maintenance Diode) without affecting the integrity of the safety function.

The SLD Functional Safety Programmable Loop Display is DTM programmable with user oriented basic configuration for fast and accurate setup. The SLD can be programed with any FDT compliant host or program such as PACTware utilizing Moore Industries’ DTM and USB communication cable.

DTM programmability allows the SLD to be custom scaled to display percent or scaled directly in engineering units to show process measurements such as pressure, temperature, level, or flow. Additional settings for display such as span, zero, input range, display range, and filtering frequency are easy to program. The free software allows users to select square root or linear curve from the library, or quickly create a custom one or even import a curve from Microsoft Excel.

The SLD flexibility doesn’t end there; it is loop-powered using less than 2.3 Volts, includes robust RFI/EMI protection and has an easy-to- read display with two rows of large characters. With 360 degree mounting, the SLD can be mounted at any angle in almost any environment using one of the Moore Industries’ explosion-proof and flameproof housings..

SIL 3 capable third-party certified SLD Functional Safety Programmable Loop Display is the perfect reliable solution to accurately display process status in a safety loop. The SLD has superior accuracy reading any 4-20mA signal, displays information with phenomenal accuracy of ±0.012% of input scale, and flexible enough to mount anywhere. The SLD continues to support Moore Industries’ reputation for reliability and customer satisfaction with exceptional accuracy and longterm stability with up to 5 years between scheduled calibrations.

For more information contact Moore Industries, Crawley, West Sussex.

Tel: 01293 514488 | E-mail: sales@mooreind.com or visit www.miinet.com 15

FEATURED ARTICLE

THE INDUSTRY PIPELINE:

THE EVOLVING WORKFORCE, TECHNOLOGY & OPERATIONS

By Martin Walder, VP Industry at Schneider Electric Industries today are under pressure from tighter regulations, increasing market speed and volatility, and the need to modernise ageing systems. In order to keep pace, our industrial environments must adapt to improve agility, attract new talent and provide employees with the insight they need to maintain productivity. While Industry 4.0 and the Industrial Internet of Things (IIoT) are becoming two of the most overused industrial automation buzzwords today, they serve as a positive reminder that we must advance.

U

nderstanding the potential that the IIoT and automation technologies hold in helping businesses to move more quickly and avoid falling behind the competition, is a critical first step. Applying this potential in order to futureproof existing environments, is the second important step. In order to both understand and apply new technologies effectively, businesses within the industry market must consider the impact of operations, technology and people in the workplace and how these impact on success.

KEEPING PACE Today, industrial operations must respond to market changes in

real-time. Critical business variables have begun to fluctuate with more frequency and the price of electricity might change every 15 minutes. This is impacting the production value and costs of an operation. In order to overcome this, process designs need to be changed by improving agility. For automation systems to play a role in this, they must be designed from their inception to be extremely agile and flexible enough to process change quickly and easily. As these process changes are implemented, object-based industrial service-orientated architectures can help companies to adapt flexibly, future-proofing their operations while maintaining the operational integrity of their plants.

EVOLVING FOR THE TIMES Using modern process automation systems also future-proofs the technology in use. The most effective automation systems embody a ‘continuously current’ approach, allowing plants to evolve to the latest state-of-the-art technology, while preserving existing hardware, software and applications. This approach supports the notion that teams must accommodate change by introducing new solutions alongside existing applications, rather than conducting a ‘rip and replace’ exercise. This ensures greater business control and drives the evolution towards a smart environment that is more efficient, safe and sustainable. While many see the IIoT as a revolution, in reality it is an evolution of technologies and functionalities developed by visionaries over a decade ago. Therefore, rather than scrambling to replace existing technology, taking a considered approach to update existing investments is essential.

MANAGING FOR THE FUTURE Added to these challenges, across all industries today there are fewer and fewer skilled operators inside the plant, as the older, expert workforce moves into retirement. This creates a challenge

for both attracting and retaining talent. New recruits naturally seek employers with modern working practices and the latest technology. That means industrial organisations must empower them with the intelligence they need to be productive and the tools to make their experience richer, irrespective of where they are. By using industrial automation applications, businesses can provide simpler, easier to use, and deeper insight to make plants user-centric (not machine). Furthermore, enabling employees to work using a mobile device provides better connectivity, with instant access to their system and plant floor.

Once industry organisations have hired new talent, they face a second challenge. They must now ensure that the intellectual property and operational insight from the ‘grey market’ is available to inform a new generation of engineers. This requires the use of software to capture and embed IP into the system environment before employees retire. Organisations can then build on this by combining operator training simulators and contextualised virtual reality training to help new operators achieve certification levels quickly. In fact, by embedding lifetime training capabilities into the online environment (using performance feedback and prediction software), new operators can actually reach higher levels of performance than their predecessors.

NOW MORE THAN EVER Those who begin making adjustments to the way they operate now, will be much better equipped to deal with the IIoT. By phasing in new processes and tools to complement existing structures, industry businesses the world over can create smart environments that are well connected, optimised to processs change and meet fluctuating market demand. Manufacturing in particular is undergoing significant technical change, hence future-proofing systems to maintain momentum and remain competitive, has never been more critical.

AUTUMN EDITION 2017

FOREWORD Welcome to the Pump Industry News and I hope you have all enjoyed a pleasant summer. Since our last edition we have had a UK General Election and now have a Conservative hung parliament which surprised many.

Unfortunately a hung parliament does not portray a strong government in power and it is hoped that this will not affect the Brexit negotiations with the European Commission , only time will tell.

There is still continued uncertainty in many sectors which is holding up potential investment, this being said the BPMA are receiving reports that some areas within our industry are seeing an improvement in orders booked and it is hoped that this will continue in the coming months.

On a brighter note we have actually seen some traction with the National Measurement Regulatory office (NMRO) with regards to market surveillance on circulator Pumps . They have tested many of the pumps we identified and are now moving into a phase of visiting these companies and removing non- compliant products from the market.

Regards Peter Reynolds BPMA President

IN THIS ISSUE...

- News from the BPMA & Members - Our popular Q & A Solutions Form Editorial articles: - How will the Pump look in the future?

- Meeting challenges with Cavity Pumps - EU Compliance for booster sets

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TRAINING BPMA TRAINING

CITY & GUILDS BPMA COMPETENCY ELECTRICAL COURSE (3 DAY) £ 495.00 + VAT per delegate per course NEXT DATE: 3 - 5 October 2017 This three-day course, designed specifically to assist nonelectrical employees prepare themselves for cross trade working, and to help companies comply with the requirements of current legislation regarding the use of such people for minor electrical tasks.

Course Objectives: After completing the course, students should be able to: • Recognise safe working practices (related to electricity in the workplace) • Work within the requirements of current electrical legislation (relating to topics covered) • Understand the fundamental principles of electrical energy • Perform routine electrical tasks at a basic level • Perform safe isolation of electrical circuits • Enhance their workplace skills • Relate to electrical circuit diagrams Course Costs This is a Three day course held at our offices in West Bromwich and the total cost of the course including notes, buffet lunch on all three days and a certificate of completion is Email s.smith@bpma.org.uk for booking form Places are limited

CPSA (Certified Pump System Auditor) - an industry specific professional qualification developed by the BPMA (British Pump Manufacturers Association Limited) which is already an established and highly regarded body within the industry.

The objective of the scheme is to help improve the levels of professionalism in the sector by creating a universally recognised and respected industry ‘standard’ for individuals assessing the performance of a pumping system.

The 4 day course will take place between: Monday 20th November-Thursday 23rd November 2017. held at The Park Inn, Birmingham West and includes 3 nights B & B accommodation Who should attend and what is involved?

CPSA is open to any competent engineer.

To successfully achieve the CPSA designation (and the benefits that accrue), candidates must do all of the following: •Attend a 3-day Pumping System Requirements and Analysis training course and pass an examination.

•Attend a 1-day course covering both the ISO 14414 Standard for Energy Assessments of Pump Systems and Pump System Optimisation •Carry out a Pump System Audit in accordance with ISO 14414.

•Produce a Pump System Audit report in accordance with ISO 14414.

•Demonstrate active involvement in the industry.

Who will benefit from taking this course?

•Pump engineers (sales, service, commissioning etc).

•Upper and middle management.

•Working for a manufacturer, distributor, consultant, contractor or end user in the Pump industry, who is involved in pumping equipment related products and services.

• Interested in personal growth, ambitious, inspirational and competitive.

Key Benefits •Improve your personal competitive position.

•Become more effective in your role •Recognition of your pump industry specific knowledge.

•Gain industry recognition by achieving a qualification that is accepted and respected by key employers, industry bodies and your peers.

•A unique qualification for staff specific to the pump industry.

•Compete more effectively through having a better qualified, more knowledgeable and more professional workforce.

•Increase motivation and engagement amongst key customer facing employees by developing their own skills and knowledge as well as encouraging and facilitating their own personal and professional development.

Certification Engineers who are trained in accordance with the CPSA requirements will receive the following certification: •A certificate from the US Department of Energy (DOE) confirming they have become a “Qualified Pumping System Specialist”. In addition their name will be listed on the DOE website.

•A certificate from the BPMA stating that the engineer has completed a 1/2-day course on ISO 14414 Standard for Energy Assessments of a Pumping System.

•A certificate from the BPMA stating that the engineer has completed a 1/2-day Pump System Optimisation course.

For more information and availability on any of these courses please email Steve Smith on s.smith@bpma.org.uk or go to www.bpma.org.uk to download a BPMA Training Guide

2017 BPMA TRAINING CALENDAR For further information relating to the BPMA please contact British Pump Manufacturers Association, National Metalforming Centre, 47 Birmingham Road, West Bromwich B70 6PY, UK Tel: 0121 601 6350 Fax: 0121 601 6373 E-mail: enquiry@bpma.org.uk or visit our website: www.bpma.org.uk The BPMA takes no responsability for the statements, claims or opinions expressed in this Newsletter

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SEPTEMBER 25 Sept.

Module One - Pumping Fundamentals 26 Sept.

Module Four - Pump Systems OCTOBER 3 – 5 Oct. Basic Electrical Competency (3 day)

NOVEMBER 6 Nov. Module One - Pumping Fundamentals 7 Nov. Module Four - Pump Selection 20 – 23 Nov CPSA Certified Pump Auditor Scheme (4 Day including B & B Accommodation)

Booking forms for all these training course can be downloaded by going to www.bpma.org.uk or you can email s.smith@bpma.org.uk

BPMA GOLF DAY 2017

The 2017 BPMA Golf day took place this year on 25th May, on the Bainbridge Course at Heythrop Park, located 12 miles north of Oxford in the Cotswolds proved a challenge for most of our

golfers The 7088 yard par 72 course meandering over ridges and through valleys studded with ancient woodland, lakes, and streams proved a challenge for our 16 teams.

With so many teams entered this year and to speed things up slightly players teed off from both the first and tenth tees at 10-minute intervals.

The day began with the course bathed in glorious sunshine, something players from recent BPMA golf days were unprepared for, as rain, and on occasions torrential rain has become something of the norm. Sensing this our friends at Croner sponsored the event with free umbrellas for all our players, something that surely had an influence on weather!

Following an excellent dinner served in the Enstone Suite overlooking the landscaped gardens Steve Schofield , BPMA Director & Chief Executive thanked all of the sponsors for their continued support of this annual event.

Ken Hall, Managing Director of Calpeda UK then proceeded to give out the individual team scores and to thank all the

players for making this year’s event such a huge success and announcing the winners for 2017.

The Trophies were then presented by Grant Sinclair of Flowserve who were this year’s Trophy sponsors.

1st Flowserve

2nd Wilo

3rd Flowserve SIHI

THE RESULTS

Longest Drive - Jonathan Grace Flowserve

Nearest Pin - Jamie Springer Calpeda

BPMA GOLF DAY 2018

WYCHWOOD PARK Wychwood Park, Crewe, Cheshire CW2 5GP Thursday 24 May 2018 - Tea, coffee & bacon rolls at registration - 18 hole texas scramble team competition - Buggies - Prize giving dinner - Overnight accommodation - Breakfast on departure For reservations contact s.smith@bpma.org.uk 03

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ECONOMIC VIEWPOINT – GLOBAL AND UK (AUGUST 2017) OXFORD ECONOMICS Our forecasts for world GDP growth have remained broadly unchanged, at 2.8% for this year and 3% in 2018. However, there has been a change in composition, with a stronger outlook for China compensating for a weaker US outlook this year.

Our most important forecast change is a stronger euro, which we now see appreciating to $1.20 by end-2017. The euro continues to benefit from improved sentiment and dollar weakness, as the dollar yield surplus continues to shrink.

Global indicators still point to robust and stable world economic activity. July manufacturing PMI figures show the sector started H2 on a solid footing, in line with healthy industrial output figures. PMI readings are strongest in Europe as the region continues to benefit from strong export orders. But the recent loss of momentum in Asian trade flows points to a slightly less positive picture in H2.

Despite a moderate acceleration in Q2, the US remains stuck in its 2% growth phase. We expect economic activity to accelerate in 2018 on the back of a modest fiscal stimulus package, but there are significant risks of a policy disappointment. Low inflation will limit the Fed to two rate hikes in 2018 while balance sheet normalization should start in the fourth quarter of this year.

The Eurozone is growing at its fastest pace in years, driven by a shift in sentiment and stronger external demand. This, in turn, is supporting labour markets improvements, which are helping maintain households’ incomes. Despite the strong momentum, we think the ECB will withdraw its monetary stimulus gradually and will not pre-commit to an end date for its QE programme.

US dollar weakness combined with strong portfolio flows have been positive for emerging market currencies over the last month, and together with low inflation trends have provided some EM central banks with a good opportunity for monetary easing.

In the UK, our forecasts for GDP growth in 2017 and 2018 are are 1.7% and 1.5% respectively. We expect activity to remain sluggish while high inflation weighs on household spending power and the government implements its programme of fiscal austerity, with growth unlikely to break out of this subdued pace until the pressures on households begin to ease from the latter part of next year.

The preliminary estimate for Q2 2017 saw quarterly GDP growth edge up to 0.3%, from 0.2% in Q1. Growth was entirely dependent on the services sector, which saw output recover firmly after Q1 had been dampened by falling retail sales. But the recovery in services output was partly offset by falling production in the industrial and construction sectors. The monthly data suggests that the economy carried decent momentum into Q3 so a further modest uptick in growth to 0.4% looks possible.

The UK and EU have completed their second round of Brexit talks. Some progress has been made, particularly on the rights of existing migrants, but there has been little movement in other areas, most notably the ‘divorce bill.’.

But these are still early days and an amicable deal remains the most likely outcome. Encouragingly, even the most eurosceptic cabinet members appear to be convinced of the need for a transitional deal and are willing to make the compromises to make this happen.

Almost all MPC members have given speeches or media interviews over the past month. Ian McCafferty and Michael Saunders appear likely to be the only two members to vote for a rate hike in August. And while Andy Haldane has suggested he may vote for a hike later in the year, all other members have stated that a range of criteria must be fulfilled before they vote for tighter policy. We would not expect these criteria to be fulfilled met until at least 2019.

HOW WILL THE PUMP OF THE FUTURE LOOK LIKE?

By Bryan Orchard of Orchard PR in discussion with Dr Thomas Paulus & Daniel Gontermann of KSB Pumps

Few components in plant and equipment engineering are as steeped in tradition as the pump. But how does this fit in with the age of digitalisation? And is it even possible to design a hydraulic element that is fit for Industry 4.0? KSB has been reconciling these two world successfully for some time now.

KSB has always focused primarily on the optimisation of pumps –knowing the exact load profile and tuning the pump to the operating point. This is borne out by the sheer number of different pump casings and materials used and the impeller adjustment options available.

However, conditions can change during the life of a pump and it often happens that a pump no longer runs at the optimum operating point. This also applies to newly installed pumps.

For years now, KSB experts have therefore been investigating how to optimise pumps more easily without using complex analytics or even having to replace the pump.

Digitalisation offers tremendous potential for this. However, it takes time to develop new approaches and put them into practice. “It’s a matter of transferring decades of experience and expertise into an algorithm and a software solution,” explains Dr Thomas Paulus, Head of Programme Office Digitalisation & Startup Projects at KSB. “This cannot be done in a single step: It involves many different components and aspects. By bringing together these component parts, however, you end up with an intelligent and practical concept that provides real added value for the pump operator.”

STEP 1 – THE DIGITAL MONITORING UNIT The KSB “PumpMeter” monitoring unit (Figure 1), which shows in plain language what goes on inside a pump, has already established itself successfully on the market. The monitoring unit comprises pressure sensors as well as an analysing and display unit fitted to the pump. Two sensors in the pump measure the suction and discharge pressures around the clock. The PumpMeter uses this data to calculate the differential pressure and determines the current operating point, which is updated continuously in real time. A typical four-quadrant pump characteristic Figure 1: PumpMeter continuously analyses the pump curve shows the range in which the operating data, establishes a load profile, and makes pump is operating at a point in time. the operator aware of energy saving potential that could be leveraged by using a variable speed system. A flashing outer segment on the left or right of the display indicates that action is required – because the flow rate is either extremely low or too high. A flashing third quadrant in the pump curve indicates the optimum operating range. If the segment on the left (the second segment) is flashing, this indicates a long-term need for optimisation. This display allows the operator to evaluate the operating point immediately upon start- up and adjust the pump accordingly. Operators can see at a glance whether the availability of their pumps is at risk and whether they are operating economically. A flashing EFF (energy efficiency) symbol also indicates potential for

06

significant energy savings.

STEP 2 – ALGORITHMS ARE USED TO INTERPRET VIBRATION CHARACTERISTICS This analysis now needs to be simplified further.

In the future, instead of using wetted sensors, it will be possible to record vibrations and transfer this operating data to the cloud using mobile communication.

This has two advantages: First, conventional m e a s u r e m e n t s Figure 2: The operating data is transferred to the cloud via a portal. KSB using wetted processes the data and the user receives an automatically generated sensors are PDF with clear recommendations and, where applicable, improvement not always suggestions for the pump. straightforward, particularly when the medium being pumped is a chemical product. Second, cloud access means that technicians can obtain information about the status of a pump from anywhere in the world without having to be on site.

This application is currently being piloted very successfully with 100 selected project partners.

“Those involved include some automotive suppliers, who are very open to the project.”

Measurements taken in parallel using the PumpMeter are being used to verify the values obtained using the vibration sensor. At the same time, the KSB team is continuing to optimise the underlying algorithms. According to Dr Paulus: “Based on these results, it is already easy to see whether it makes sense to switch to closed-loop control, whether the settings or modes of operation need to be changed, or whether it would be better to buy a new pump.” The operating data is transferred to the cloud via a portal. KSB processes the data and the user receives an automatically generated PDF with clear recommendations and, where applicable, improvement suggestions for the pump“ (Figure 2).

STEP 3 – OPERATING POINT OPTIMISATION WITH MYFLOW But how can these improvement suggestions be put into action? The traditional approach would

be to call a KSB service technician.

But what if it were possible, based on the information obtained, to adjust the pump using software instead of having to adjust the impeller manually?

“This is actually possible with our MyFlow Technology,” (Figure 3) says Daniel Gontermann, Head of Product Management - Drives and Mechatronic Solutions at KSB. This is a combination of the KSB SuPremE IE5 motor and the MyFlow Drive, which is based on the proven PumpDrive speedcontrol system. The conventional approach for fixed speed pumps is to match the flow rate and Figure 3: MyFlow Drive allows the pump operator to increase head to the calculated operating or reduce the volume flow rate with just a few simple point by trimming the impeller. adjustments.

Now, the pump can be adjusted by changing the speed.

MyFlow Technology already offers many advantages in day-to- day work. Because the operating voltage of the IE5 synchronous reluctance motor is modulated by the minimum frequency inverter mounted on the motor, it can be used in almost any power grid around the world. This is also a huge advantage for global engineering contractors because they no longer need to consider the local mains voltage when selecting pumps. The direction of rotation is now defined at the factory, saving the time and costs usually incurred by conventional direction-of- rotation checks.

STEP 4 – SOFTWARE-CONTROLLED PUMP ADJUSTMENT “Although these advantages make the pump operator’s job much easier, they are not enough to make a pump fit for Industry 4,” acknowledges Daniel Gontermann. “Nevertheless, they form the basis for the next crucial step: pump optimisation using virtual impeller trimming.”

In the further course of the product life cycle, the pump speed can simply be adjusted to individual requirements by smartphone – pump optimisation with virtual impeller trimming.

“A software application can be used to bring the pump closer to its optimum operating point,” says the pump specialist. Unlike with mechanical impeller trimming, the operating process does not need to be interrupted. This is how you can quickly and economically optimise energy efficiency if the actual Q/H point deviates from the design values, or respond to a systeminduced change in the operating point. “Because a change in speed is always associated with a change in power, substantial savings can also be made,” says Daniel Gontermann.

Pump optimisation through virtual impeller trimming is fast and convenient by smartphone or tablet via a Bluetooth gateway. “During development, special attention was paid to security. The KSB FlowManager app establishes a point-to- point connection, which ensures that the correct pump is being addressed, and only by the person entitled to do so,” says Daniel Gontermann.

“The great thing is that you can now defer the individualisation of the pump to a much later point in the supply chain, which of course means that fewer variants are required.” This is another aspect that is likely to play a major role in pump selection in the future. With individual fixed speed adjustment, fewer pump sizes now cover the entire selection chart – with efficiency and NPSH values remaining practically constant. The variant complexity for hydraulics is reduced by more than 50%, saving time and money on design and administration. “Simply reducing the complexity by having fewer variants will promote the topic of virtual impeller trimming,” says Daniel Gontermann.

QUESTION & ANSWER

SOLUTIONS FORUM YOUR PUMPING QUESTIONS

By David Mullin - Director of Business Development, Intelliquip Europe Ltd. Q: DO CHANGES IN LIQUIDS PUMPED AND CONFIGURATION AFFECT CENTRIFUGAL PUMP PERFORMANCE? A: In short, yes they can. By the nature of our industry, we are constantly challenged with pumping a wide range of liquids at various viscosities, specific gravities, flows, pressures and temperatures. Configuring and sizing the proper pump for each unique application may require the use of certain configuration options, which may affect the efficiency, head and flow characteristics of a pump. Proper sizing and comparison of various pump models should consider any applicable performance corrections.

Every pump manufacturer has their own method for dealing with these issues. Some may require engineering involvement to “correct” a standard curve, while others incorporate these corrections within their selector software itself. Obviously for those companies focusing on water pumps, this is a nonissue. It becomes much more prevalent in the industrial, petrochemical and oil and gas industries.

The following is not meant to be an exhaustive nor deep discussion of performance corrections—this is the domain of each manufacturer. Rather, it is meant as a quick summary discussion of several variables that might impact pump performance.

Common areas where performance may be affected are materials of construction, sealing options and viscosity.

MATERIALS OF CONSTRUCTION

Typical pump curves are based on water and a standard metallurgy (example - cast iron or steel). Changing the metallurgy to better handle the corrosiveness or pressure requirements of a particular application may change the efficiency, and/or the flow head characteristics of a pump. So, changing from a standard cast iron pump to a stainless steel material may drop efficiency by a point or two from the standard published curve.

SEALING ARRANGEMENT

Mechanical seals have loss components introduced by face friction and seal flush piping configuration. For example, configuring a tandem seal in a smaller pump might introduce significant loss components which should be reflected in a corrected performance curve and datasheet.

VISCOSITY CORRECTIONS

Viscosities can have a dramatic effect on performance. There are a number of industry standard correction calculations available (Intelliquip currently incorporates five into their Selector: four various ANSI/Hydraulic Institute standards and one Karassik). In the attached curve you can see a comparison of a curve based on water and then a 200cP viscosity.

OUTLOOK Original equipment manufacturers (OEMs) will therefore be the first to benefit from the new opportunities presented by digitalisation, by being able to drastically reduce their stock, for example. Nevertheless, this shows the direction in which pump technology will move.

“Digitalisation is not an end in itself,” emphasises Dr Paulus. “Our users will only accept the new technologies if they bring added value to their day-to- day work and, above all, are workable.” This last point is certainly one of the greatest challenges. It is useful that KSB has set out on the road to the digital future at an early stage. “In the same way that we have been getting the most out of pumps in terms’ of performance and efficiency for decades, we are now also making progress in developing the algorithms and software. Without our many years of pump expertise, it would be simply impossible to make a pump fit for the Industry 4.0 era.” Dr Paulus and Daniel’ Gontermann are sure of this.

Head curve performance with viscous correction (solid line) and non-viscous (dotted line) Source: Intelliquip Intelligent Front End (IFE) These are just a few factors which could affect performance and are presented to invoke some thought and discussion. Every manufacturer handles performance corrections differently.

With today’s technology, many, if not all of these corrections can be handled automatically in properly designed pump selection software. This gives real- time feedback to the user, eliminating the work and time previously required in sending the application to engineering for review. In today’s world, users want relevant data quickly, so they can do a better, faster and more accurate job in selecting the proper pump for any application

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MACHINE SENTRY – NOW AVAILABLE WITH ATEX AND IECEX CERTIFICATION AVT Reliability is pleased to announce the recent ATEX and IECEx certification of its Machine Sentry ® condition monitoring product. The certification enables the Machine Sentry ® mobile vibration sensor to be used in a diverse range of industries from hazardous oil and gas applications right through to pharmaceutical and food and beverage.

Classed for Zone 1 and Zone 2 hazardous areas, this enables Machine Sentry ® to be used within any harsh industry that requires this level or less.

The Machine Sentry ® predictive technology platform integrates a wide range of condition monitoring techniques as well as watchkeeping data into one easy to access database (fully inclusive of thermography, oil analysis, vibration, visual inspection, planned maintenance, process parameters and lubrication management). It provides the first fully integrated and effective Condition Based Maintenance (CBM) solution to the industry today. This enables effective maintenance planning and reporting.

Utilizing the power and accessibility of the internet through Wi-Fi and mobile networks, data can be easily acquired and accessed anywhere in the world from any web enabled device.

Use of hazardous area certified Android tablets or smart

phones, means Machine Sentry® can now be used in the harshest environments making it the most versatile, user friendly and cost effective solution for condition monitoring for expert and inexperienced users.

The wireless triaxle vibration sensor is up to five times faster than other solutions. With a 60 hour battery life this enables even most frequent user to take vibration and temperature readings from the same easy to use sensor. Correct positioning can also be assured with a base plate attachment and with a simple to follow diagram prompt on the data collector.

Designed to endure the test of time, the sensor is IP67 rated, and can survive a 1m drop.

Additionally, with the power of Bluetooth technology, access to previously inaccessible vibration measurement points is now possible with no need for awkward cables leading to much improved ease of use and manipulation

for safer operation in the most difficult to access areas.

Machine Sentry ® also boasts an automatic fault diagnosis assistant to help identify potential issues with rotating equipment and support the most inexperienced users.

This, combined with access to AVT’s team of condition monitoring experts, provides the platform necessary to deploy an effective condition monitoring strategy regardless of whether the user is a proficient condition monitoring engineer or complete beginner.

The flexibility of the tool and software makes it scalable and versatile enough to suits the needs of all.

Frederic Thomas, Managing Director, AVT Reliability said, “AVT Reliability is delighted and proud to bring this new solution to the market. The ATEX and IECEx accreditation was a natural progression and complement to our current product range. We believe this is the most effective tool on the market today which will revolutionise the approach to traditional condition monitoring provisions being deployed without having to trade off any technical abilities.”

To support the new classification, AVT Reliability can also supply data collection devices suitable for use in hazardous areas as defined by the ATEX Workplace Directive.

For more information on Machine Sentry, visit www.machinesentry.com.

To find out more about AVT Reliability, visit: www.avtreliability.com.

PUMP GENIUS

Pumping Control Software WEG’s Pump Genius process control software is designed to reduce pumping system operation and maintenance costs whilst increasing process accuracy and protection.

Working with the CFW11 variable speed drive the software provides multiple pump control and protection as well as system monitoring, flow and pressure management for up to six pumps.

For more information visit www.weg.net 08

WEG EXPANDS CFW500 VARIABLE SPEED DRIVE SERIES TO BRING EFFICIENCY TO HIGH-POWER APPLICATIONS

WMFTG COMPLETES PROCESS PUMP RANGE FOR INDUSTRIAL APPLICATIONS With the addition of two larger models, Watson-Marlow Fluid Technology Group (WMFTG) has nowcompleted its range of process pumps for industrial, environmental and food industry applications.The existing 530 model is joined by the 630 and 730, which feature an enhanced operator andcontrol system interface, and a bright colour display.

With no valves or seals in the product stream and an unrivaled flow turndown, Watson-Marlow 530, 630, and 730 peristaltic pumps play an increasingly important role for the reliable metering of aggressive and shear-sensitive fluids without contamination. The pumped fluid is totally contained within the tube, providing complete isolation of the fluid. Backed by a five year warranty, the new pumps offer users the complete confidence needed in harsh industrial applications.

Reduce downtime WMFTG’s latest process pumps are designed to reduce downtime, optimise metering and offer the ultimate in process flexibility – one range of pumps for all flow demands.

Flow range extends from microlitre up to 55 L/min with the 730. Both the new 630 and 730 are available with four drive options and two pumpheads for single channel flows. The 630 offers a precise 2650:1 speed control range, which is increased to 3600:1 on the 730.

Impressive accuracy and process integrity is assured via a new, simple-to- use HMI requiring minimal key presses to reduce the opportunity for costly mistakes. Furthermore,

WEG, a leading global manufacturer of motor and drive technology, has expanded its CFW500 series of variable speed drives (VSDs) to enable users in a wide range high-power applications achieve further energy efficiency. The new E frame size for the rated power range 18.5 kW - 22 kW is a great fit for applications such as mechanical engineering systems for conveying, turning, hoisting, pumping and ventilation.

“In light of EN 50598, the new standard looking at Ecodesign for power driven systems and their applications, an integrated approach to electrical drive technology is becoming more widespread and VSDs are particularly sought after across broader sections of the industrial market,” says Johannes Schwenger, Head of Product Management Low- and Medium-voltage Drive Systems Europe at WEG. “As a leading manufacturer of both electric motors, drives and automation components, we can supply optimally matched motor and VSD packages that help boost energy efficiency and offer outstanding value for money.”

With a plug-and-play user-friendly design, the CFW500 VSDs feature an integrated micro PLC with pre-programmed macros for positioning, timing and acceleration functions. They can be programmed locally with the convenient LCD display or externally with a computer over a variety of interfaces, including CRS232, USB and CRS485. Users also can download the corresponding SuperDrive G2 programming software from the WEG website free of charge.

The VSDs are designed for fast installation and easy operation. The numerous plug-and-play modules are ideal for distributed automation architectures and can easily be connected to all common fieldbuses, including Profibus DP, Grow your bottom Profinet IO, Ethernet IP, DeviceNet, CANopen line with the pump and Modbus RTU. Individual adaptations to industry’s most specific customer requirements can also be advanced selection, configuration, pricing easily implemented thanks to additional plug-in and quoting software. extension modules.

For more information on WEG’s energy efficient Call today for a free video or drive solutions visit www.weg.net/uk. in-person demonstration

users and process engineers will benefit from enhanced process security with the addition of a 3-level PIN lock. The pumps are self- contained and easily configurable, so there is no need for separate variable frequency drives or complex control devices. Control options include manual, remote, analogue and RS485 digital communications, along with integrated PROFIBUS networking capabilities.

Applications Watson-Marlow process pumps are preferred in many industries where reliable metering of aggressive chemicals is required. For example, the process pumps range are widely used in water and wastewater treatment for metering sodium hypochlorite and other common disinfection chemicals resulting in reduced maintenance and the elimination of vapor lock.

The 530, 650, and 730 pumps are proven to outperform other technologies with a superior flow range and easy integration into a user’s control system to reduce chemical costs and improve the process. A typical diaphragm metering pump has a flow control range of 100:1, in comparison with 3600:1 from a WMFTG process pump. Food and beverage manufacturers also rely on these pumps to maintain product integrity throughout production. The 530, 630 and 730 pumps ensure the safe dosing, metering and transfer of colours, flavours, finings and additives along with a lowshear, gentle action.

Tubing options The company’s long life and chemical resistant Marprene thermoplastic elastomer tubing is the ideal choice for industrial applications as it offers wide chemical compatibility and long life, along with low gas permeability. Where good suction and pressure capabilities are required in abrasive slurry applications.

Depending on a user’s process needs, the pumps can feature LoadSure tube elements, which provide simple, error-free tube loading. Using the patented LoadSure D-connectors and easy-grip clutched rotor, the tube element can be changed in less than one minute without the need for special skills.

For more information contact Watson-Marlow Fluid Technology Group, Falmouth, Cornwall.

Tel: 01326 370370 or Web: www.wmftg.com

MOVE AT THE SPEED OF SALES.

Now accessible to your users through easy-to-use customer portals.

David Mullin, Intelliquip Europe Ltd

P: +44 7983 385971 www.intelliquip.com E: dmullin@intelliquip.com

09

EU COMPLIANCE FOR BOOSTER SETS IS A LEGAL REQUIREMENT If you are part of the booster set supply chain you have legal obligations to ensure that the booster sets which you place on the market are fully compliant in respect of EU legislation. In this article, Steve Schofield of the BPMA highlights the issue and urges users to ‘buy with confidence’.

The European pump sector through its network of national trade associations and Europump (the European Pump Manufacturers Association), have for many years been working with the European Commission to ensure the introduction of appropriate legislation covering health and safety, the environment and energy reduction. Europump has led much of this work especially on the energy front through its Ecopump initiative and the BPMA along with its members have been at the forefront of this work.

Companies have invested a great deal of time and money to ensure the success of the legislative process in protecting users and the environment. It is therefore no surprise that our sector is keen to ensure, both directly and via appropriate market surveillance, that products being placed on the UK market are compliant.

To enhance this process, BPMA member companies have joined together under its ‘buy with confidence’ initiative to ensure that its members are fully compliant, and in doing so, provide a professional advisory service detailing the legislative implementation process. However, there remain a significant number of suppliers outside of the ‘BPMA umbrella’ who continue to feed illegal booster sets into the UK market. If you are buying from these organisations, you not only put at risk the safety of users, but you too may be acting illegally.

complete set is a machine in its own right and must therefore have a label affixed with a CE mark and be supported by all the appropriate documentation, including a Declaration of Conformity. (Fig 1)

COMPLIANCE OF INDIVIDUAL COMPONENTS IS NOT ENOUGH As a complete machine, the booster set will need to have its own identification label affixed with an appropriate CE mark and will need to comply with the correct legislation. The label will need to carry a minimum amount of information such as a serial number, product type, supply voltage, and performance data along with details of the manufacturer and where the set was manufactured. But this is only the start of the process as other vital assessments need to be made and documents provided. (Fig 2)

Fig. 2

WHAT TO LOOK OUT FOR A number of booster set suppliers believe that it is acceptable to simply bring together components such as pumps, drives and controls and rely on the CE marking placed on those individual items as compliance for the set; this however is not the case. The

THE PAPER CHAIN

Fig. 1 10

Each set will need to be supplied with a full and comprehensive instruction manual. The set will also need to be supplied with a Declaration of Conformity referencing the appropriate legislation and standards where applicable. Most importantly however, the set manufacturer will need to prepare a technical file.

(Fig 3) (Fig 4) This file, although not published externally, will need to cov-

er a great deal of material including risk evaluation, product data, product features, production methodology and health and safety considerations. The typical file runs to 168 pages and benefits from independent scrutiny during its preparation. (Fig 5) Fig. 3 Because of the pump sectors huge capital investment and the time its experts have spent on these issues, the BPMA is keen to ensure that all pumps and booster sets placed on the UK market are fully compliant. This is not only to protect the safety of users, but also to ensure the integrity of our environment and protect our sector and its employees Fig. 4 from those who seek to undermine the legal process and bypass the cost and impact of proper implementation. The BPMA through its ‘buy with confidence’ programme helps to give users Fig. 5 a benchmark and will seek to ensure that illegal products are brought to the attention of the authorities and removed from the market. (Fig 6) The BPMA would like to thank Calpeda, Grundfos and Xylem for their assistance in producing this article.

If you would like more information on any of the issues highlighted in this article, please contact the BPMA or go to www.bpma.org.uk.

AXFLOW TAKES ON NEW VERTICAL WATER PUMP RANGE

AxFlow has introduced Gruppo Aturia’s PAG range of semi-submersible mixed flow pumps to its portfolio.

The Aturia PAG range comprises vertical single, multistage mixed-flow and semi-axial pumps, all of which are suitable for use in both wet and dry pits. The pumps can deliver flows of up to 44,000 m3/hr and differential heads of up to 120m. They are available in a large range of materials including Cast iron, Steel, Bronze, Stainless Steel, Hastelloy, Duplex and Super Duplex.

Closed and open impellers can be fitted depending on the application and several types of shaft bearing supports are available. Applications where PAG pumps have been used include iron and steel, petrochemical, power generation, construction, agriculture, municipalities, irrigation and flood defences.

Enabling high savings to be achieved in the construction of pumping stations, PAG vertical pumps are suitable for the transfer of most liquids, including clean water and liquids containing small solids.

For more information contact AxFlow Limited, Ealing, London.

GRUNDFOS IMPROVES ASSET AVAILABILITY AND REDUCES COST OF DOWNTIME A Wessex Water location in Dorset recently saved valuable time, money and stress when Grundfos was used to deliver a pump solution in a breakdown situation.

A multi pump failure at the inlet works had the potential to have very serious consequences when a problem with a wastewater pump meant that a non-standard pump needed to be replaced very quickly. Any disruption to the plant’s operation had many consequences including the high costs associated with over-pumping and compliance risk while waiting on a new pump to be delivered. The average delivery time for replacement equipment would mean 8 weeks’ disruption.

However, they contacted Grundfos who, understood the urgency and hold stock of over 2000 wastewater pumps for the UK market, could deliver a pump replacement in just 4 days. This meant they were up and running in just a fraction of the expected time and the added benefit of simple installation solutions for existing applications, meant that the plant was running smoothly again. As well as reliable products and exemplar service, the plant savings in over-pumping financed the replacement pumps, resulting in financial savings and significant compliance risk reduction.

A Wessex Water spokesperson explained ”Grundfos are keen to make sure that our service level agreements are met, and keen that we get the service we really need”.

Reader Enquiries to: Literature Request, Grundfos Pumps Ltd,Leighton Buzzard, Bedfordshire.

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

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guest article

PROGRESSIVE CAVITY PUMPS OVERCOME THE TOUGHEST PROCESSING CHALLENGES

By Lesley Eaton, Business Development and Marketing Manager, SEEPEX

Process pumps are the world’s most popular piece of rotating equipment, outnumbering all other process equipment such as compressors, mixers, blowers – in some plants they can represent as much as 85% of rotating equipment, and they use 90% of all industrial electric motors. Industries as diverse as oil and gas, food and beverage, environmental water and waste water treatment, pharmaceutical and chemical, all rely on pumps to move products around their processes.

Despite pumps being essential to many processing operations, there remain challenges associated with choosing the correct pump for the job. However, developments in technology mean that the progressive cavity (PC) pump can deliver superior pumping ability while overcoming some of the common top pumping headaches found across all industries.

CHALLENGE 1: MAINTAINING PRODUCT INTEGRITY

The design of the PC pump moves the product through the pump in a series of cavities, which prevents slip from the discharge back through the pump. Slip creates shear, so compared to other pump designs, which have clearances between the lobes, screws or gears, PC pumps have a very low shear action. This preserves the quality of shear-sensitive products, such as multiphase products in the oil industry, polymers used in waste water treatment, even whipped products in food and beverage production, all of which are transferred without loss of integrity and functionality.

CHALLENGE 2: LIFTING PRODUCTS

High suction lifts of up to nine metres can be achieved, making PC pumps ideal for lifting products from IBC, barrels or mixing tanks.

The ability to pump against almost a full vacuum ensures the efficient use of degassing equipment and enhances the quality of the final product in many food products as well. Furthermore, surface-mounted PC pumps can lift from wastewater sumps, removing the need for submersible equipment.

CHALLENGE 3: BATCH AND CONTINUOUS DOSING

The cavities have a given chamber volume which means the PC pump is ideal for batch dosing applications where specific amounts of product must be dosed extremely accurately; for example, dosing tomato sauce directly onto pizza dough or addition of polymers or chemicals to make up tanks. Furthermore, since the flow has very low pulsation, dosing into mixers or pipelines delivers the right amount in a smooth, continuous action, meaning that the accurate addition of ingredients or chemicals into a liquid flow is possible without complicated controls or lengthy calibration methods.

CHALLENGE 4: HANDLING SOLID PARTICLES

The PC pump is able to handle solid particles without compromising either the product or the pump efficiency - ideal in applications as diverse as waste water treatment, to sauces containing vegetables and spices. They are used in any area where solid particles prove problematical for other pump designs, often causing check valves to stick which result in breakdowns and downtime issues.

CHALLENGE 5: VARIABLE FLOW RATES

PC pumps are available with flow rates from 100ml/hr to 500m³/

12

hr, and the ability to handle temperatures ranging from -20 C to 220 C. As the flow volume is constant for each cycle of operation, and is proportional to the rotational speed, calibration is simple and is unaffected by the viscosity of the product, unlike some pumps which slow when viscosity is high. This linear accuracy means that only one variable – pump speed – needs to be changed to vary the flow volume.

CHALLENGE 6: VISCOSITY

PC pumps have excellent suction characteristics and can handle a wide range of viscosities; from water to products with viscosity over 1,000,000 cps. The pumping action means that variations in viscosity do not affect the flow rate. This has practical advantages in applications where ds% and viscosity can vary such as waste water treatment, or when viscosity is affected by temperature, for example molasses transfer into pharmaceutical processes. The ability to keep a steady flow rate despite product viscosity variation offers accuracy, process stability and reduced downtime unlike some pump designs which stall when viscosity exceeds their operating parameters.

CHALLENGE 7: SOLIDS PUMPING

There are some instances where products don’t free flow hence the development of auger mechanisms to constantly feed non-flowable media into the pumping elements. The auger is fabricated as part of the integral coupling rod between the drive and rotor, using the rotation produced by the drive to push forward viscous and even solid products. As a result, products that do not flow are pushed into the pumping elements and can then be moved through pipes (the alternative would have been to use a conveyor). This technique makes long distance transfer possible, plus waste products from production areas can be moved to the factory exterior. In addition, the development of sophisticated auger mechanisms in some PC pumps means that they have the ability to handle and even mix solids – liquid can be added to solids in the feed auger, or solids can be added to a paste, with the action of the auger mixing the two before feeding them into the pump. These large pumps are used extensively to mix sludges in waste PC’s for Solids applications water treatment. Fur-

thermore, products with dry solids content up to 45 per cent and a viscosity in excess of 1,000,000cps can be successfully transferred using these open hopper designs.

CHALLENGE 8: DESIGN COMPATIBILITY

Corrosive and abrasive products, water industry standards, strict hygiene requirements, low/high pH, or high temperature, are all factors that need to be considered when configuring or choosing a pump to ensure that the build materials are suitable for the product and processing conditions. PC pumps can be constructed – and the product feed mechanism adapted – in line with the application requirements. For example, a fully stainless steel pump with PC’ for Hygienic application CIP capability can be used for hygienic applications, whilst one used to dose corrosive or abrasive chemicals can be manufactured from chemically resistant materials.

CHALLENGE 9: OPERATING PRESSURES

Pumps have to overcome pressure when transferring products.

These can be generated by several factors including pipework and valve configuration, length of pipework, as well as the product characteristics which can cause high friction losses in the pipework if they are very sticky. The need to overcome operating pressures of downstream equipment such as heat exchangers also puts demands on the pump. PC pumps are able to generate pressures up to 48bar as standard, due to the interference fit between the rotor and stator plus the absence of slip between the pumping elements, meaning that they can pump long distances - many km in some cases!

CHALLENGE 10: INSTALLATION AND OPERATION

PC pumps are easy to operate and install. They have both forward and backward pumping action in the same pump, so one PC pump can often do the job of two alternative designs. System costs are reduced due to the fact that calibration pots, check valves and pulsation dampeners are not needed, plus they can be installed horizontally or vertically, making them ideal for factories with restricted floor space. Designs such as our Smart Conveying Technology have smaller installation needs, plus inspection of the pumping elements, removal of blockages and planned maintenance can be carried out without removing pipework thus reducing downtime, as well as maintenance costs.

ITT GOULDS PUMPS – INNOVATORS FOR OVER 160 YEARS INTRODUCES i-ALERT2 The i-ALERT Equipment Health Monitor is a Bluetooth Smart-enabled machine health Monitor that allows customers to identify potential equipment problems before they become costly failures.

ITT’s ALERT2 tracks vibration, temperature and run-time hours and wirelessly syncs the date with smartphone or tablet through the i-ALERT2 mobile app.

This condition monitor combines the latest in Bluetooth low-energy and sensor technologies commonly used in the newest consumer health and fitness trackers and smart watches. It is the first condition monitor to successfully integrate these technologies into an industrial package in a small footprint for [2.24 in. (L) by 1.54 in. (W) by 1.40 in. (H] which is half the size of a credit card. It is engineered and rated for use in a wide range of industrial environments. It is chemical resistant, rated for extreme temperatures (40 to 183 F) and is rated to operate in environments with explosive gases, dust and fibres.

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

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

The i-ALERT2 is fitted as standard to Goulds ANSI and ISO process pumps and comes with a 5 year warranty.

For more information contact: Tel: 01297 639100 www.gouldspumps.com www.ittproservices.com

MULTIPLE ZEROLOSS BENEFITS

XYLEM LAUNCHES UV DISINFECTION SYSTEMS FOR SENSITIVE PROCESSES Offering effective, chemical-free disinfection, Xylem has launched the Wedeco Spektron Industrial UV Disinfection Systems – designed specifically for use in sensitive processes, such as those found in the food and beverage or pharmaceutical industries.

Spektron Industrial systems use closedvessel UV reactors with Wedeco Ecoray® UV lamps and ballasts, which make them highly sustainable while assuring consistent quality of disinfection without added taste or colour. The Ecoray® technology in particular can provide energy savings of up to 20 per cent due to its optimised hydraulics and variable power control. In addition, Ecoray® lamps achieve a high output with minimal maintenance requirements and contain less mercury than similar technologies on the market.

As with other disinfection solutions in the Wedeco range, the Spektron Industrial Systems include a standard EcoTouch controller and OptiDose closed-loop control, which monitors operating conditions such as flow, UV transmittance, and UV intensity in real time. For added efficiency, the controller can adjust the energy consumption of the Spektron Industrial models depending on the dosing requirements.

Systems are available in four models, ranging from 28m3 per hour to a maximum flow of 150m3 per hour, to meet customer needs. Featuring an improved inner surface, compact stainless steel cabinet and hygienic flanges, the series delivers reliable and accurate disinfection, in-line with strict hygiene requirements – potentially of benefit to the food and beverage or pharmaceutical industries and processes such as microelectronics.

Duncan Leathley, General Manager Treatment at Xylem, said: “At Xylem, we understand what it takes to achieve effective, chemical-free disinfection, particularly in sensitive processes involving consumable products. The Spektron series has undergone extensive testing to ensure it meets the latest applicable legislation, and provides an environmentally-sustainable, highly efficient disinfection solution that manufacturers can rely on to maintain their own high standards.”

Spektron Industrial forms part of the Wedeco brand, a premier manufacturer of ultraviolet (UV) disinfection and ozone (O3) oxidation systems.

For more information on Xylem please contact 0115 940 0111 or visit www.xylem.com/uk

Sundyne HMD Kontro Extends ZeroLoss™ Containment Shells to Frames l, ll & lll Pumps

NEW PNEUMATIC ACTUATOR FOR DIAPHRAGM VALVES USED IN STERILE APPLICATIONS

Due to increasing customer emphasis on reliable, safe and efficient pump operation, Sundyne HMD Kontro has extended the availability of its ZeroLoss™ containment shell to now encompass Frame l, ll and lll versions of its most popular sealless pump ranges.

The robust qualities of ZeroLoss™ has been a significant factor in establishing the success of this optional containment shell which eliminates the eddy current losses in a pump, considerably increasing margin-to- flash safety as well as reducing energy consumption.

Five times lighter than steel but just as strong, the ZeroLoss™ shell is engineered from a composite material of poly-ether- ether-ketone (PEEK) and carbon fibres. In addition to its higher specific strength, the material is tough and durable, essential for applications pumping volatile and heat sensitive liquids.

Tests by Sundyne HMD Kontro have shown that installing a ZeroLoss™ containment shell in a sealless pump can result in a 20% reduction in power consumption, leading to major operational cost savings. The advantage increases in proportion with the magnetic coupling size and is particularly appropriate for larger pumps, making the magnetic drive option even more attractive because through life costs are reduced further. Lower power consumption not only results in reduced running costs but also potentially provides lower initial capital costs, as smaller motors can be specified.

For further information about using ZeroLoss™ containment shells with Sundyne HMD Kontro sealless pumps, please see www.sundyne.com/hmdkontro. Alternatively, please call +44(0) 1323 452000 or send an email to vince.lee@sundyne.com for product literature detailing this unique robust, power saving technology.

September 2017 will see KSB’s Luxembourg subsidiary SISTO Armaturen S.A. launch a new double-acting or single-acting pneumatic actuator. It is designed for diaphragm valves used for sterile applications in the beverage, food and pharmaceutical industries.

A special technical feature of the new MD30-MD202 actuator range is that the actuator housing and the valve bonnet are made from a single piece of material. Compared with predecessor models, this design change substantially reduces the actuator’s overall height so that considerably less space is required to accommodate block-bodied multi-port valves. The actuators are also 45 percent lighter than the two-piece design. In addition to the stainless steel variant, the two largest actuator sizes are also available in a weight-saving aluminium design. The actuator can be fitted to the valve body without nuts as the threads are integrated in the body, significantly facilitating mounting.

The orientation of the air connection can be adjusted in 90° steps.

Accessories such as travel stop, positioner or proximity switches for actual-position feedback can be retrofitted by the operator as and when required. The actuators can be replaced with manual actuation bonnets at any time. Thanks to their special design with enclosed, metal spiral supported diaphragm, Sisto C valves offer a long service life and can be operated at pressures as high as 16 bar.

For more information please contact: KSB Aktiengesellschaft, Christoph P. Pauly Tel.: +49 6233 86 - 3702 Fax: +49 6233 86–3456 E-Mail: christoph.pauly@ksb.com

13

NOW THERE ARE A DOZEN GREAT REASONS TO JOIN GRUNDFOS WIN & EARN

The Grundfos WIN & EARN loyalty scheme has continued to gain in popularity since it launched in 2015. Today, there are more reasons to join, as we have now added even more products to the line up This means that you can now earn rewards on an extended range of twelve great product family groups that cover the range of solutions that are available from Grundfos for the many different pumping demands around the home from circulators, water boosters, macerators, condensate removal to drainage pumps.

Once you have joined the scheme you can immediately start collecting points from participating pump purchases simply by scanning or entering the code you will find on the WIN & EARN stickers that are attached to the outside of all the participating pump boxes.

Being able to earn points from purchases across the diverse Grundfos range means that points will be accumulated even more quickly. These accumulated points can be redeemed either for Amazon vouchers, or a range of sports equipment, once the minimum threshold of 2,000 points has been reached.

To get started simply download the Grundfos GO Install App or visit www.grundfos.co.uk/win and join this scheme, today because there are now dozens of good reasons to do so.

14

SAVE TIME & LOST REVENUE WITH THIS EASY VALVE MATRIX SOLUTION Processes in hygienic industries - such as beverage, food, dairy, pharma and personal care - are becoming increasingly complex. Some of the challenges include higher volumes, increased efficiency, reduction in water and energy use. That is why it is essential to optimize flow management without compromising flexibility, plant safety, product quality or hygiene.

A valve matrix - also known as valve cluster - is a great option for maximizing process efficiency through optimized flow management. Each stage of the design and installation process is an important component to fully realizing potential in your process by saving time and avoiding lost revenue associated with production downtime.

Compared to traditional flow plates, a valve matrix is designed to allow simultaneous circulation of liquids - including CIP - on several levels with the exact number of lines and rows to match the specific requirements of your process. The matrix ensures the flexibility for you to run multiple products to multiple destinations, while other lines are being cleaned.

Installing a valve matrix with Alfa Laval Unique Mixproof Valves brings you outstanding product safety with good cleaning conditions and no risk of cross-contamination. It rules out the opportunity of human errors, which can occur using manual connection of lines and handling of swing bends.

Pre-built matrices customized to meet your specific requirements In Alfa Laval, we are specialists in providing pre-built valve matrices customized to meet specific, individual requirements. Our expertise helps ensure you the most efficient flow management, using as few components as possible and dealing effectively with key issues that include thermal cycling, cleanability, drainability and flow control.

Alfa Laval valve matrices can be supplied pre-assembled and pre-tested as well as fully wired and with all the necessary pneumatic tubing, junction boxes and control panels pre-connected. This means you can bring even complex installations online as quickly as possible, saving time and avoiding lost revenue associated with on-site assembly, troubleshooting and downtime.

Advice on optimal solution address product type, process flexibility, utility consumption, plant constraints, thermal expansion and many more considerations.

For more information contact www.alfalaval.com/

STUART TURNER INTRODUCE FLOMATE IBOOST, THE ULTIMATE SOLUTION TO LOW MAINS WATER PRESSURE Flomate iBoost has been developed to boost the mains supply to larger properties with multiple bathrooms, using high flow combination boilers or an unvented cylinder system, where

higher pressure and flow are required.

This fully integrated system combines a 200 litre cold water break tank which overcomes restricted mains water flow with a high performance multi-stage pump to dramatically boost pressure.

Flomate iBoost is capable of delivering water up to 4.5 bar and flow rates in excess of 100 ltrs/min and is designed to sit alongside other appliances within a kitchen or utility room or can be concealed within any standard 600mm kitchen larder cabinet.

For more information contact Stuart Turner Ltd, Tel: 0141 637 7141 E-mail: info@spumps.co.uk Web: www.stuart-turner.co.uk

ALBANY PUMPS LAUNCHES ONLINE PUMP CONFIGURATOR TOOL Albany Pumps has launched an online Pump Configurator tool – which can be used to critical effect in understanding the company’s new product portfolio and specifying a pump more quickly. Designed with flexibility mind, this tool will help customers, agents & distributors to build their perfect pump solution through a series of key questions.

As Phil Dykes, Managing Director of Albany Pumps explains, the new ‘Configure a Pump’ service is part of a major improvement programme to offer an easier and faster way for customers to access the impressive services from this 100-year old company: “We are proud to be investing in a new online resource for our customers. When creating our new website, we drew inspiration from customer feedback and as a result, we’ve created a really impressive online resource for all sorts of useful tools and data including application databases and case studies. In particular, we have built a Pump Configurator that will allow users to create their specification relevant to particular needs such as market sectors, or liquid to be pumped, or pump construction materials. Our dedicated sales team will then work to make your pump solution a reality.

We believe our tool is bringing innovation to the positive displacement pump industry, and we’re thrilled to be offering such a helpful aid.”

For more information on Albany Pumps and its range of pump products, please call Albany Pumps direct on Tel: +44 (0) 1594 842275 or visit www.albany-pumps.co.uk.

SMART PRODUCTS & SERVICES HEADLINE IN ABB’S BIGGEST EVER UK PRODUCT GUIDE

PERFORMANCE AND SAFETY ON THE RISE FOR OVEN MANUFACTURER WITH ABB DRIVES

IoT-enabled drives, motors Oven manufacturer Acrivarn has and controls together improved the performance and safety with application-specific of its range of industrial rotating rack packages feature in ABB’s ovens by installing ABB drives on the new 120-page guide. motor controlling the ovens’ turntable.

Smart sensors, apps and The turntable is built into the oven services that enable users floor and is used to move racks around of motors, variable speed the oven during the baking process. drives (VSDs) and controls Previously, the motor controlling the to tap into the opportunities turntable was connected direct-on- line. offered by the Internet of However, the rapid acceleration of the Things (IoT) headline in motor each time the turntable was ABB’s 2017 catalogue. revolved made the racks of food in the These include the world’s oven jolt, causing liquid products such first affordable sensor for as quiches and custards splash up the tracking the performance of low voltage (LV) motors. The ABB side of their tin foil containers. smart sensor for LV motors is simply attached, without wiring, to ABB authorised value provider Halcyon the frame and monitors key parameters such as temperature and Drives recommended installing a 0.55 vibration. The data is drawn into a central cloud-based dashboard kW ABB general machinery drive on the to provide maintenance crews with a real-time view of key motor controlling the turntable. The drive’s soft start function slows performance indicators, showing which motors need servicing and the acceleration of the motor, providing a smooth turntable start when. and eliminating the jolt when the racks rotate. End product quality Advanced apps for VSDs that provide access to cloud-based was immediately improved with no spillages and cleaning time was services and information throughout the product’s life cycle reduced to a minimum. The drive’s safe torque-off function has are also featured. The Drivetune app enables service engineers improved the safety of the ovens by ensuring the turntable cannot to commission and tune the performance of VSDs via wireless be operated when the oven door is open. This has enabled Acrivarn Bluetooth connection. Meanwhile, the Drivebase app allows plant to achieve EN ISO13849 accreditation for the range. personnel to access ABB’s vast drive knowledge base via the cloud, For more information contact ABB Ltd, Daresbury, Cheshire. to assist with installation and troubleshooting, simply by scanning a Tel: 01925 741517 | E-mail: layla.hewitt@gb.abb.com dynamic QR code generated by the VSD on its control panel.

Web: www.abb.co.uk The catalogue includes VSDs and motors designed for use in specific industries.

TEC ELECTRIC MOTORS These include the ABB drive for water and wastewater, 01299 253597 01299 252990 ACQ580, and the ABB HVAC drive, ACH580.

ABB’s range of motor-drive Electric Motors packages aimed at specific • 2/4/6/8/10/12 Pole industries and applications • 56-355 Frame are also detailed in the • Multi mount 56-200 Aluminium guide. As one of the only • Multi mount 80-280 Cast Iron companies manufacturing • Fixed feet 315-355 Cast Iron both VSDs and low voltage AC • IE1, IE2, IE3, IE4 Efficiency rated motors, ABB is able to offer motors customers perfectly designed, • Megawatt Motors tested and approved matched • Increased output IE1 and IE2 pairs. ABB’s extensive • 1ph motors 56-112 frame range includes synchronous • 1ph motors 230v/110v reluctance motor (SynRM) • 60hz 1ph motors on request and drive packages for • ATEX EExde Zone 1 71-355 frame industry, water and machines • ATEX Zone 2/22 56-355 frame and an enhanced range of • ATEX Zone 21 & ATEX 1ph ATEX-compliant motor and • Brake motors, retro brake fitting • Two speed Dual & Tap wound drive packages for hazardous • Special voltage, special shaft areas.

• Vector encoder motors The guide contains detailed • Forced ventilation motors information and specifications for the full range of ABB Gearboxes drives and controls, motors • In-line helical gearboxes and mechanical power • Right angle bevel helical gearboxes • Right angle worm gearboxes transmission products all in • Mechanical Speed Variators one place.

• Slow speed combination units For a free printed copy of the guide email energy@ Inverters gb.abb.com or call 07000 • TECDrive Inverter - IP66 & IP20 DRIVES (07000 374837) or • Lenze Inverter - IP65, IP31 & IP20 to download a PDF of the guide go to www.abb.co.uk/ www.tecmotors.co.uk energy.

TEC NORTH - TEC SCOTLAND - TEC WALES - TEC WORCESTER

15

PUMP INDUSTRY AWARDS 2018

The Pump Industry Awards are back!

The Pump industry awards have grown into one of the leading industrial awards programmes, celebrating the achievements of pump businesses, large and small. if you or your company have something to shout about, these awards provide the perfect platform to get noticed.

We believe the best way to celebrate excellence is by bringing people together at live events, so the annual gala presentation dinner caps off the awards programme in style. As always there will be excellent networking opportunities, great food and superb entertainment. It’s your chance to celebrate with colleagues, connect with peers and be part of the pump industry’s biggest and best celebration; put the 22nd March 2018 in your diary now.

Peter Reynolds, Managing Director of Grundfos Pumps, and BPMA President, says of the Pump Industry Awards, “The competitive nature of the pump industry, and the constant search for greater operational performance and improved efficiencies across its myriad customer base, requires all those operating within this important sector to be at the top of their game. This awards programme allows the pump industry to come together in recognition of that drive for engineering excellence”.

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

www.pumpindustryawards.com

EVENT calENdar NomiNaTioNs oPEN

NomiNaTioNs closE

judgiNg sEssioN

fiNalisTs aNNouNcEd

wiNNErs aNNouNcEd

September

January

January 2018

February 2018

March

14

15

22

2018 ParTNErs

Organised by

on behalf of

www.pumpindustryawards.com

DATA ACQUISITION NEXT-GENERATION GAS ANALYZERS EASE AIR QUALITY DATA ACQUISITION AND CONTROL Thermo Scientific iQ Series gas analyzers, the first instruments built on the new Thermo Scientific iQ Series platform, are designed to maximize uptime and provide access to uninterrupted data A new, easy-to-use air quality monitoring solution is now available to technicians and managers within the power generation industry and government agencies charged with air quality oversight.

The Thermo Scientific iQ Series gas analyzers are the first instruments developed on the new, innovative Thermo Scientific iQ Series environmental monitoring platform and build upon earlier generations. They are designed to be more reliable and more accessible than predecessor models while offering faster, more precise and uninterrupted data acquisition capabilities.

The analyzers also feature a new touchscreen interface designed to optimize user control over source emission and ambient monitoring data. Additionally, predictive diagnostics and preventative maintenance alerts allow operators to proactively plan their routine servicing activities, which helps to mitigate emergency situations and optimize efficiency during remote operation.

The Thermo Scientific iQ Series gas analyzers also offer: • A mobile application for remote monitoring and control; • Wireless connectivity capability to personal devices; • A modular design that enables increased instrument uptime, ease of serviceability and maximum data availability over previous-generation models; and • iQ360, a 24/7 customer support service for rapid response to equipment and service needs.

For more information on the Thermo Scientific iQ Series gas analyzers or the Thermo Scientific iQ Seriesplatform, please visit www.thermofisher.com/iQseries.

ETHERNET CONNECTIVITY HARTING ADDS ETHERCAT CONNECTIVITY TO MICA® INDUSTRIAL COMPUTER ARCHITECTURE HARTING has added EtherCAT connectivity to its MICA® (Modular Industrial Computing Architecture) system: an open source platform for industrial applications.

EtherCAT is a real-time Industrial Ethernet technology originally developed by Beckhoff Automation. The EtherCAT protocol which is disclosed in the IEC standard IEC61158 is suitable for hard and soft real-time requirements in automation technology, in test and measurement

and many other applications.

The main focus during the development of EtherCAT was on short cycle times (not greater than 100 µs), low jitter for accurate synchronisation (not greater than 1 µs) and low hardware costs.

With the EtherCAT interface, MICA can capture directly from industrial production networks via two M8 connectors, then pre-process it and transmit it to higher-level systems and cloud applications via various standard protocols such as OPC-UA and MQTT. MICA®s modular Open Source Software Architecture makes it the ideal solution for developing edge and cloud applications in production. Creating the EtherCAT functionality as an internal MICA® function module enables MICA® to deliver further benefits, such as protection class IP67, connectors suitable for industrial use and compliance with major industry standards.

For further information on the HARTING MICA EtherCAT connectivity please click here or call Tel: +4 (0) 1604 827500 or Email: salesUK@HARTING.com SEPTEMBER 2017 - PROCESS INDUSTRY INFORMER

ENCLOSURES CLIMATE CONTROL IN THE FOOD INDUSTRY Climate control of enclosures using water cooling is highly efficient, especially if there is already a central cold water supply available in the production plant.

The new Hygienic Design air/water heat exchangers from Rittal are ideally suited to the food industry, where hygiene standards are exceptionally stringent.

Hygiene is an absolute must in the food industry: machinery, plant and components must readily withstand daily cleaning with pressure washers and jet steam cleaners. All surfaces must also be easy to clean, and/or designed to prevent contaminants from adhering to them.

Use water cooling to dissipate heat Liquid cooling of enclosures offers a number of benefits: Because water has a higher thermal capacity than air, liquid cooling can dissipate large quantities of heat. What’s more, industrial environments often already have a central cooling water supply available that can be used for enclosure cooling. All that’s left to do is to mount suitable air/water heat exchangers on the enclosure. With Hygienic Design, it is particularly important that no air exchange takes place between the enclosure and the environment.

Rittal has revamped its air/water heat exchangers, and can now offer its clients in the food industry two variants of Hygienic Design. Air/water heat exchangers for wall mounting can supply cooling outputs of either 0.65 kW or 1.2 kW. The hygienic design reduces the risk of contamination in the food industry, thus helping to ensure product safety.

Modified design Rittal has modified the design of Hygienic Design in a number of respects.

For example, the attachment to the enclosure wall using threaded bolts and nuts has been designed so that the screw fastening is not visible from the outside. The enclosure is made from stainless steel with a brushed grain size of 400, producing a surface roughness Ra of less than 0.8 μm. The smooth surface finish is easy to clean and disinfect. There are no hardto-clean gaps where contamination could collect.

The silicone seal between the enclosure and the case prevents the transfer of colourants, flavourings and unwanted odours. The seal eliminates gaps between the air/water heat exchanger and the enclosure which would be difficult to clean.

The seals are available as spare parts, and are easily replaced in the event of mechanical damage. The seals are dyed blue in accordance with FDA Guideline 21 CFR 177.2600, making them clearly distinguishable from contaminants such as food residues. The flat seals on the water connection fittings are likewise dyed blue, and geometrically designed to sit flush against the shape of the fitting. A metal end stop prevents compression of the seal, so that edges cannot protrude and allow contaminants or micro-organisms to accumulate.

Tested hygiene The top of the enclosure tilts forwards by 30 degrees. This prevents objects from being placed on top of the enclosure, while at the same time ensuring that liquids, such as detergents and disinfectants, run off quickly.

Air/water heat exchangers have protection categories of IP56/59, meeting the demanding requirements of pressure washing and steam cleaning.

The air/water heat exchangers have C-UR and CSA approval, making them suitable for international use.

The Hygienic Design was tested by the DGUV Food department testing and certification agency in accordance with GS-NV 6 (test principles for hygiene). The devices comply with standard DIN EN ISO 14159:2008 and are suitable for use in the food sector in conformity with DIN EN 1672-2:2009.

Further information at Web: www.rittal.co.uk and Web: www.friedhelm-loh-group.com or on twitter @rittal_ltd.

33

FEATURED ARTICLE

THE COMPASS TO NAVIGATE INDUSTRY 4.0:

INDUSTRIAL ANALYTICS

by Edwin van Dijk, VP of Marketing, TrendMiner

As disruption escalates in 2017, industry faces increasing pressure to transform in order to remain competitive. This means finding ways to leverage new technologies and identify opportunities for optimization.

O

ne of the best ways to gain insight is to apply advanced analytics to the data generated by your revenue-generating assets and processes, but until now the challenges associated with achieving this goal have prevented many companies from enjoying the potential benefits.

In this article, we’re going to show how a new generation of industrial analytics solutions has solved many of the historical challenges, why this has democratized access to analytics-based insights and how this can help all manufacturers to improve plant profitability.

WHAT ARE INDUSTRIAL ANALYTICS? Industrial analytics refers to the collection, analysis and usage of data generated in industrial operations. This covers a very wide range of data captured from all kinds of sources and devices, whether an asset or a production process. Anything with a sensor creates data – and industrial analytics looks at all this data.

Naturally this means Big Data analytics – but industrial analytics differ from generic big data analytics systems in that they are designed to meet the exacting standards of the industry to which they apply. This includes the ability to process vast quantities of time series data from various sources, and turn it into actionable insights for the users.

This makes industrial analytics relevant to any company that is manufacturing and/or selling physical products.

34

THE PROBLEM WITH INDUSTRIAL ANALYTICS Many organizations can see the potential benefits of such an analytics solution, but the time and money needed to achieve it have historically put it out of reach. That’s because historically industrial analytics have been run like generic big data analytics projects.

The traditional and most common approach to industrial analytics involves data scientists building an analytics model. Data scientists must understand the use case and then gather, transform, optimize and load the data in the developed data model, which needs to be validated, optimized and trained to get to business value. The completed data model provides the answers to the initial questions.

Aside from the long time needed to realize results and the high cost associated, this way of working has another major disadvantage: it leaves companies completely dependent on their data scientists, and results in a solution that the subject matter experts (engineers and operators) may not fully understand.

SOLVING THE INDUSTRIAL ANALYTICS STALEMATE Luckily, as disruptive technology creates new challenges, so it also creates new solutions. In the last few years, there has been a growing trend towards self-service applications.

This next generation of software utilizes advanced search algorithms, machine learning and pattern recognition technologies to make querying industrial data as easy as using Google.

NO DATA SCIENTIST REQUIRED With self-service industrial analytics, there is no need to model data. Companies do not require a data scientist to use the software, and there is no long project timeline or high cost. Instead, the subject matter experts directly query their process data at any time in a self-service application.

Using pattern recognition and machine learning algorithms permits users to search process trends for specific events or to detect process anomalies. By combining search capabilities on both the structured time series process data and the data captured by operators and other subject matter

experts, users can predict more precisely what is occurring or what likely will occur within their continuous and batch industrial processes. For example, an operator can compare multiple data layers or time periods to discover which sensors are more or less deviating from the baseline then make adjustments to improve production efficiency.

DESIGNED TO BE USED Self-service analytics tools are designed with end users in mind. They incorporate robust algorithms and familiar interfaces to maximize ease of use without requiring indepth knowledge of data science. No model selection, training and validation are required; instead users can directly query information from their own process historians and get one-click results. Immediate access to answers encourages adoption of the analytics tool as the value is proven instantly: precious time is saved and previously hidden opportunities for improvement are unlocked.

This self-service analytics approach puts the power into the hands of the process experts, engineers and operators, who can best identify and annotate areas for improvement.

WHY GIVE THIS POWER TO END USERS? Working with time-series data is best done by the subject matter experts (such as process engineers and control room staff) because they have the knowledge of what to look for in case of anomalies in process behaviour and finding root causes. They can also identify best performance regimes that can be used as define ideal production and identify conditions for live process monitoring and performance prediction. These subject matter experts are, in fact, the key to improving the company’s profitability – all they need is the tool.

By democratizing access to analytics insights, actionable information becomes available at all levels of the plant.

This means the ability to achieve incremental improvements at all stages of the production process.

THE REAL BENEFITS OF INDUSTRIAL ANALYTICS With an industrial analytics solution, you can gain insight into all your assets and processes. Previously hidden trends PROCESS INDUSTRY INFORMER - SEPTEMBER 2017

incl. Pumps & Valves

FLUIDS & LIQUIDS HANDLING

BIFOLD PNEUMATIC ACTUATOR CONTROLS

EFFECTIVE PUMPING OF DELICATE INGREDIENTS

The Best Technology at the Lowest Cost – At Least 22% to 39% Cost Saving Bifold offer configurable valve control products, simplified for ease of selection with the highest safety factors and reduced spares requirements, offering the highest flow at the lowest cost.

Maximise flow of typical tubed systems with Bifold components With traditional tubed pneumatic control circuits Bifold elements are capable of the highest possible flow in the market but the output is limited by the change in the bore size through the tubes and fittings.

Maximise flow of typical nippled systems with Bifold components With traditional nippled pneumatic control circuits Bifold elements are capable of the highest possible flow in the market but the output is restricted by the diameter of the nipples.

Optimise flow with Bifold patented modular solution Bifold developed an unrestricted common bore system that optimises the high flow capability of their components.

Bifold have furthered this logic and developed a range of patented Filter Boosters removing as many elements as possible from the flow line including the filter and regulator, amplifying the possible flow for any given tube size.

This principle results in smaller tube sizes being used and can be supplied in up to a 2” connection.

Bifold are dedicated to maintaining the excellence of their products and their new facility confirms their commitment to shortening lead times and meeting customer demands.

Bifold Group would like to take this opportunity to thank all their customers for their continued support.

If you are interested in the lowest cost solution for your application, please visit bifold.co.uk for further details and a video outlining the above. You can also contact Bifold on Tel: +44 (0) 161 345 4777.

The CSF range of progressive cavity pumps is ideal for transferring a wide variety of products and ingredients or those with suspended solids and particles which often occur in the food, brewing, beverage and pharmaceutical industries. Available from liquids handling specialists PUMP ENGINEERING, the CSF range includes the eccentric screw, positive displacement MAN series of pumps.

CSF MAN hygienic series progressive cavity self-priming pumps are extremely versatile and ideally suited to transferring low viscosity products like soups or sauces, high viscosity products such as jams, creams, pastes and pie fillings or delicate ingredients such as fruits and vegetables, with a gentle pumping action which does not damage these sensitive ingredients. The positive displacement pumping action from the rotor and stator arrangement delivers a consistent flow, without the need for pulsation dampeners or non-return valves.

When used in conjunction with a variable speed drive they can be used for dosing or proportioning applications and where applications involve high viscosity products the pumps can be fitted with a hopper or wide throat inlet.

All wetted parts are manufactured from polished or satin AISI 316L stainless steel and the pump’s tie-rod construction allows for quick and simple inspection, cleaning and maintenance. Stators are available in white rubber for food use or other elastomers to suit the application. MAN Series pumps are available with a single mechanical seal as standard with double seals, or packed glands if required.

CSF progressive cavity pumps are identical to Helios™ progressive cavity pumps which are no longer marketed by MonoPumps. End-users will therefore appreciate that as the UK’s leading distributor of CSF pumps, Pump Engineering are able to supply all spares and replacement parts for these pumps.

Further details on CSF pumps are available from: Christopher Newberry, Pump Engineering Ltd, Tel: 01903 730900 | E-mail: sales@pumpeng.co.uk |Web: www.pumpeng.co.uk

ACTUATED SOLUTIONS ANNOUNCES ATEX APPROVAL OF HQ006 ACTUATOR Just months after the launch of the HQ005 actuator, the UK’s leading provider of valve automation products, Actuated Solutions, is announcing ATEX approval of its HQ006 electric quarter turn actuator.

Comprising high quality electrical components and alloy gearing, the compact yet powerful HQ006 ensures more consistent and reliable operations and an extended life span. Meanwhile, the product’s ATEX rating of EX II 2G, Exd IIB T4 confirms its suitability for use within explosive environments.

Especially designed for quarter turn applications, such as small ball, butterfly, plug valves and dampers, the HQ006 is relatively small yet provides impressively high output torques of up to 60Nm. Other key features and benefits include: a reversible motor with low current consumption, two M20 cable entries, manual override functionality, four limit switches and a high visibility beacon. The HQ006 also boasts a push button terminal strip, an anti-condensation heater, and its IP67 housing is hard anodised prior to painting to increase corrosion resistance.

Managing director, Paul Slaughter, comments: “We’re really pleased to able to offer the market small electric actuators suitable for ATEX environments, not many actuators have ATEX approval and certainly not for small bore valves, we’re sure the unique mounting system covering, F4, F5 & F7, along with the wide range of voltages which are available from, 24V to 240V, will help customers enormously.

The HQ006 is available in Europe exclusively from Actuated Solutions.

For more information please contact your local independent distributor, or visit www.Actuated-Solutions.co.uk SEPTEMBER 2017 - PROCESS INDUSTRY INFORMER

35

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

The Straub Coupling joins plainend metal (black, cunifer, galv., or stainless) pipe with axial restraint and without the associated risks of ‘hot-work’, welding, or burden of expensive grooving/threading machines. The slim-line coupling encases a patented sealing gasket that is progressively activated by the media pressure in the line, whether it be gas or liquid. Since Straub’s progressive seal encapsulates the line medium, ensuring no contact with the coupling’s metallic casing, it provides a cost-effective means of joining stainless or exotic alloy pipes in chemical applications. Straub’s unique patented design guarantees full re-usability performance in joining plain-end pipework in high maintenance applications, such as frequent blockages and eroding bends, without call for preparation (machining), pipe setting-up, or coded welders and other complicated procedures involving safety permits.Increased coupling range now available from Ø26 to 609mm.

Temperatures -30°C to +125°C in the range Ø26 to 60mm, and -30°C to +100°C up to Ø219mm, and beyond to 80°C. For more information contact MV Fluids Handling, Tel: 0118 9503707 E-mail: straub@mvfh.co.uk Web: www.straub.co.uk

Your Right Connection For Hygienic Process Systems Valves

Fittings

Hose

Engineered Products

Fabrication

Tel: +44 (0)1772 323529 Email: sales@dixoneurope.co.uk www.dixoneurope.co.uk 36

PROCESS INDUSTRY INFORMER - SEPTEMBER 2017

LIGHT CURTAINS ROCKWELL AUTOMATION INTRODUCES LIGHT CURTAINS WITH PATENTED TRANSCEIVER TECHNOLOGY As production processes become increasingly automated and robots play a larger role on the production line, manufacturers are looking for more ways to maintain and reinforce a safe work environment. The new Allen-Bradley GuardShield 450L safety light curtain system from Rockwell Automation is a flexible, cost-effective solution that enhances safety while improving productivity through innovative transceiver technology. Unlike traditional safety light curtains based on pre-defined transmitter and receiver units, this next-generation light curtain system features a patented transceiver design that employs plug-in modules to establish each unit’s function as a transmitter or receiver. Once powered up, the transceiver learns its functionality from the plug-in module.

Ideal for hand and finger detection, and offered in a wide range of protective heights, the light curtain system is also equipped with an active protective field that senses the entire length of the transceiver.

This feature reduces the inactive sensing areas that generally appear at the top and bottom of other light curtains.

Unlike traditional light curtain systems, the active sensing field and compact design allow customers to install the GuardShield 450L light curtain system inside a machine frame as opposed to outside or on the machine. Additionally, flexible mounting kits and builtin alignment indication allow for quick, trouble-free installation.

For more information contact Rockwell Automation Ltd, Milton Keynes, Buckinghamshire Tel: 0870 242 5004

LUBRICATION SKF MAINTENANCE & LUBRICATION PRODUCTS CATALOGUE NOW IN ITS 2017 EDITION If bearings are to provide long life and high reliability they must be properly installed, monitored, maintained and lubricated. With its latest 192-page Maintenance and Lubrication Products catalogue, SKF guides the user step-by-step through these essential tasks.

This fully updated 192-page publication is divided logically into sections that take the user through the entire bearing care plan, from correct mounting and shaft alignment procedures, through basic condition monitoring practices to the allimportant subject of lubrication.

The catalogue is available now, either directly from SKF and its approved distributors, or downloaded free of charge by visiting: www.skf.com/ binary/68-163650/03000EN.pdf SEPTEMBER 2017 - PROCESS INDUSTRY INFORMER

37

FEATURED ARTICLE

A BRIEF HISTORY & FUTURE OF INSTRUMENTATION

By Sebastian Amos BSc (Hons) CEng MInstMC, Sector Head – Process Instrumentation & Control, GAMBICA Instrumentation is a collective term for sensors incorporated into measuring instruments used for indicating, measuring and recording physical quantities.

Forming the basis of process control, instruments continue to improve their capability, repeatability, accuracy, reliability and cost.

instrumentation needed to be measurement in a format that could be visualised, recorded and understood.

Continuing the steam engine theme, the possible measurements that can be taken include steam pressure and temperature, water levels, flow rates and speed. The instruments were mechanical, using basic sensors for example; bimetallic strips for temperature, bellows for pressure and simple sight glasses for level. The instruments, by today’s standards, were works of art. Large brass enclosures and carefully inscribed dials.

These original instruments are now confined to working museums, where basic maintenance requires a tin of Brasso™.

The picture below shows these basic instruments as installed on the Mid Hants Railway 34007 Wadebridge Footplate, built in 1945.

T

hroughout the first and second industrial revolutions of mechanical innovation and mass production, instrumentation and its development were a key supporting technology.

Instrument developments at the sensor level have engaged both the mechanical, and chemical sectors, whilst the transmission of values has made use of the electronic industries forging the advancements through the third industrial revolution using electronics and computers to further the analysis of signal data processing.

As we enter the period dubbed the fourth industrial revolution, Artificial Intelligence, Big Data and more, this article follows the impact of instrumentation within the first three revolutions and examines how the instrumentation industry must engage in a world of digital data and forensic analytics to meet the challenges and expectations of this fourth industrial revolution.

EARLY HISTORY – THE FIRST INDUSTRIAL REVOLUTION With the coming of mechanisation, their soon developed a need for very basic control, but to control something, you first need a measure something.

It is probable that the steam engine governor could be considered the first closed loop control system using instrumentation.

Invented in 1788 by James Watt, this very basic and functional solution was able to measure engine speed through the rotation of two metal balls. As the machine went faster, the balls would simply move apart through centrifugal force. This provided a direct measurement of speed and when coupled into a steam control valve, controlled the final speed of the engine by regulating flow. Wikipedia provides a good article on how the system works. (1) Whilst the governor is still with us today, the next step in 38

Fig 2: Taken from an article in Flow Control magazine (3)

Fig 1. 34007 Wadebridge Footplate (2) Focusing on pressure, measuring pressure is one of the most basic instrumentation functions in any industry and certainly on early steam powered machines. Three types are of key interest; Absolute Pressure, measuring against a vacuum, Differential Pressure, measuring against two specific points with basic calculations deriving flow and Gauge Pressure, measuring against atmospheric pressure. Traditional systems used mercury manometers as seen in barometers and the Bourdon tube, a very simple system still widely manufactured and used.

EARLY HISTORY – THE SECOND INDUSTRIAL REVOLUTION In terms of instrumentation, there is a blur between the first and second industrial revolutions. The first brought the steam engine and the second focussed on motive electricity with the start of mass production, initially in steel and then into the chemical and petroleum sectors in the early 1900’s. The real start of the

second industrial revolution could be defined as mass production in the automotive industry at the start of the 20th century, still requiring nearly 100% manual labour and yet to progress more mechanised automation.

Instrumentation was developing but the sensors were still basically mechanical.

A recent trip to HMS Belfast, built in 1936 and now moored near Tower Bridge in London, had me examining the gauges installed on the boiler panels.

Many manufacturers devices are present and key to their procurement would have been their ability to show the same readings regardless.

Consequently, once there is a mechanism for measurement, there needs to be standards to enable all manufacturers to develop instruments that provide repeatable readings, in units engineers understand, that can be calibrated, are long lasting and of course are directly compatible with each other. The second industrial revolution focused on these areas.

As the ability to measure improved, so the ability to control also made leaps forwards.

Other than speed, governed automatically on steam engines, control was still a very manual activity.

Industrial control systems were developing, with the introduction of pneumatic solutions.

For example, absolute pressure can be measured using bellows containing a vacuum and instead of driving a needle on an instrument, a setpoint is provided through an air valve into the system and there is a pneumatic connection to a control valve providing proportional and integral PROCESS INDUSTRY INFORMER - SEPTEMBER 2017

functionality. There are many examples of developments in these technologies, no more so than in the aircraft and process industries.

Temperature (K), Luminosity (Cd) and the Amount of Substance (Mol).

Electrical primary sensors were developing. Simple physics i.e. pressure = force/area enabled Bordon gauges to be replaced with strain gauges.

Simple electronics provided temperature stabilisation and linearization. Temperature devices were able to take input from a range of thermocouples and provide linear outputs. Indicators could now be mounted remotely in large mimic panels and data collected on paper chart recorders.

One key area of innovation was, and still is, the use of 4-20mA as a standard instrument output. The standard seems to have be set up in the mid 1970’s and in the UK, developments are still managed under the BSI GEL65 committee.

Areas of improvement were Fig 3 – Pneumatic PI Controller Fundamentals (4) vast including; accuracy, precision, resolution, repeatability, linearity, hysteresis, the list goes on. Developments in In addition to these pneumatic measurements, there would be a measurement techniques have been continuous. Pressure mechanical gauge mounted close by. Even today, many Process transducers now include differential capacitance and load & Instrumentation Diagrams (P&IDs) still identify both a control cell, flow systems use ultrasonic, vortex and electromagnetic instrument and a local mechanical/electrical gauge. measurements, level uses nucleonics, weight has new The second industrial revolution remained broadly static in strain gauges, and the number of temperature measuring instrumentation technology and it was not until the 1960’s that thermocouples continues to grow along with IR systems. A major innovations took place. For example, electronic pressure good reference is found in Section 2 of Jonathan Love’s Process sensors are now available with at least 10 additional measuring Automation Handbook. (6) technologies.

The world of small analogue electronic packages opened up sensor design and signal processing.

THE ELECTRICAL REVOLUTION – THE THIRD INDUSTRIAL The Future of Instrumentation – The Fourth Industrial Revolution The fourth industrial revolution is really a focus on the REVOLUTION digitisation of industry. The process industries have their Up until the start of the third industrial revolution with the challenges in this area as do those engaged with manufacturing. explosion in development of electronic systems in the 1960’s, The end game should be a completely integrated supply chain, instrumentation had still been largely based on the mechanical from feedstock specification and order, through high quality and efficient manufacturing to providing customers with their sensors and gauge readouts from the earlier steam engines.

In 1875, the Metre Convention was signed by 17 nations to specific order. Mass customisation at mass production costs. coordinate international metrology. Whilst there had been a We have discussed at a very high level how instrumentation number of updates along the way, in 1960, the system was has developed from the simple around the primary sensors, overhauled and relaunched where International Standards analogue signal processing and on to early adoption of some were defined and SI units, established from the French digital integration through such solutions as HART. Computer Système International d&Unités, identified the seven base systems from the late 1960’s were already taking advantage units from which all measurements can be calculated; Length of the ability to take the electrical signals and now represent (m), Mass (kg), Time (S), Electric Current (A), Thermodynamic them on computer generated mimics. Some of the original systems were based on the DEC PDP8 introduced in 1965, Fig 4. Boiler Room Analog Control Room (5) a computer system designed for use in industry.

We now need to look at the basis of the digital revolution, that is the focus on digital data, either raw or pre-processed, and its transmission.

As we saw during the previous revolutions, it is not just the sensors that have improved.

As digital has taken over from analogue, computer power has increased and reduced in size and cost, signal conditioning, processing and conditioning has become more SEPTEMBER 2017 - PROCESS INDUSTRY INFORMER

effective. Universities continue to develop new ways to process signals and remove noise. Oxford University is in the process of licencing it’s PRISM technology that is a major leap in signal processing capabilities only possible with the huge processing power now available. (7) It is not only the physical manufacturing of sensors and instruments that has evolved, with the start of the 3D printing revolution, we can now print temperature and humidity sensors.

The CPI Printed Electronics group has already published and proven the concept of printed sensors for manufacturing processes and healthcare. (4) Our view is that the digitisation developments required for the instrumentation industry need to follow a structured thought process.

1. Digitisation of the value from the primary measuring element.

Whilst this does not preclude the continuation of an analogue interface e.g. 4-20mA, it would be true to say that this technology could now be retired. All instrumentation that is integrated into the digital supply chain will need to have some technology embedded that provides not only configuration parameters, but connectivity. It is not easy to predict the protocols required but as the size and power of embedded processing coupled with its low cost, adopting configurable systems would be a safe bet.

2. Pre-processing either at the instrument or a local edge computer As the quantity of available data increases, and the prediction is that this will be exponential, a reduction of raw data transfer will be required. There are still limits to the communications bandwidths, especially if radio networks are considered.

Edge computing will allow the pre-processing of raw data into manageable packets. The use of embedded processing will provide an instrument with its own edge processing and configurable data compression algorithms.

3. Embrace Digital. Users of instrumentation will need to embrace the wholly digital concept. There is an older generation who will need to accept that what they see on a computer screen is accurate and that there is no longer a need to tap the glass on the front of the instrument. The younger generation will simply expect to stand next to the process line and see the values on their tablet.

Manufacturers of instrumentation need to plan. Their development budgets need to recognise that in parallel with the continuing development of the instruments, packaging and certifications, the interface must have equal focus. There are several SME instrumentation companies in the UK who still believe that a 4-20mA interface is all that is, and will ever be, required. So, as was stated at the start, in order to control something, we need to measure something, but the concept of control has developed to include many more systems than just the control of the physical process. Manufacturers need to understand that while making products, constant monitoring of raw materials, process variables and control, digital instrumentation is key to any enterprise in the digital revolution.

There are many organisations that can help companies onboard the digital revolution. GAMBICA is able to help and we can be contacted through our website.

References.

(1) How a Centrifugal Governor works www.en.wikipedia.org/wiki/Centrifugal_governor (2) Mid Hants Railway 34007 Wadebridge Footplate, Peter Drury 2008 www.e-group.uk.net/gallery/data/504/Wadebridge_Cab_backhead- 2154488.jpg (3) Selecting Pressure Gauges: New Advances on an Old Technology. www.flowcontrolnetwork.com/selecting-pressure- gauges-new- advances-old- technology/ (4) Pneumatic PI Controller Fundamentals www.nptel.ac.in/courses/112103174/module6/lec5/4.html (5) Boiler Room Analog Control Room www.i2.wp.com/www.processtechacademy.com/wpcontent/uploads/2015/03/ control_room11.gif (6) Process Automation Handbook by Jonathan Love, published by Springer ISBN: 9781- 84628-281- 2 (7) Prism Signal Processing for Sensor Condition Monitoring www.ora.ox.ac.uk/objects/uuid:2465f6be-abd8- 4e9a-9e79- d5f30084872e (8) Printed Sensors – CPI. www.uk-cpi.com/future-inspired/digital-manufacturing

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SENSORS UNIVERSAL DIFFERENTIAL pH WATER QUALITY SENSORS

FEATURED ARTICLE

WASTEWATER ISSUES

SOLVED

By Jon Dunham- Key Account Manager for C&B Equipment, Lenexa, Kansas, USA

Sensorex SD7500 works with any existing conventional pH transmitter Routine sensor replacement is a necessary maintenance step in continuous online pH monitoring. The Sensorex SD7500 Universal Differential pH Probe extends the working lifetime of sensors, reducing maintenance frequency, without compromising accuracy and reliability. Universal compatibility with virtually any brand of conventional pH transmitter enables easy upgrade of existing sensors for industrial and municipal wastewater treatment and neutralisation; metal finishing and plating; wet fume scrubbers; chemical processing; and other online water quality and process applications.

The SD7500 probe measures process pH differentially with three electrode sensors: a process pH electrode, a pH reference (actually a second measuring pH electrode in a known pH 7.0 buffered cell solution protected by a replaceable salt bridge reference junction), and a titanium ground electrode. The result is a highly accurate differential pH measurement that is virtually unaffected by ground loop measurement errors.

The three electrode design, coupled with durable Ryton® Polyphenylene Sulfide (PPS) body construction, resists process contamination. The double junction construction of the replaceable salt bridge further guards against fouling, even in highly aggressive chemical environments. Automatic temperature compensation with an accurate Pt1000 RTD ensures pH measurement accuracy over a wide temperature range.

Differential pH sensors are designed so the double junction salt bridge and the buffered reference cell solution can be replaced in the field by on-site operators, at a much lower cost than total sensor replacement. Compared to conventional combination sensors, differential pH sensors provide measurements of greater stability, over longer periods of time, with less downtime and maintenance. Typical sensor service lifetime ranges from 3 to 5 years.

With a self-powered preamp and combination sensor output, the SD7500 Differential pH Probe can be used with most conventional online pH/ORP transmitters and controllers.

This enables drop-in replacement in existing process installations, as well as easy integration into new systems.

Manufactured in the USA, Sensorex’s SD7500 probe is backed by a two-year limited warranty.

To learn more about the SD7500 Differential pH Probe, visit www.Sensorex.com, E-mail info@sensorex.com or phone Tel: +1 714-895-4344 40

Your use of water in your processes, in many cases, is passed on to a local treatment plant. If you have a wash down area or are just flushing process areas, chances are you are disposing of rags, gloves, wipes and other miscellaneous trash down a drain.

T

his required washing ends up in pit or wet well where submersible pumps make the transfer to the treatment plant. If you are spending time cleaning and removing clogs from pumps or trash from the wet well there is a remedy to end this. The proven system to end the trash collection or clogged pumps is a direct inline pumping system.

Submersible pumps in wet wells have been the norm for over sixty years. This old “technology” presents many problems with today’s operations especially if using disposable wipes. It may be time for your plant to modernize the wastewater pumping system to a modern direct inline pumping system with self-cleaning pumps. These modern pumps shred any of the typical refuse that clogs the old submersible pumps.

Some plant managers feel that they have to spend additional budget funds on grinders, bar screens and rakes, or trash baskets just to handle the trash issues.

Additional energy costs, the maintenance required, and just plain trash hauling is certainly not productive.

The direct inline pumping system is a better, less costly way to solve this problem.

A manufacturer of wastewater pumping systems recognized the costly issues with wipes and trash clogging pumps in 2001. It was designed, built, tested, and proved a new pumping technology that was patented in 2002. Direct inline pumping was born and since that time there have been thousands installed where clogging had been a costly, time-consuming problem. There are now end users that find better use of their time than cleaning trash from wastewater pumping systems.

This modern pumping system is innovative, sustainable, and offers pumps that clean themselves without human intervention. It uses Variable Frequency Drives (VFD’s) that provide soft starts and stops, run the pumps at only the speed required, and is energy efficient. All wetted parts are made of 304 stainless steel ending

the maintenance needed by the old corroded iron and steel. As the medium pumped is in a sealed system, there are no odours or hydrogen sulfide gas emission problems. Wet well cleaning is ended forever as it is no longer a “wet well” and float switches are no longer required. Should an impeller need changing, it can be done in as little as 15 minutes with common hand tools.

This system is not just monitored but is fully capable of remote management using a desktop, a tablet, or even a smart phone from anywhere in the plant or even

from the home office across the country. An operator can “watch” the pumps run and even order and print reports if he/she wishes. Modern direct inline pumping of wastewater is certainly gaining interest where process water is managed.

PROCESS INDUSTRY INFORMER - SEPTEMBER 2017

PROCESS MEASUREMENT & INSTRUMENTATION MULTI-FUNCTION FLOW & TEMPERATURE SENSORS IMPROVE EFFICIENCY Precise flow and temperature measurement is essential in many applications and the recently expanded range of FLEXFLOW process sensors available from BAUMER LTD provides some highly efficient and flexible solutions.

FlexFlow sensors are based on the calorimetric measurement principle which enables the monitoring of both flow and velocity in addition to media temperature in a single instrument. The combination of 2 measuring functions in a single sensor reduces the number of measuring points required in closed systems and therefore minimises installation costs, service and storage.

FlexFlow sensors incorporate features such as; an IOTHE GREEN PERISTALTIC PUMP Link and depending on settings and connections, either 2 switching outputs, or one switching and one analog output (4 / 20mA, 0 / 10V). Also, thanks to their symmetrical, centred design, the sensors can be optimally installed in the process, independent of their installation position and orientation to ensure precise and safe measurements. The range includes the PF20H and PF20S options which are suitable for hygienic and industrial applications.

The IO-Link enables users to simultaneously configure several sensors and this simplifies and saves time when point adjustment is needed for different process stages during set-up, and or for batch changeover.

FlexFlow sensors are designed to enable diagnostic data polling and process evaluation at all times which helps to maximise system uptime and improve efficiency.

Baumer Swiss made sensors are renowned for their quality and durability and the FlexFlow sensors benefit from a robust, stainless steel housing with integrated electronics. They also feature an integral evaluation unit which eliminates the need for complex wiring, a control cabinet assembly or other additional user interfaces.

All the sensors in the FlexFlow range are temperature resistant to 150ยบC and CIP (Clean-in-Place) and SIP (Steam-in-Place) capable.

Further details available at: www.baumer.com

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The Next Generation Peristaltic Cased Pump with Intuitive Touch-Screen Technology

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SEPTEMBER 2017 - PROCESS INDUSTRY INFORMER

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PROCESS MEASUREMENT & INSTRUMENTATION SICK ULTRASONIC FLOWMETER, A FIRST FOR INLINE MEASUREMENT IN HYGIENIC APPLICATIONS The SICK Dosic® ultrasonic flowmeter has opened up the benefits of ultrasonic inline measurement for process engineering applications where stringent hygiene and corrosion resistance are essential.

Developed by SICK to have fully stainless steel wetted parts without in-channel seals or moving components, the Dosic® promises robust reliability, low maintenance and long service life for flow measurement in both conductive and non-conductive liquids, including demineralised water. Offering high-temperature resistance for stringent Cleanin-Place and Sterilisation-in-Place procedures, it carries full EHEDG certification

and FDA conformity.

Ideal for process applications in the food and beverage, pharmaceutical and cosmetic industries, the SICK Dosic® is also suitable for such duties as oil/water suspensions and emulsions, osmosis and filtering units, biodiesel and light and heavy oil pump metering duties.

The fully stainless steel 316L wetted part construction, without internal seals, has a very fine electro-polished, finish (Ra ≤ 0.8 μm) to ensure maximum cleanliness and minimum flow resistance and turbulence.

The SICK Dosic® continuous process temperature capability ranges from 0 to +95oC, with resistance up to 143oC for up to 60 minutes, enabling C-I-P and S-I-P procedures as part of routine process cleaning. Process pressures from -0.5 to 16 bar ensure wide process compatibility.

For more information about the SICK Dosic® ultrasonic hygienic flow meter, please contact Andrea Hornby on Tel: 01727 831121 or email andrea.hornby@sick.co.uk

Innovative level-measurement technologies

Ex TRANSMITTER WITH KC CERTIFICATE FOR KOREA The intrinsically safe EE300Ex humidity and temperature transmitter from E+E Elektronik now also bears the “Korean Certification Mark” (KC) required in Korea.

The KC certification is comparable with the European ATEX, the American FM or the Japanese TIIS approvals already available for EE300Ex. The EE300Ex is dedicated for highly accurate humidity and temperature measurement in potentially explosive environment. The transmitter is available for wall mounting or with remote probe and can be mounted directly in both gas and dust hazardous areas of zone 0 / 20.

The two-part enclosure facilitates easy installation and rapid replacement of the measurement unit for servicing or calibration.

The enclosure and the sensing probes are made of high-quality stainless steel, which makes the transmitter suitable for both demanding industrial applications and for clean rooms. Depending on the choice of sensing probe, the EE300Ex can be used for combined humidity and temperature measurement, for temperature measurement only, or for moisture measurement in oil.

Accurate measurement in the range 0 to 100% RH (0 to 1 aw for moisture in oil) and -40 to 180°C (-40…356 °F) are possible at a pressure of up to 300 bar (4351 psi).

The E+E proprietary coating is a key feature when it comes to harsh working conditions. The coating protects the sensor from contamination and corrosion, thereby relevantly improving the long-term stability and the lifetime.

The measured humidity and temperature values, as well as calculated measurands like dew point, frost point, absolute humidity or mixing ratio are available on two analogue outputs and on the optional display.

Further information about the EE300Ex transmitter can be found online at: www.intrinsically-safe-measurement.com

BESPOKE SOLUTIONS FOR IN-LINE ANALYTICAL MEASUREMENTS

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UWT - The Level Measurement Expert

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Connection thread from 1" All-Rounder for all industries Very light bulk material >20g/l Universal voltage No calibration necessary

UWT (UK) Ltd Tel: +44 (0) 1743 718883 sales@uwtuk.com www.uwtuk.com

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METTLER TOLEDO’s in-line sensors are designed for applications in the chemical industry and help fight corrosion, reduce fouling, and increase process efficiency. Our tailored in-line analytical measurements and automated maintenance solutions can be applied to the most challenging of in-line measurements in the chemical industry.

We have released a collection of application notes providing a detailed overview of how the in-line analysis of pH and gas is vital in overcoming the most complicated chemical industry process challenges.

Our guides also show how our automated solutions can reduce maintenance, plant downtime, and minimise the risks of exposing employees to hazardous or toxic environments.

Other highlights featured in our Application Collection include: • pH control in phosgene removal in TDI manufacturing • pH control in propylene oxide manufacturing • pH control in ethylene oxide manufacturing • Gas measurement in harsh conditions Download the full Application Collection Short URL: www.mt.com/uk-application-collection For more information contact Mettler Toledo Ltd, Beaumont Leys, Leicester Tel: 0116 234 5095 | Email enquire.mtuk@mt.com | Web: www.mt.com PROCESS INDUSTRY INFORMER - SEPTEMBER 2017

PROCESS MEASUREMENT & INSTRUMENTATION NEW TMZ DUAL PC-PROGRAMMABLE MODBUS TEMPERATURE TRANSMITTER Moore Industries’ recently introduced their new TMZ Dual (2TPRG) PC-Programmable MODBUS Temperature Transmitter that allows users to increase density and reduce costs with dual RTD, thermocouple, mV, resistance or potentiometer inputs by doubling temperature monitoring capability in a single unit.

The Dual TMZ’s two independent sensor inputs are easy to configure using a free copy of Intelligent PC Configuration software available for download from Moore Industries’ website. The data from both sensors is available on the MODBUS output, allowing the host to use the data for averaging, differential or sensor backup.

Up to 32 (without repeaters) TMZs or TMZ Duals can be multi-dropped onto a single low-cost communication link (such as a twisted wire pair), eliminating the need to run a dedicated wire for each signal. The TMZ Dual provides increased sensor density delivering even more savings on installation, cable, conduit, connection and wire tray costs. Both the TMZ and TMZ Dual feature long-term stability (5 years), 20-bit input resolution, isolation and RFI/EMI protection. Since the measurement is delivered to your control system as a digital signal, the output error produced by a traditional analog transmitter is eliminated.

IN For more information on Moore ST TH SEE RU E S U Industries, visit www.miinet.com M EN S A or call 01293 514488 E S T

PROCESS READY ULTRASONIC FLOWMETER Designed to IP65 standards the Process Atrato ultrasonic flowmeter from Titan Enterprises is built for use in demanding process and control environments.

Durably constructed from 316 stainless steel and PEEK, and incorporating proprietary ultrasonic flowmeter technology, the Process Atrato offers reduced cost of ownership compared to existing flow measurement devices used in the process environment.

Rated for use up to 65°C and 20Bar the compact Process Atrato is available in 4 models operating over flow ranges from 2ml/min to 15litres/min, featuring an accuracy of ±1% over the whole flow range.

Each Process Atrato is calibrated with a pre-set ‘K’ factor so all meters of the same flow range are fully interchangeable simplifying assembly and set-up procedures for OEM manufacturers looking to integrate the flowmeter into their process and control set-up.

Using patented technology that enables it to operate accurately over wide flow ranges, the Process Atrato signal processing system permits flow measurement across the whole Reynolds number range allowing both viscous and nonviscous products to be metered.

For further information visit: Web: www.flowmeters.co.uk or contact Titan Enterprises on Tel: +44-1935-812790 or E-mail sales@flowmeters.com.

ST NTA OR AN TI S D ON & E5 S HO W

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Manufactured by Labfacility IEC and ANSI options available Mineral Insulated Thermocouples with various termination options Platinum Resistance Thermometers Pt100 Industrial Style Thermocouple with Terminal Head Environmental Sensors

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SEPTEMBER 2017 - PROCESS INDUSTRY INFORMER

sales@labfacility.com Sheffield tel: +44 (0)1909 569446

43

FEATURED ARTICLE

PROCESS MEASUREMENT & INSTRUMENTATION

TIPS FOR EXTENDING YOUR ELECTRIC MOTOR’S LIFE

By Autumn Wiberg - Copywriter (On behalf of Houghton International)

Motors are central to many industry processes. However, through extended use, motors can become worn and less efficient, driving associated costs up for businesses.

D

id you know that the initial cost of an electric motor makes up just 2% of its life-cycle cost?

With maintenance and repairs occupying such a large cost share in relation to electric motors, motor rewind specialist, Houghton International, share their tips for extending your electric motor’s life.

ADEQUATE LUBRICATION Your motor needs to be adequately lubricated given its many intricate rotating parts. Whether your motor uses grease or oil, lubricants separate rolling or sliding surfaces, minimising friction and heat to reduce overall wear. They also work to prevent corrosion and contamination.

Over- or under-lubrication can cause major problems with your electric motor. When under- lubricated, there is not enough oil or grease to protect the motor’s internal parts, leaving it susceptible to wear and tear. When the opposite occurs and the motor is overlubricated, shields can become damaged and the oil or grease can lose their lubricating capability, as caused by rising operating temperatures caused by friction.

Optimal lubrication is a key factor in extending the life of your motor. Always lubricate according to manufacturer guidelines or the motor’s lubrication plate. This will help determine how often you’ll need to oil or grease the motor and the type and grade of the lubrication you’ll need.

You must make sure the oil or grease used is compatible, otherwise your efforts could be fruitless.

Failure to choose the correct grease or oil can have varying degrees of impact, from mildly increased bearing wear to complete machine failure. It can also lead to unusual increases in: - Heat generation - Metal wear - Vibration - Noise - Unusual colour shifts in lubricants - Foreign particles - Leaks caused by viscosity changes - Foaming - Emulsion formation - Fluid separation Overall, the higher the level of compatibility, the greater the damage caused. As a general rule of thumb, use the same oil or grease that is already in the motor

44

bearings.

TEMPERATURE INCREASES An increase in temperature could cause significant damage to your motor. There are a number of reasons why temperature may increase, including overloading, under-voltage, over-voltage and improper ventilation. Because the incorrect temperature can significantly impact the performance of your electric motor, it’s important to monitor and maintain the correct temperature.

Allow the motor to cool and you will likely avoid this type of temperature damage. Keep its operating environment free of dirt and debris to ensure vents do not get obstructed and prevent hot air from being recirculated throughout the motor.

If the temperature increases suddenly, it could be an indication of another problem. Monitor changes to prevent issues from arising.

REGULAR MAINTENANCE In addition to the above, regular maintenance is important. There are three main types of maintenance: preventative, predictive and reliability-based maintenance.

PREVENTATIVE MAINTENANCE As the name suggests, preventative maintenance aims to discover issues before they have an opportunity to take effect. This type of maintenance can include electrical tests, measuring winding resistance and mechanical assessments.

PREDICTIVE MAINTENANCE Relying on trend analysis, predictive maintenance is the process of forecasting when maintenance or repairs will be required. In essence, this allows you to predict the lifespan of the motor’s parts.

RELIABILITY-BASED MAINTENANCE Through motor analysis, reliability-based maintenance allows you to establish the most suitable maintenance solution to ensure motor longevity. This type reduces maintenance to the most costeffective activities.

EDWARDS LAUNCHES NEW FULLY MOBILE, EASY TO USE LEAK DETECTOR Edwards recently launched their new ELD500 precision leak detector. It is designed for fast, accurate leak detection and is customisable for any application.

Edwards’ ELD500 is ready to go in under two minutes from power on. Users can benefit from simple pass/fail readings through to detailed analysis via the easy to read control interface, and due to the low weight and integrated carry handles it is mobile enough to be bench top or trolley mounted. At the push of a button the ELD500 can easily be set to work in either vacuum mode for precise measurement of leak rate, or sniffer mode for identifying the leak location. The proven design of Edwards’ ELD500 leak detector, combined with low energy consumption, extended warranty and even longer life ion source, ensures exceptional low cost of ownership with no compromise on performance.

Edwards’ ELD500 achieves excellent repeatable accuracy through calibration with the integrated test leak source and high quality mass spectrometer, so it could be used on a production line, where consistent measurement repeatability is critical, or in a laboratory environment where typically the measurement of extremely low leak rates is needed. The ELD500 has three variants, the FLEX, WET and DRY plus an extensive catalogue of accessories.

Full details can be found at www.edwardsvacuum.com/ELD500

ALICAT EXPANDS INDUSTRIAL AUTOMATION PROTOCOL OPTIONS WITH ADDITION OF MODBUS TCP/ IP A full range of communication protocols to integrate Alicat mass flow and pressure instruments into process scheme Alicat Scientific has added Modbus TCP/IP compatibility to its line of mass flow, pressure, and liquid instrumentation. The new option allows PLCs running the Modbus industrial automation protocol to connect to Alicat instruments over Ethernet cable.

Alicat instruments rapidly and precisely monitor and control critical process parameters in chemical, medical, manufacturing and power industries. All the mass flow or pressure controller’s data, including: mass flow, volumetric flow, pressure, temperature, selected gas calibration, setpoint, and totalised flow can be output to a central PLC running a compatible automation protocol. Users may also change setpoint or gas selection, and issue other commands remotely. Now these capabilities are available in a Modbus intranet or internet environment, using the TCP/IP protocol.

In addition to the new Modbus TCP/IP protocols, Alicat offers standard Modbus-RTU, EtherNet/IP, DeviceNet and PROFIBUS communication options to fit new or existing systems. For easy drop-in replacement of older industrial units, Alicat instruments are made to fit the same space as common industry mass flow controllers. All Alicat instruments are backed by NIST-traceable calibration, comprehensive technical support and a lifetime warranty.

To learn more about Alicat’s protocol options, visit www.alicat.com/ModbusTCPIPnews, or contact Alicat’s European office at Tel: 01223 472804, Email: europe@alicat.com.

PROCESS INDUSTRY INFORMER - SEPTEMBER 2017

RECYCLED POLYMERS CARBON FOOTPRINT REVIEW SHOWS ‘LARGE’ SAVINGS FOR AXION’S RECYCLED POLYMERS Recycled polymers have significantly lower carbon footprint than oil-based virgin plastics – up to 89% for ABS – according to latest research by Axion Polymers.

The Manchester-based plastic recycler’s 2017 Axpoly® Carbon Footprint Analysis also reveals a carbon saving of 82.5% for recycled (HIPS) and 73% for recycled (PP).

The CO2 savings are large, according to Axion. Their team calculated that using just one tonne of Axpoly ABS instead of virgin material to make goods would give a saving of 3,380 kgs of CO2 – equivalent to a 40ft articulated lorry transporting the material 2,272 miles. On one fullload, the same lorry could be driven 45,500 miles or almost twice round the world on the equivalent CO2 savings.

Axion Polymers produces three types of recycled polymer from their advanced reprocessing plants for Automotive Shredder Residue (ASR) derived from End of Life Vehicles (ELV) and WEEE. These are Axpoly® PP (polypropylene), ABS (Acrylonitrile Butadiene Styrene) and HIPS (high impact polystyrene) and are the most common plastics used in the automotive and E& E markets over the past 15 years.

The Axpoly® polymers can be used as a direct replacement for virgin polymer, or combined with virgin polymers to produce a highgrade polymer with recycled content that can be used in demanding applications. The new study was prompted by recent investment in more efficient separation processes and improving throughput that has increased the yield of finished polymers.

Axion based its methodology on the similar process stages to making oil-based polymer from crude oil to allow a direct comparison between the process routes and resulting carbon emissions.

The calculations were done by Axion’s Head of Engineering &; Research, Richard McKinlay who says: “These ‘new metrics’ of the circular economy are the numbers that need to be considered by designers and specifiers of polymer materials when selecting plastic for use in new parts and components on all types of consumer goods and vehicles.”

SEPTEMBER 2017 - PROCESS INDUSTRY INFORMER

WEIGHING HYGIENIC DESIGN MEETS HIGH SPEED: THE NEW CHECKWEIGHER FROM MINEBEA INTEC Since the launch of the checkweigher Flexus last year, the hygienic design features for the food industry have been systematically enhanced. The new Flexus Highspeed from Minebea Intec features hygienic design right down to the finest detail, and also offers faster processing speeds. The in-line checkweigher now reliably checks the weight of small packaged foods such as tinned fish, yoghurt or snacks at high speed.

Along production lines, checkweighers can often slow down the speed of production and therefore reduce its efficiency. Flexus Highspeed offers processing speeds of up to 2.6 m/s, opening up new possibilities in the food industry in terms of economy. “The success of our in-line checkweigher Flexus has shown us that hygienic design is right at the cutting edge. Therefore, when optimising the hygienic design of Flexus, it was clear that we needed to consider both product innovation and product diversification,” explains Stefanie Dahmen, Product Manager Inspection at Minebea Intec, “The new Flexus Highspeed is our response to the demand for a checkweigher specifically for weighing smaller products quickly. We are anticipating high demand in the 1 kg weighing range, and higher speeds in the weighing range up to 7 kg are of course also possible.”

Faster processing speeds, shorter cleaning times All checkweighers in the Flexus range have been consistently developed according to the EHEDG hygienic design guidelines, in order to comply with the strict hygiene standards in the food industry. As a result, contact surfaces and horizontal surfaces have been minimised, and the need for hollowed sections has been eliminated due the open frame. Together with the increased floor clearance, hygienic feet and a hygienic box for the pneumatics, the checkweighers thus guarantee straightforward inspection and quick and reliable cleaning. The resulting shorter cleaning times offer additional potential in terms of economy and efficiency.

Configurable for a wide range of applications Flexus doesn’t just stand for hygienic design: the checkweighers also offer a wealth of configuration options that provide greater flexibility. This means, for example, that it is easy to attach additional modules to the sturdy constructions upper frame. For optimal inspection in limited space, there is the Flexus Combi with integrated Vistus metal detection technology. There is also a comprehensive selection of separators and a wide range of data interfaces for seamless integration into any IT landscape.

For more information contact Flexus at www.minebea-intec.com Minebea Intec UK Ltd (formely Sartorius) Birmingham, West Midlands.

Tel: 0121 779 3131 E-mail: cs.uk@minebea-intec.com

45

FEATURED ARTICLE

DO PLANT MANAGERS MAKE THE BEST OF THEIR

DOWNTIME?

By Robert Glass, Global Communications Manager at ABB P l a n n e d downtime is a a critical part of the production c y c l e , allowing maintenance and plant engineers to assess the status of equipment and ensure it is fully functional and make planned repairs and upgrades.

While necessary, this process has traditionally been a bugbear of many plant managers. Yet the development of smart technologies is changing this. Here, Robert Glass, global communications manager for ABB’s food and beverage program, explains how food and beverage plant managers can make the most of downtime.

T

he digitalization boom of the past decade has had a significant impact on industrial plants.

The advent of technologies such as smart robotics, cloud computing and predictive analytics means there is little preventing businesses from adopting an always-on approach to operation. However, the main reason this is not yet a widespread reality is planned system downtime, which, as every plant manager understands, is a necessity.

Of course, planned downtime itself is not a bad thing.

During a set period, production lines and equipment are temporarily switched off so that maintenance engineers can assess the health of the system, make repairs and clean equipment. This is particularly important for the food and beverage industry, where hygiene is critical and production equipment must be contaminant-free. These functions are carried out to ensure that production lines can continuously operate reliably and safety, which makes this preferable to unplanned downtime due to fault or 46

failure.

However, this still poses an issue for plant managers because any downtime, scheduled or otherwise, results in a dip in production. In continuous production industries like food manufacturing and processing, the hours lost to scheduled maintenance can account for a noticeable short-term fall in business profitability. This is exacerbated by the fact that downtime has not traditionally been scheduled using operational performance data, which may make its timing not optimal.

The solution to this is to plan maintenance work on specific systems separately, using performance data collected by smart technologies as an indicator of equipment health. Plant managers can review this accumulated data during planned downtime, allowing them to use the time productively to devise an informed and data-driven approach to maintenance in the future.

This process effectively shifts the time-tested maintenance paradigm. Instead of carrying out reactive maintenance on equipment and systems when things go wrong, engineers can conduct predictive maintenance that pre-empts problems. Plant managers capitalizing on this opportunity can truly realize the potential of digitalization and interconnected devices.

For example, most food processing plants include some form of conveyor system to move food through the production line effectively.

The importance of these systems means that they are always operational, Electric motors are used throughout the conveyor system, yet because motors can be difficult to access and see into, a motor’s

health is typically not known, and they are run until they stop. As a motor’s health deteriorates, performance drops significantly and there are several consequences such as elevated vibration levels and temperature.

Using a smart sensor on motors to monitor and assess a motor’s health allows plant managers o make an informed assessment. Plant managers can then use this data to identify when a motor needs maintenance and schedule it accordingly. To establish an informed maintenance schedule, plant managers should also use periods of planned downtime to review historic performance data and identify any patterns or trends.

While line downtime is currently an unavoidable part of production, digitalization may allow this to be minimized in the future. In the meantime, plant managers can make the most of planned downtime by reviewing performance data and making effective plans for the future.

PROCESS INDUSTRY INFORMER - SEPTEMBER 2017