Process Industry Informer Magazine Jan/Feb 2014 Edition by Process Industry Informer

PROCESS INDUSTRY INFORMER.

JAN/FEB 2014 Volume 10 No. 1

THE UK’S BIGGEST PUBLICATION SERVING THE PROCESS INDUSTRIES

From Laboratory to Health & Safety, Consultancy to Management:

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In this issue... • 14 Editorial Articles • News & Applications • Product Introductions • BPMA News • Solids Handling & Processing Supplement/SHAPA News

From process control to managing chemicals, from modern SCADA to digital control valves, from piping systems to waste management, from leak detection to bin level measurement, from dust suppression to chain conveyors, from fluid sampling to water hammer solutions and much more – with you our readers in mind…

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

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CONTENTS

EDITORIAL FEATURES Adaptive Process Control 9

News & Events 4-5

Filtration 23

Applications 6-8

Stainless Steel Floor Drainage 23

Network Communications 11

Power Measurement 24

Spray Nozzles/Safety Showers 12

BPMA News - from The British Pump Manufacturers Association 25-32

Waste Management 12

Health & Safety 36-37

Fluids & Liquids Handling inc. Pumps & Valves 12-14

Enclosures 37

Instrumentation 18

Wiring Systems 37

Sensors 18

Calibration 37

Difference between Mineral & Synthetic fluid sampling 10 Talking Turbine Pumps 15 Digital valve controllers help drive performance optimisation 16/17 Water Hammer in Valves 20/21 Sealing Piping Systems for Sustainability 22 Refrigeration leak detection 33 Modern SCADA Systems 35/35 Managing Chemicals safely 38

SHAPA NEWS - SOLIDS HANDLING & PROCESSING SUPPLEMENT (Starts on page 39) SHAPA Update 1SP

Drives & Motors 19

SHAPA News - Solids Handling & Processing Supplement 39-55

Getting to grips with WASTE 4SP Keep up with ATEX and stop dust fires 6SP The true cost of En-Masse Chain Conveyors 8SP Bin Level Measurement 12/13SP Assessing the need for Dust Suppression 14SP

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

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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

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NEWS & EVENTS

PLAN FOR 2014 TRAINING WITH SPIRAX SARCO Spirax Sarco has launched a new training brochure for 2014, giving plant operators and managers more ways to save energy, increase productivity, improve product quality and reduce risk. Discover the latest boiler guidance by enrolling on the Boiler Operation Accreditation Scheme (BOAS) course. Recommended as the qualification of best practice by the Health & Safety Executive, Combustion Engineering Association and The Safety Assessment Federation, BOAS provides a national accreditation for boiler operation or management. The BOAS Renewal course also features within the 2014 prospectus. Qualified engineers with a BOAS certificate must retake a refresher course every five years to remain BOAS accredited. This course gives an update on best practice and safety to candidates and covers any new legislation or guidance notes. The 2014 training course brochure offers a wide range of courses covering the latest legislation and aspects of the design, operation and maintenance of steam systems. Each course is taught by leading experts in steam technology and is approved by professional bodies such as Pearson BTEC; City & Guilds; CEA; and CIBSE. Training can be completed at Spirax Sarco’s Steam Technology Centre. It is the only UK facility to offer a fully operational steam system with SCADA control. Spirax Sarco provides a selection of national qualifications, correspondence courses and on-site training to suit any training need. For more information on Spirax Sarco’s range of training courses visit www.spiraxsarco.com/uk/training, or speak to the UK Steam Technology centre Tel: 01242 535211 or training@uk.spiraxsarco.com.

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NEW IEC 61439 ELFAB AWARDED ISO/TS 29001:2010 STANDARDS ARE CERTIFICATION FAST APPROACHING Pressure relief specialist Elfab has been awarded ISO/ TS 29001:2010 approval for its quality management system. Elfab is the first rupture disc manufacturer to satisfy the third edition of technical specification ISO/ TS 29001, developed specifically for the petroleum, petrochemical and natural gas industries. Explaining the significance of the accreditation, Elfab’s quality manager Bryan Tate said: “This approval demonstrates Elfab’s commitment to industry best practice and continual quality improvement. It allows us to streamline operations to continually improve our technical knowledge and reduce waste, which will benefit our customers in the long term.” Lloyd’s Register Quality Assurance carried out an internal audit at Elfab’s premises in August 2013, with official certification following two months later. This is a further addition to Elfab’s extensive range of quality approvals. Ed Durante, project leader of the ISO/TC 67 working group that developed ISO/TS 29001:2010, described the standard as “the baseline requirement for quality management systems in the exploration and production sector of the petroleum and natural gas industry. The document is gaining acceptance in the refining sector and is being seriously considered in the pipeline sector.”

Rittal has produced a guide book, Standardcompliant Switchgear and Control Protection, which offers an insight into the new IEC 61439 standards and to assist Rittal customers and give guidance on how to comply with the standards. Relating to building of control panels and electrical distribution systems, the new IEC 61439 standards will be in force from November 2014 and impact upon the design of the panel, selection of components and the testing methodology. Basically, the panel will become a system, which means the designer/panel builder must consider: the enclosure, the effects of heat upon the components, cooling equipment, busbar system, mechanical properties and the generation of test documentation, which is a requirement. For further information please e-mail Mark Guest (mguest@rittal.co.uk) or for a free copy of the guide book, please use powerdistribution@rittal. co.uk. For more information contact Rittal Ltd, Rotherham, South Yorks. Tel: 01709 704000 E-mail: information@rittal.co.uk Web: www.rittal.co.uk

For more information contact Elfab Ltd, North Shields, Tyne & Wear Tel: +44 (0)191 293 1208 Fax: +44 (0)191 293 1200 E-mail: pr@elfab.com Web: www.elfab.com

NOV Mono extends its German partnership network NOV Mono has entered into a new working partnership to expand the levels of support and service it delivers to water and wastewater customers in Germany. Under the new agreement, Würdig Pumpentechnik will provide sales and service support from its offices in Berlin, Potsdam and Fürstenwalde. “Würdig Pumpentechnik covers various areas in Eastern and North Eastern Germany, such as Berlin, Brandenburg, Mecklenburg-Vorpommern and SachsenAnhalt,” says Werner Potrafke who manages sales of Mono Universal Parts and Mono’s EZstrip™ products in Northern Germany. “The company offers a range of services for the water and wastewater industry, from design and construction through to delivery and repair,” he adds. “Over the past 33 years the company has serviced more than 100,000 pumps and thereby gained an excellent reputation for reliability and service quality. Their knowledge of engineering, plant construction and pumps is first-class. This has led to them working with a wide range of water and wastewater customers, in both the public and private sectors, so they are an excellent fit for the Mono™ range of products and services.” For more information contact Nov Mono Pumps, Audenshaw, Manchester Tel: +44 (0)161 339 9000 Web: www.mono-pumps.com

ABB launches UK’s largest technical channel network for drives and motors At a recent press conference ABB announced that they have amalgamated its UK variable-speed drives and electric motors networks into a single brand identity, to create a new benchmark for technical advice, delivery, life cycle services and overall customer satisfaction. Under the umbrella of “The Authorised Value Provider” this has been achieved by amalgamating their ABB Drives and ABB Motor Service Partner networks and is a global initiative designated to see the development of more third parties selling ABB products and services. From a UK perspective the underlying objective is one of growth as this is an initial step to developing its business around the “packages” concept. In the longer term the idea is of course to establish a greater customer base and to serve existing and new customers with faster and expert support. This initiative sees a group of 18 Authorised Value Providers who when appropriate, can network together in order to provide a quicker and more efficient service in both the sales and service objectives. Needless to say existing and new AVP’s have to have a viable business and have had to be involved with motor driven systems for several years and be prepared to invest in dedicated internal engineers, sales personnel and service engineers and to have suitable premises with a training facility and workshop. Moreover they have to agree stock levels and a joint business plan. In order to ensure that all engineers, sales & service employees are “up to scratch & +” they are required to complete rigorous training courses and exams and are given direct access to ABB engineers with expert knowledge in different areas thereby ensuring ABB customers that they have the high quality of technical support and product back up , required by ABB customers. “Industry is evolving

at a fast pace and the demands of customers are changing quicker than ever,” says Neil Ritchie, Local Business Unit Manager for ABB’s drives and controls business. “The Authorised Value Provider programme marks the growth of the already successful ABB channel network into a bigger, better, stronger one; a network that is designed to meet the rapidly changing requirements of global business by providing consistent access to ABB products and services.” So what are these “rapidly changing requirements” that customers want and to have then encouraged ABB to make this move? Broadly they are: 1.Greater customer demand for outsourcing 2. Increased interest in packaged solutions 3. Widening legislations, regulations and directives 4. More engineering tools 5. Advanced products 6. Broader range of life cycle services. How do the Authorised Value Providers meet these needs? Products • ABB low voltage electric motors up to 500 kW including a range of special motors available ex stock within the UK • ABB variable-speed drives up to 500 kW, ex stock within the UK Applications • Know-how of all rotating equipment including pumps, fans or transmission assets • Extensive technical knowledge and back-up of all electric motor-driven applications Expertise • Up-to-the-minute expertise on the latest legislation, regulations and directives affecting motor-driven applications Services • Support drives and motors throughout the entire life cycle including services covering: o Pre-purchase o Order & delivery o Installation & start-up

PROCESS INDUSTRY INFORMER January-February 2014

o Operation & maintenance o Retrofit & upgrade o Replacement & recycling • Common service standards throughout the UK • Access to ABB’s motors and drives design and technical support Partners • Support from world leading automation and electrical company, ABB • Personnel trained by ABB; products warranted by ABB; partners approved by ABB Visibility • Authorised Value Provider member, their authorised services and ABB products are visible to customers on the web. They can be searched via the respective country and product page, www.abb.com and www.abb. com/drivespartners pages. Knowledge • Authorised Value Providers have access to extensive training opportunities, both locally and globally. The training consists of product, tool, service, and process courses as well as access to technical and commercial documentation and tools. Business • Structured business planning practices ensure a customer driven market approach, intensive network cooperation and optimised support from ABB. Long term planning • Authorised Value Providers not only have access to ABB processes, support mechanism, services, tools and products, but also have an opportunity to influence the future offerings of these. In order to meet and exceed customer’s needs, also in the long term, the programme strongly emphasises the value of continuous joint development. On the face of it, it makes good sense and is refreshingly “customer” designed and appears that ABB have “stolen a march” on their competitors – it will be interesting now to see how they react!!! PU.

APPLICATIONS

Durapipe ABB DRIVES protects water CUT OUT treatment works £10,000 PUMP REPAIRS FOR ALKANE ENERGY

ABB is helping a major producer of energy from coal mine methane to cut its pumping costs by using variable-speed drives (VSDs) to make its process more reliable. Alkane Energy, one of the UK’s fastest growing independent power generators, operates mid-sized ‘gas to power’ electricity to the grid. Alkane now has a total of 81 MW of installed generating capacity and an electricity grid capacity of 100 MW. The company uses VSDs to control the vacuum pumps on new sites but was keen to see if they could be retrofitted to existing sites. The challenge with these is that the pumps are run direct-on-line and operate at full capacity all the time. This causes extreme wear on pumps, which tend to fail after only a few months. ABB Drives Alliance member Inverter Drive Systems installed a 75 kW ABB industrial drive which modulates the pump to keep the pressure constant. For more information contact ABB Ltd, Warrington, Cheshire Tel: 01925 741 111 Fax: 01925 741 212 E-mail: energy@gb.abb.com Web: www.abb.co.uk/energy

Durapipe’s specialist dual contained pipework system, Durapipe Guardian, has been installed as part of a refurbishment project at Rivington Water Treatment Works. A United Utilities facility, Rivington Water Treatment Works was undergoing an upgrade to its plant, which included replacing the existing pumps and tasked contractors Byzak with installing a reliable pipework solution to feed the new pumps. The pumps are utilised in the water chlorinating process and so the pipework was needed to transport sodium hypochloride from the bulk storage tanks to each of the seven new pumps. Needing a pipework system that could safely transport the specified chemical substance, Durapipe Guardian was selected as the most effective solution. The pipework was being installed in the ceiling voids of the plant so, due to the nature of the chemicals being carried, it was vital that the system was dual contained to prevent any potential leakages spilling out into the plant and endangering unprotected workers. After investigating a variety of different options for dual contained pipework systems, Byzak opted for the Durapipe Guardian system due to its chemical resistance properties and ease of installation. Its corrosion resistant properties also ensure that the pipework system operates effectively over the lifetime of the system, reducing maintenance and replacement costs. Commenting on the project, David Fielding from Byzak, said: “Sourcing a reliable secondary containment system was imperative for this project to ensure the health and safety of those working at the plant. For further information on Durapipe Guardian or any other products within the Durapipe UK portfolio please call 01543 279909 or log onto www.durapipe.co.uk.

Denso Protal again chosen for brine fields weld joints Having used Winn & Coales Denso Protal, with its corrosion resistant properties, to coat steel welded joints and fittings on the 900mm Stublach Minimum Offtake contract for National Grid, J Murphy and Sons Limited have again chosen Denso Protal 7000 brush grade to protect additional welded joints and fittings. These are on the 750mm bi-directional pipeline tie-in to the Minimum Offtake to connect the underground Gas Storage Infrastructure being developed by Storengy UK Ltd, a subsidiary of Gaz de France.

Denso Protal 7000 brush grade applied to the 900mm full encirclement Class 600 split tee at Stublach Following shotblasting to the Swedish St 2 standard, Murphy applied the Denso Protal 7000 which enabled them to obtain a required coating thickness of 1000 microns in two applications. Winn & Coales Denso Protal coatings give effective anticorrosion properties by forming a firmly bound corrosion inhibiting film on the metal surface. The result is a thick, effective physical barrier against air and moisture which remains permanently flexible. The brush grade can be applied by plural Hydrocat spray. For more information contact Winn & Coales (Denso) Ltd, Chapel Road, London Tel: 020 8670 7511 Fax: 020 8761 2456 E-mail: mail@denso.net Web: www.denso.net

CENTRICA ENERGY USE MICRONICS CLAMP-ON FLOW MEASUREMENT TO MONITOR WATER USAGE Power stations are heavily regulated and one key measurement is the volume of water being used at any one time. This includes river water for cooling and normal water for steam generation. Excessive use incurs considerable fines. Centrica Energy, part of the British Gas Group, own and run Killingholme Power Station in North Lincolnshire which is a combined gas turbine (CCGT) power station which began operation in 1994. It can send out over 3,000GWh of energy annually when the station is running at full load. At present the station runs a two shift system, which means they switch on and off twice a day allowing a competitive station with low losses. The station uses fresh water which is then conditioned for steam generation. 200 gallons of water can be used daily, through a 4 inch pipe from a mains water system. A flow meter is required to measure the volume metric flow rate which enters the storage tank; normal flow rate can be near 100 meters cubed per hour. The original meter broke down in 2011 and was found to be obsolete; a new flow meter was fitted in April 2013.

Jon Dixon, Centrica’s Control Instrument Technician determined that to avoid costly and disruptive downtime in the plant the replacement flow meter would have to be easy to fix without any need to break into the system. He compared suppliers and found that the Micronics Ultraflow 3000 offered the best value for money and its operation has proved exceptional. It uses non-invasive ultrasonic sound transmission and detects liquid flow velocity inside closed pipes; it is simple to operate and gives accurate measurements. Jon explains how the meter works: “When ultrasound is transmitted between the transducers, the speed at which the sound travels through the liquid is accelerated slightly by the velocity of the liquid through the pipe. When ultrasound is transmitted in the opposite direction, the flow of the liquid causes the transmitted sound to decelerate. The subsequent time difference is directly proportional to the flow velocity in the pipe.” There are considerable opportunities to use Ultraflow throughout Centrica’s network and in similar applications

in other industries, including in the Building Services, Energy Management, Power Generation, Chemical, Pharmaceutical, Petrochemical and Food industries, where all that is required is to set up the product and calibrate it. It renders the use of mechanical meters unnecessary and is an excellent alternative to cutting pipes. It offers simple, low cost flow measurement from outside the pipe meaning that there is no interruption to process and no downtime whilst the flow meter units are installed. Micronics Ltd is a UK based company established for nearly 30 years with customers in over 40 countries. For further information on this project or the Micronics range contact Micronics Ltd, High Wycombe, Bucks. Tel: +44(0)1628 810456 Web: www.micronicsflowmeters.com.

PROCESS INDUSTRY INFORMER January-February 2014

APPLICATIONS BABCOCK WANSON WINS PROCESS HEATING ORDER FOR FIBRE & YARN COMPANY A long standing Babcock Wanson customer, Drake Extrusion has been using a small steam generator since 2001 and a thermal fluid heater, both built by Babcock Wanson, plus 16 electric thermal fluid heaters supplied as part of the yarn processing equipment. Whilst still operational, this equipment is reaching the end of its natural life providing Drake with the opportunity to upgrade to modern, more efficient equipment and save substantial energy costs. Two Babcock Wanson TPC1000B gas fired Thermal Fluid Heaters have been installed in their place, with each heat user having a secondary circuit to ensure the correct design thermal flow rate and temperature, which varies from 100 to 280°C. This will allow Drake to reduce fuel costs by replacing electrical heating with natural gas and will also free up space within the factory as the 16 separate heaters located around the factory along with much of the pipe work will be removed. Instead, the new Babcock Wanson heaters have been installed in a new external housing, which also makes for an improved working environment. In addition to the TPC1000B Thermal Fluid Heaters, Babcock Wanson has supplied all necessary ancillary equipment including pumps, tanks, control valves, manual valves, thermal fluid pipe work, gas pipe work and the external heater house. They were also responsible for removal of redundant equipment. For more information, please contact Babcock Wanson on 020 8953 7111 or info@babcock-wanson.co.uk or go to www.babcock-wanson.co.uk

Heraeus Short Wave InfraRed Speeds UP Tool Heating At Mettis Aerospace Offers significant energy savings and improved controllability Short wave infra-red emitters from Heraeus Noblelight have allowed Mettis Aerospace to reduce the time required for the heating of tools and dies used in the manufacture of high specification titanium aircraft components to one seventh of the heating times required by a previous gas system. This has provided significant energy savings and improved controllability, as well as improved forging practices at the company’s Redditch site. Mettis Aerospace has decades of experience in the production of highly complex forged and machined, safety-critical aircraft components. Today, Mettis is an important global supplier of complex alloy components to industry giants such as Rolls Royce, Boeing and Airbus. Previously, die heating had been carried out by an open flame gas system, which directed its heat onto support plates. The gas system remained switched on for 24 hours to ensure that the plates were at the correct temperature before the tools were loaded into position. Heating by this method could take up to ten hours, with limited control of the heat transfer. Heraeus was asked to provide an alternative infra-red solution. The short wave system installed consists of two 72kW infrared cassettes, each mounted on an aluminium vertical profile frame. Since installation, the new system has allowed significant energy savings, as it is now only switched on when required, while tool heating times have been reduced, in some cases, from ten hours to just 90 minutes. For more information contact Heraeus Noblelight, Neston, Merseyside. Tel: 0150 353 2710 Web: www.heraeus-infraredsolutions.co.uk

PROCESS INDUSTRY INFORMER January-February 2014

Nov Mono ends 20-year pump project to preserve historic artefact When a number of Mono™ pumps were switched off recently, it marked the end of a 20-year operation to preserve the remains of an historic Tudor warship, the Mary Rose. The progressing cavity pumps from Mono™ have been used to help spray the fragile timbers of the Mary Rose with a mixture of water and wax – a crucial stage in the preservation process which has now come to an end. The race to preserve the remains of Henry VIII’s flagship began after she was recovered from the Solent, where she had sunk some 430 years earlier. In 1994, a pair of Mono E122 progressing cavity pumps were chosen for duty/standby roles to help spray the hull continuously with a solution of Polyethylene Glycol (PEG) to stabilize its waterlogged timbers. The pumps provided a continuous stream of PEG to 360 spray nozzles located around the ship, and were supported by four smaller Mono pumps, which operated the heating and cooling circuits that maintained the PEG at an optimum spray temperature. After 10 years of operation when maintenance was required on a gearbox, the Mono pumps were also inspected and found only to need one stator component replacing. The pumps then returned to operating at speeds of 279rpm, circulating 2,000 litres per minute of PEG solution around the spray system. Six additional Mono Industrial E range pumps were later added to increase the capacity of the heating and cooling circuits. “The ship’s timbers had to be kept fully moistened at all times, so the pumps used had to be totally reliable if the timbers were to be properly preserved,” comments Mono’s Senior Sales Engineer, Mike Burton. “This project really has shown how Monopumps can provide consistently high levels of performance year after year and simply go on giving excellent service.” For more information contact Nov Mono, Audenshaw, Manchester Tel: 44 (0)161 339 9000 Web: www.mono-pumps.com

PUMPING

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APPLICATIONS Qdos metering pumps selected by Russian automotive plant • Qdos 30 pumps used to help automate water treatment unit at wheel factory • Qdos chosen over diaphragm metering pumps based on rigorous trials • High accuracy characteristics deliver impressive results After a comprehensive evaluation and trial period, the Russian plant of steel wheel manufacturer, Mefro Wheels, has opted to use the latest Qdos 30 metering pumps from Watson-Marlow Pumps Group at its facility in Togliatti. Selected ahead of diaphragm metering pumps, the Qdos 30 pumps have been fully integrated into a complex process control system at the plant’s water treatment unit. With over 4000 employees and a turnover of circa e500 million, Mefro Wheels GmbH operates nine plants worldwide, including two in Russia. As a group, it produces more than 20 million car wheels, 3.5 million truck wheels and 1.5 million wheels for tractors, agricultural and construction machinery every year. Automated operation The Togliatti facility, which is located some 800 km east of Moscow, was acquired by Mefro from established Russian car manufacturer Autovaz in 2011. Seeking to impart greater levels of automation at the factory, Mefro began to consider peristaltic pump technology for its water treatment unit. In 2012, a presentation of

Qdos 30 metering pumps was delivered by Sergey Davidyan, Sales Engineer at Watson-Marlow, after which commenced an intensive period of demonstration and testing on site at Togliatti. “After careful product consideration, together with colleagues from Camozzi Pneumatics [an Italian manufacturer of pneumatic components with responsibility for automating the wheel fabrication shop], a decision was made to use Qdos 30 pumps with ReNu pumpheads in our water treatment unit,” says a spokesman at Mefro. “The Qdos 30 pumps proved to be excellent both in the demonstration tests and in day-today operation.” High quality Being a German wheel manufacturer, Mefro has high expectations in terms of pump reliability, metering accuracy and performance characteristics, along with ease of integration, operation and maintenance. Fortunately, the Qdos specification matches up to the most rigorous of demands. For instance, the pumps deliver a flow range from 0.1 to 500 ml/min, and 7 bar, while integrating easily through IP66 manual, analogue and PROFIBUS control options. Featuring patented ReNu pumphead technology which is fully contained for safe, tool-free maintenance. Furthermore, the pump’s metering accuracy clearly caught the eye of Mefro engineers.

WERNERT SUBMERSIBLE PUMPS FOR CHEMICAL EFFLUENT TRANSFER Wernert vertical VKPF- 50-250 pumps are proving to be a great success for transferring chemical effluent from collection tanks to a treatment/neutralisation facility at a chemical processing plant in the north of England. Sometimes referred by to Wernert as ‘forget me pumps’ because of their reliability, AxFlow now has five variable speed vertical, cantilever shaft pumps handling a mixed acidic solution. The chemical plant produces refrigerants/propellants such as A22 and Klea, and because of the highly corrosive and hazardous nature of the effluent, the pump shaft in the liquid area is protected by a plastic sleeve whilst the bearing in the thrust bearing lantern is protected from aggressive vapours and gases by a PTFE radial shaft seal ring. First installed in 2010 and added to in 2012, all five pumps were required in order that the plant could comply with new emission controls. It is important that the continuous transfer of the chemical effluent is done reliably in order to prevent an overflow that could result in an emission to the local waterway. The Wernert pump is capable of handling this challenging application as it is especially suited to pumping liquids that are contaminated with solids. It is a true “cantilever shaft pump”, having support bearings above any process liquid, thus eliminating need for external bearing lubrication or chance of wear due to exposure to the process liquid. This type of pump is not provided with any sealing against the pumped liquid because leakages flow out above the impeller through lateral openings in the delivery suspension pipe. “When it came to designing and building the pump installation, the challenges involved matching the required duty, ensuring the pumps were able to withstand the fluid duty and designing a means to easily remove the pumps when required,” says Mike Buhagiar, AxFlow Senior Sales Engineer - Process Dept. “We were called upon to provide technical advice and explain the pump details,” he continues. “We provided cross sectional drawings to explain the pump construction, supplied the pumps on time and offered installation and commissioning advice. To date, pump performance has been good and very reliable, no pump changes have been required and minimal maintenance has been required.”

“When compared with some manufacturers of metering pumps, including diaphragm types, we were surprised by the high accuracy characteristics declared in the brochure,” says the Mefro spokesman. “However, following operational measurements, these characteristics were substantiated completely.” Impressive performance The Qdos 30 pumps have now been running at Togliatti for over six months. The pumps operate at low flows, with the performance based on process requirements, these vary within a range from 3 to 5 litres per hour. The discharge pressure is determined by the piping length and height to which the liquid is pumped, and is approximately 4 bar. To control performance, a current analogue signal of 4-20mA is transmitted from the central control unit to the input of the Qdos 30 pump. “It is particularly gratifying that no ReNu pumpheads have been replaced for the entire period of being in service, despite almost constant operation since the time of commissioning,” concludes the spokesman. For more information contact Watson-Marlow Pumps Group, Falmouth, Cornwall. Tel: 01326 370370 E-mail: Heather.Beale@wmpg.com Web: www.wmpg.co.uk

Flow meters provide solution for lng ‘boil-off’ application Level and flow instrumentation suppliers ALLISON ENGINEERING have enjoyed success with a specialist flow meter application for their ST110 Gas Flow Meters being used on board LNG ships to measure ‘boil-off’ gas, the natural wastage gas generated in the storage tanks. The process involves natural gas being cooled down to minus 163ºC at atmospheric pressure. The tanks on board an LNG carrier functions as giant thermoses to keep the liquid gas cold during storage. However, no insulation is perfect and the liquid is often boiling during the voyage and the solution is for reliquefaction and boil-off. Typically LNG tankers are powered by steam turbines with boilers which are dualfuel so they run on either methane or oil, or a combination of both and conveniently the boil-off gas which is produced is used as fuel for the vessel. Where ‘low emission’ zones exist, especially within European Union waters, it is mandatory for tanker operators to accurately measure how much boil-off gas they are using in their engines. Accurate and reliable measurement and specifically, in-line calibration and verification of boil-off gas, is crucial to tanker operators helping them to comply with current regulations. The ST110 is unique in its ability to be functionally tested and calibrated without the need to remove the sensor from the pipeline. It features an internal purge tube that runs the length of the sensor and allows the operator to generate a known flow across the sensor element. The resultant signal output can then be compared to the factory baseline test certificate. For more information contact Allison Engineering, Basildon, Essex Tel: 01268 526161 E-mail: generalsales@allison.co.uk Web: www.allison.co.uk

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

PROCESS INDUSTRY INFORMER January-February 2014

Adaptive Process Control delivers Built-in, Bottom Line Benefits How the Chemicals Industry Can Benefit from Advanced Control Technologies by Rachel Lowell, APC Products Group, AspenTech Optimising plant operations and maximising the profitability of assets is essential for petrochemical, oil and gas companies alike to compete in today’s market. The chemicals industries, in particular, encompass a wide range of complex challenges, including the need to maintain product quality, reduce energy consumption, maximise throughput and increase yield, whilst Evolution and innovation in APC Over the last few decades model-based predictive control has matured from a differentiating technology enjoyed by only the largest bulk chemical and refining entities to an essential technology for all continuous process companies. Driven by industry consolidation and market volatility the applicability of APC has expanded to smaller and less complex processing units, with companies seeing greater benefit of APC through improved integration with other plant systems (e.g. DCS), significant cost reductions, better ease of use, faster time-to-benefit, simpler maintainability and sustained value. Experimentation with electronic instrumentation and control began in the late 1950s to early 1960s, soon replacing pneumatic transmitters and manual tuning practices. Consequently, some standardisation was achieved while instrumentation vendors advocated their own systems. Through collaborative efforts with major users, instrument and computer control systems software companies began to swiftly evolve. Through the 1970s computing power expanded enormously and monitor displays gained in popularity as this era saw the emergence of the Distributed Control System (DCS) to improve functionality and flexibility. In early to mid-1980s APC was seen as a strategic edge for major industrial companies. In-house teams drove the technology adoption, which became an accepted standard in refining and ethylene with deployment on major plants across the world. For more than 20 years, Aspen DMCplus has been the industry standard for advanced process control software. The application has been successfully applied on large and small units and is the most scalable commercial technology in the industry. By the early 2000s, technology innovation saw the development of industrial non-linear control and batch capabilities.

Where do we stand today? APC has progressed over the years to allow the process industries, including bulk chemicals companies, to improve their operations, resulting in continuous management, control and optimisation of complex process interactions. Once a dynamic multivariable model is developed by an APC team and utilised with well-proven control software, the model can predict the future path of the process, comply with the operating boundaries and implement an optimal move plan to drive the plant to the desired targets. Essentially, APC comprises a supervisory control and optimisation layer above the basic level of regulatory control. Today, APC eliminates the need for operators to repeatedly adjust PID controller setpoints manually. APC provides models that automate regulatory and constraint control, while optimising the process. Savings of up to 2 - 6 % of annual operating costs can be gained with payback often measured in months and almost always in less than one year. Moreover, APC can be used on any process, especially processes that are difficult to control with single loop PID feedback controls. These processes can have long time delays, changing conditions, complex heat integration, frequent or periodic upsets (such as dryer switches) or quality variables that are measured intermittently or offline. With regards to batch processes, improvements in automation and regulatory control will help manufacture the product in a consistent way resulting in reliable product quality and allow operators to successfully manage varying conditions. By shortening batch times, production increases and companies can be flexible when operational requirements change.

meeting safety and environmental standards. Advanced Process Control (APC) solutions help to successfully address these diverse production process issues. With the evolution of APC, innovative model-based predictive control techniques today deliver increased profits by reducing process variability and allow plants to be operated closer to their true constraints.

With continuous process industries, APC can better coordinate the interactions that invariably occur in single loop control systems, reduce the process variability and allow the plants to run closer to their operating constraints. Advanced multivariable constrained control is a major advantage in helping to cut energy use, as well as raw materials and waste processing costs. It can also improve product yield and process safety and productivity.

Typical benefits of APC summary: • Reduced product quality variation by up to 75% through improved process inferentials leading to better control and understanding of the process • Increase yield of high value products by 2 - 5% due to reduction of losses due to quality issues • Increased throughput or production capacity by up to 10% through pushing the plant up against its true operating constraints. Agility gains, such as manufacturing flexibility, customer responsiveness, need to reduce working capital by processing to order not to stock • Reduced energy consumption by up to 10% by maintaining operations within desired limits and not over purifying products • All of these factors combined lead to an increase in reliability by up to 4%.

Expanding capabilities in APC In the past, many users of APC solutions suffered from steadily degrading benefits over time. Process changes, equipment aging and changing economic conditions are just a few factors that drive the need to maintain controller models. Adaptive Process Control developed by AspenTech is a break-through in technology that eliminates the need to approach APC maintenance as a project and creates a continuous process of assessing model quality, collecting current data and generating new models as the behaviour of the plant changes over time. The software can detect, isolate and correct problems without increasing the burden on engineering staff. There is a crucial difference between the traditional approach to controller maintenance (sustained value) and Adaptive Process Control. With sustained value, revamping the controller was done as a lengthy and costly project. Under Adaptive Process Control, however, the controller is modified over time in more of a continuous process. The update of the model occurs without the need to take the controller off-line and enables a company to reap the benefits of control and optimisation while the model is under maintenance. Model quality analysis, which continually runs and assesses the accuracy of the model, can detect when degradation of performance occurs. It can pinpoint a specific part of a controller, thereby helping engineers to determine the underlying cause of the degradation in performance. Companies now have the ability to collect new model identification data using small perturbation background testing. The new model identification algorithm also supports the use of high degrees of closed loop data. This reduces the need for the aggressive step-testing methods traditionally used. As the new data are collected they are monitored in real-time and, using the new automated slicing technology, bad data are automatically removed producing a clean data set for model identification. Adaptive modelling creates candidate models and those are automatically presented to the engineer for review. The engineer always has the final decision before the

PROCESS INDUSTRY INFORMER January-February 2014

model is deployed. This entire process is monitored by an automated test agent and the engineer is notified in real-time of any problems that occur within the workflow.

The additional benefits of Adaptive Process Control are to squeeze out costs and increase benefits from making improvements to existing solutions by adopting new technology breakthroughs: • • • •

Minimise erosion of benefits Return controllers to service faster after turnarounds Reduce Controller Maintenance Costs by 25% Increase benefits by continually improving performance • 10% - 20% increase in total APC benefits Today, with Adaptive Process Control non-expert engineers can do everything required to update the models without the need to turn off the controller. They can also ensure that the controller exhibits robust behaviour during the periods between model updates, make maintenance a built-in and continuous part of the process and eliminate the need to wait for turnarounds to revamp controllers. Crucially, the software permits the engineer to always be in the loop in terms of making decisions when new models would replace existing ones in on-line applications.

Conclusion Since the early days of process automation, chemicals and refining companies have experienced rapid increases in operational challenges. The game has become more complex. Traditional advanced process control and offline, open-loop optimisation no longer delivers sufficient economic benefits because of the constantly changing conditions of today’s plants. For companies to be competitive, economic benefits must be achieved through continuously improved process control techniques and innovations.

Adaptive Process Control provides a set of innovative, patented techniques for automatic adjustment of the controllers in real-time and elevates maintenance to a built-in and continuous part of the management process. For process industries, in particular chemical companies, operating today the message is simple. APC software delivers sustainable measurable benefits and allows companies to operate their facilities with greater profitability, safety, cost effectiveness, reliability and compliance with environmental regulations. APC delivers very significant built-in, bottom line returns. AspenTech – Europe, Reading, Berkshire Can be contacted on: Tel: +44-(0)-1189-22640 E-mail: esales@aspentech.com Web: aspentech.com

Forgetting the London Hydraulic Company ~ How mineral and synthetic fluid sampling differs ~ Over a five-year year period, a properly focussed maintenance plan will save at least half the cost of unplanned production stoppages caused by thermal fluid breakdown. However, the frequency of gathering sampling data for a heat transfer fluid, on which the maintenance plan depends, is determined by whether the fluid is mineral or synthetic. Clive Jones, Managing Director of Global Heat Transfer explains more. In the nineteenth century, the London Hydraulic Company had 181 miles of hydraulic cable running underneath the UK capital, providing power to its factories. Yet these are rarely referenced in the history books. This illustrates that the provision of energy to manufacturing, irrespective of its form, has always been hidden. In the process industry, the transfer of energy in the form of heat is so hidden that it is extremely common for a plant manager or chief engineer to have no idea of the correct methods of thermal fluid maintenance. System maintenance work on thermal fluid may not be the first thing that comes to mind for the average plant manager, but without periodic system drain, flush and full charge of new thermal fluid or planned preventative maintenance, systems have a habit of breaking down at the most inconvenient and expensive time.

Regular sampling Regular thermal fluid sampling serves as an early warning system for future events and enables us to plan effectively how to increase the productivity of a system so that it runs efficiently at all times. Plant managers want to operate a safe business knowing that thermal fluid is managed in line with DSEAR and ATEX requirements to monitor its condition.

plan will regularly assess the extent of system wear by incorporating regular thermal fluid sampling. Regular fluid sampling may also highlight an increase in carbon which will ultimately reduce the efficiency of the thermal fluid because carbon acts as an insulator. When carbon is present in thermal fluid it demands more energy to maintain temperature which results in higher fuel costs. A plant manager can ensure continual output and a safe and legal system by proactively taking thermal fluid samples and using the results to prompt a series of corrective actions, including periodic dilution, filtration and regular venting to ensure a safer system. This negates the need to flush the system and, as such, reduces waste and responsibility associated with waste management. Top-up of thermal fluid is sufficient in some cases but proper thermal fluid management is preferable. The minimum annual requirement for system safety surveillance, to check for things like leaking flanges, provides a baseline service from which a maintenance plan can be developed. This can be achieved by switching the frequency to a half yearly cycle, or to a three monthly cycle in an ideal situation. Analysis and sampling to check for flashpoint, viscosity and carbon build up should be more frequent; twice a year minimum, but every three months is better, and less than three monthly is best..

Leaks and cavities In the case of top-ups, the analogy of a central heating system can be quite useful. Radiators are bled and water is topped up every year before the cold season to remedy any leaks and air cavities that may have formed through an air collector. If you don’t do this, the flow of a system can easily be compromised, making it perform less efficiently.

Over a five-year year period, a properly focussed maintenance plan will save at least half the cost of unplanned production stoppages caused by thermal fluid breakdown.

Proper maintenance reduces carbon deposition and fouling which damages systems. Average capital expenditure costs for replacement parts are up to £21,000 ($32,657, B25,000) for a heater coil and £45,000 ($70,000, B53,378) for a new heater - based on a system of just 50,000 litres. This does not include the cost of draining the system, flushing it and replacing the thermal fluid. By proactively managing thermal fluid, focussed maintenance also lowers the environmental impact of a plant by reducing waste, and decreasing health and safety risks whilst complying with insurance requirements. Degraded oil in a system wastes energy because pumps have to work harder. As a result, a maintenance

Similarly, leaks and air cavities in a thermal fluid system can typically account for a five percent fluid loss, which needs to be topped up. However, top-up is a poor substitute for a complete fluid management system, which will ensure that the fluid is in a safe and healthy condition. Complete fluid care is a lifecycle management process, involving fluid sampling and analysis of the results, as well as getting fluid to the site and correct disposal of old fluid.

Synthetic or mineral? Synthetic heat transfer fluids are designed to resist thermal cracking and oxidation better than mineral fluids. As a result, a minimum maintenance plan may be appropriate for a synthetic fluid, whereas more frequent sampling may be needed for mineral fluids, which are subject to quicker thermal cracking. Light ends are a common result of thermal cracking. Thermal oil with excessive light ends will build an explosive atmosphere in the expansion tank, in the drain tank, the boiler room or factory, in the event of a leak. Light ends are the lower-boiling components of a mixture

of hydrocarbons, such as those evaporated or distilled off easily in comparison to the bulk of the mixture. Examples include low molecular weight organic compounds such as methane, ethane and propane which can be included as components in the oil.

Frequent sampling Another reason for frequent sampling and regular maintenance - which should include a safety survey and safety training - is to produce trend data from the results. In an ideal world, there would be continuous measurement of temperature fluctuations, carbon buildup and other important parameters which affect thermal fluid performance and present health and safety risks. The annual fluid analysis should be complemented by adequate environmental allowances for workers, which may necessitate fitting flash guards or similar equipment. This is particularly true if there is activity in a zoned explosive risk area. Ideally, the entire site should be covered by an engineer who is trained to take thermal fluid samples and staff who are fully briefed in how to read and interpret analysis results. While heat transfer fluid might be a hidden form of transferring energy from one point to another, and perhaps not one most associated with the concept of sustainability, The frequency of gathering sampling data for a heat it’s essential that we transfer fluid, on which the begin thinking about it maintenance plan depends, is in this way. They have determined by whether the fluid to be sustainable from a is mineral or synthetic. maintenance perspective, sustainable from an energy management standpoint and sustainable economically. The correct choice of fluid and the correct maintenance will go a long way towards achieving this. We may have forgotten the London Hydraulic Company and its 181 miles of cable, but we can’t afford to forget the maintenance of our own heat transfer fluids.

Global Heat Transfer Ltd, The Global Group of Companies, Stone, Staffordshire. Can be contacted on: Tel: +44 (0) 1785 760555 Fax: +44 (0) 1785 760444 E-mail: carolinel@globalgroup.org Web: www.globalheattransfer.co.uk

PROCESS INDUSTRY INFORMER January-February 2014

NETWORK COMMUNICATIONS

HARTING EXPANDS HAN-ECO® SERIES OF CONNECTORS WITH MONOBLOCK INSERTS INCORPORATING TOOL-FREE INSTALLATION HARTING has expanded its HanEco® series of robust lightweight industrial connectors with a range of monoblock inserts offering higher contact densities and a snapin function that provides tool-free installation. The Han-Eco® series comprises robust connector housings made of glass-fibre reinforced highperformance plastics. The series has established itself on the market since its launch in 2012 thanks to its ability to offer advantages such as lighter weight and savings in time during assembly and installation. The new monoblock E units, which have been developed primarily for use in housings from the Han-Eco(R) series, retain the proven Han-Eco(R) “click and mate” snap-in function, offering simple tool-free mounting. A special feature of the new HanEco® monoblock E inserts is that they achieve up to 67% higher contact density than Han E standard screw inserts of the same size. The inserts feature a pre-leading protective earth contact and a six-fold coding system resulting in contact numbers of 10+PE, 14+PE, 20+PE and 28+PE for the four sizes. It is also possible to combine a monoblock E insert with modules from the Han-Modular® series in a housing from the Han-Eco® series or in the Han-Modular(R) docking frame. The new contacts are based on the proven Han® E contacts with screw termination. The monoblock E inserts have a rated voltage of 500 V and a rated current of 16 A. The cable connection cross-section is 0.75 mm2 (AWG 18) minimum and 2.5 mm2 (AWG 14) maximum. For more information please contact, HARTING Limited, Northampton Tel: +44 (0) 1604 827500 Fax: +44 (0) 1604 706777 E-mail: gb@harting.com http://www.harting.co.uk

PROCESS INDUSTRY INFORMER January-February 2014

SPRAY NOZZLES/SAFETY SHOWERS

WASTE MANAGEMENT

FROM SPRAY HOW TO FUTURE-PROOF NOZZLES TO MRF DESIGN TO MAXIMISE SAFETY SHOWERS PLANT EFFICIENCY Wherever hazardous materials are being handled, used or processed the deployment of safety showers is often required by law and compliance with safety standards and regulations is an increasing necessity as failure to provide adequate showers can expose any company to potential litigation. To meet the increasing demand BETE Ltd - The Spray Nozzle People, are pleased to announce a significant expansion and diversification of their product range. BETE will now be representing FSP Tech, a German manufacturer of industrial safety showers and eye wash units, as their exclusive UK distributor. The new range of products fits very well with BETE’s existing customer base. Therefore, to avoid possible confusion BETE have made the decision to market their safety product through a new trading name “The Safety Shower People”. To this end a new website www.safetyshowerpeople.co.uk has been launched which gives detailed information on all safety shower products, tips on satisfying safety standards and information on safety shower best practice. The aim of the site is to provide prospective customers with clear and concise information to guide them to the correct products for their specific needs. For more information contact The Safety Shower People, Lewes, West Sussex Tel: +44 (0) 1273 400092 Web: www.safetyshowerpeople.co.uk

Incorporating ‘future-proof’ design concepts into the layout and operating principles of new Materials Recycling Facilities (MRFs) is vital if managers are to improve quality and maximise profits from their multi-million pound investments, conference delegates heard. Planning for expansion, predicting likely changes in feed composition and installing good management information systems are other essential elements for ensuring a MRF can meet future waste management and processing challenges, Keith Freegard told representatives at the recent Paper Recycling Conference Europe, held in Warsaw, Poland. The conference looked at the challenges and opportunities available for companies involved in the paper recycling industry, including the key issue of infeed quality. “There’s a great need in this industry to do a more consistent, higher quality job of the infeed sortation as any contaminants can create problems in the pulping process,” said Keith, Director of resource recovery specialist Axion Consulting. In his presentation ‘How to make my recycling plant work better’, he emphasised how clever design, precise knowledge of infeed materials and getting the right skills mix can help MRF operators to extract the most from their process plants and be ready to meet future waste management challenges. “Good management systems are vital in MRFs; and now new technological developments should be welcomed – you will need them one day!” For more information, contact Axion Consulting, Bramhall, Cheshire on 0161 426 7731 Fax: 0161 426 7732 E-mail: info@axionconsulting.co.uk Web: www.axionconsulting.co.uk

FLUIDS & LIQUIDS HANDLING INC. PUMPS & VALVES

Compact drum pumps for safer, no-spills liquids transfer

Transferring liquids from small drums, buckets and carboys using hand-operated, manual pumps can be a time-consuming and messy process, even if correct procedures are followed. An easier, safer and more efficient method is by using light and compact motor driven drum pumps like Finish Thompson EF Series drum pumps. Available through pumping specialists MICHAEL SMITH ENGINEERS the EF series of sealless drum pumps are acknowledged as being the most competitively priced and highest quality powered drum pumps in their class. They are ideal for light to medium duty, transferring oils, detergents and other similar liquids at flow rates up to 64 lit/min at discharge

pressures up to 6.1 metres. In contrast to hand-operated pumps Finish Thompson drum pumps enable precise amounts of liquid to be transferred to smaller containers with less risk of spillage and also help to eliminate the handling problems associated with heavy containers. Tube length options start from 40 cm for smaller containers, also 70 cm, 100 cm and 120 cm for most popular sized drums and 140 cm for larger IBC’s and carboys which typically hold volumes up to 1250 litres (330 gallons). The EF series of pumps have motors which are interchangeable with any tube selection and are offered in a choice of construction materials of polypropylene and pure polypro/pure PVDF. For more challenging applications, such as transferring corrosive liquids, the EFS stainless steel option is available which features a 316 SS tube and shaft. Other features include dual speed, adjustable, continuous duty electric motors, or air motors which have CSA or CE certifications and a built-in hose and cord clip for convenient storage. For more information contact Michael Smith Engineers Ltd, Woking, Surrey Tel: FREEPHONE 0800 316 7891 Fax: 01483 723110 E-mail: info@michael-smith-engineers. co.uk Web: www.michael-smith-engineers.co.uk

PROCESS INDUSTRY INFORMER January-February 2014

FLUIDS & LIQUIDS HANDLING INC. PUMPS & VALVES

Hydra-Cell® pumps

Wanner offers a solution to leaking pump seals… it’s called the Hydra-Cell seal-less pump.

ONE-PIECE BALL VALVES FROM BOISWOOD OFFER HIGH RELIABILITY

Dynamic seals in pumps can be basic or works of great ingenuity. However, since almost all seals utilize the process liquid to lubricate the seal faces, they are fundamentally designed to leak. Torque to overcome a dry running seal is 2 to 3 times that of a lubricated seal. Even the best designed and fitted seal is prone to wear and eventually will need to be replaced. The fact is that in excess of 85% of mechanical seals fail prematurely because of abrasive particles, shaft vibration, pipe strain, misalignment etc. Replacing a seal will often bring respite but it seldom provides a long-term cure to a leak problem. Hydra-Cell pumps are high-efficiency, hydraulically balanced diaphragm pumps that have no dynamic seals in contact with the pumped liquid; totally eliminating the need for seal maintenance. Many Hydra-Cell models can operate at pressures in excess of 140 bar, offering 100% safe containment of corrosive, aggressive and abrasive liquids. Pump manufacturers make claims about the time taken to replace shaft seals but any time taken in seal maintenance is downtime for the pump and potentially for the process. In terms of parts and labour this can be costly… In terms of lost production this can be disastrous. Users of Hydra-Cell pumps don’t have such problems.

A new range of ball valves introduced by Boiswood have a one-piece forged body which reduces the number of potential leak points compared with other valve designs. The 40 Series ball valves are a new addition to the FloLok range from US manufacturer SSP, and are ideal for control systems, analytical sampling, process measurement and other high cycle, medium pressure applications. Encapsulated one-piece packing ensures leaktight operation and provides positive shutoff in high, low and dynamic pressure applications. This packing also virtually eliminates dead space to reduce purging time and improve system cleanliness. The valves are available in two-way, three-way and angle patterns and feature an innovative packing retainer that prevents the stem from blowing out when making inline packing adjustments in a pressurised system. Reliability is further enhanced by their extremely strong forged body. Modified PTFE packing ensures broad chemical resistance and extended life over a wide temperature range from -55degC to +150degC. The first sizes available are the FloLok 41, 42 and 43 Series which have end connections from 1/16” to 3/8”, with corresponding metric sizes. The larger 44 and 45 Series will be available later in the year. Body materials are 316 stainless steel and brass and the pressure range covers vacuum to 3000 psig. Remote sensors can be mounted in the handles to indicate the open or closed position.

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

For more information contact Boiswood, Gloucester. Tel: +44 (0) 1452 330011 Fax: +44 (0) 1452 330088 E-mail: info@boiswood.co.uk Web: www.boiswood.co.uk

eliminate seal maintenance

Verderflex Dura 5 & 7 HPLV High Pressure Low Volume dosing Solving your dosing problems: Reliable dosing of off-gassing liquids Superior secondary containment Dry running Elimates pre-wetting No ancillary equipment needed

info@verderflex.com

www.verderflex.com Process Industry Informer.indd 1

PROCESS INDUSTRY INFORMER January-February 2014

2/4/2014 2:45:59 PM

FLUIDS & LIQUIDS HANDLING INC. PUMPS & VALVES

Why Use Dura 5 & Dura 7 HPLV High Pressure Low Volume Dosing Pumps? • High Pressure Low Volume Dosing: The Dura 5 & Dura 7 deliver stable sub-litre per hour flows at either 5 or 8 Bar in a rugged hose pump format. • Care Free Pumping of Off Gassing Liquids: Municipalities regularly use Sodium Hypochlorite (“Hypo”) to disinfect drinking water and the food industry uses Hypo to prevent bacterial contamination. When pumped, Hypo off gases, vapour locking a diaphragm pump’s chamber resulting in additional degassing valves. Often pumps are set to “over-dose” to compensate for the loss of performance leading to increased chemical usage. Hose pumps are a well proven solution and also address the associated crystallisation issues. • Eliminate Abrasive Wear Costs: Lime or Kalkmilch is a very common pH adjustment chemical, used in water treatment, industrial waste remediation and process acidity control. Lime’s fine particles are highly abrasive and cause severe stator and valve wear resulting in high pump ownership costs. Verderflex has many years experience solving this pumping problem and peristaltic pumps are accepted as the proven valve free solution to pump lime, the Dura 5 & 7 now bring this proven performance to lower flow rates. • Reduce Chemical Usage: Peristaltic pumps have a gentle, low shear pumping action that maintain particle size and reduce the flocculation chemical volumes. In contrast, traditional solutions often shear flocculent particles increasing chemical use and result in higher operating costs. The Dura 5 and 7 now bring these benefits to lower chemical low flow rates. • Kill Clogging Costs: Viscosity variations cause metering pumps to clog up requiring maintenance intervention. The Dura 5 & 7 use re-enforced hoses to generate powerful suction eliminating both the performance variability caused by minor viscosity fluctuations and the consequential clogging maintenance costs. Additionally, the truly reversible Dura 5 & 7 allow pumps to run backward and clear blockages unlike non-symmetrical tube pumps where flow rates change

with pumping direction. • Crystallisation: Many reagents crystallise when the metered chemical flows are interrupted coating the seats result in a loss of performance whereas the abrasion resistant Dura 5 & 7 pumps maintain flow rates. • No Tube Re-tensioning: Some peristaltic pumps use continuous lengths of non re-enforced tubes which require re-tensioning after initial installation. The long life heavy duty Dura 5 & 7 hoses are fit and forget. • True Dry Priming: Dura 5 and Dura 7 dry prime to 9.5m of water compared to sub 5m wet-primed lifts associated with diaphragm pumps. The Dura 5 and 7 now eliminate the need for pre-wetting and priming in lower volume chemical feed systems. • Halt Dry Running Problems: Progressing cavity pumps cannot tolerate any interruption in their liquid feed lines or the result is costly burnt stators and downtime. The Dura 5 & 7’s hoses are lubricated from the outside and bring care-free, operator proof pumping to lower flow rates. • No Ancillary Equipment: Conventional metering solutions need back pressure, foot & degassing valves. The Dura 5 and 7 fixed occlusion rotors simplify installations and eliminate additional parts by maintaining a separation between supply and discharge lines. • Stable Liquid Delivery: Many metering pumps lose accuracy when flow rates or system pressures change, however, the powerful restitution of the Dura 5 & 7 hoses give consistent dosing accuracy even under varying operating conditions. • Superior Secondary Containment: The pumped liquid is totally contained inside the Dura 5 & 7’s high pressure hose and each hose is totally contained inside the pump casing. This results in superior secondary containment, allows pre-spillage detection and may eliminate special spillage bunds. • High Margin of Safety and Secure Clamping: The heart of the Dura 5 & 7 is the re-enforced hose with a

HYDRA-CELL PUMPS SHEAR SENSITIVE LIQUIDS Pumping shear sensitive materials can be problematical. Shear helps non-Newtonian fluids flow but too much shear can cause temporary or even irrevocable damage. Hydra-Cell diaphragm pumps from Wanner International are claimed to impose only low levels of tangential stress on the pumped fluid making them ideal for pumping a wide range of shear sensitive materials such as polymers, paints, coatings, dyes, inks, latex solutions and technical suspensions. As soon as the liquid leaves the vessel and enters the suction piping, it begins to shear as the liquid travelling through the middle of the pipe moves in relation to the pipe walls. Rotary pumps impart more shear between the rotating elements and the stationary casing. However, because Hydra-Cell pumps have no rotating elements in contact with the pumped liquid and no tight internal tolerances, they impose minimal tangential stress to cause shear. “Having as many as five individual diaphragms in a single pump head, each with its own spring supported horizontal check valves also helps minimize tangential stress,” said Nick Herrington, Wanner’s Technical Support Manager. “The open area of each valve is large, relative to the volume of liquid being pumped by each diaphragm, so shear stress is minimised.” The fact that one of Europe’s largest paint and coatings manufacturer uses HydraCell pumps for a range of transfer and dosing duties would tend to substantiate these claims. For more information contact Wanner International, Fleet, Hants. Tel: +44 (0)1252 816847 E-mail: NHerrington@wannerint.com Web: www.hydra-cell.eu

burst pressure in excess of 80 Bar (1150 PSI) unlike non-reenforced tubes that can easily burst and rely on crimped connections unlike the Dura 5 and 7’s high compression taper fit clamping system. • Superior Viscous Performance: Diaphragm dosing pumps require customers to use more complex special liquid ends for 200 CPS liquids and non-re-enforced tubing’s recovery limits tube pumps operating speeds. The powerful restitution of the Dura 5 and Dura 7‘s re-enforced hoses give problem free pumping of 1000 CPS plus liquids and eliminate flow fluctuations without requiring additional parts. • Maintenance Simplicity: Only the easy to change hose is in contact with the pumped liquid. Downtime is minimised dramatically with infrequent servicing and hose lives in the thousands of hours. Simple on site changeovers can be made by semi-skilled staff, lowering the total metering solution ownership cost. • Simple User Controls: Hose pumps need no complex local keypads. Dura 5 & 7 pumps can be remotely controlled by inverters eliminating operator confusion and maintaining control system simplicity. These inverters can be the familiar site standard brand further simplifying the control system support requirements. • Scalable Performance: The Dura 5 and 7 have the same common casing and mounting frames as the Dura 10. Should system demands change, flow rates are easily scaled up on site or down by replacing the hose and a few standard components. For more information contact Verderflex, Verder Limited, Castleford, West Yorkshire. Tel: +44 (0)1924 221 020 Fax.: +44 (0)113 222 0291 E-mail: info@remove-this.verderflex.com Web: verderflex.com

GENTLE AND RELIABLE PUMPING OF DELICATE INGREDIENTS 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. For more information contact Pump Engineering Ltd, Littlehampton, West Sussex Tel: 01903 730900 Fax: 01903 73023 E-mail: sales@pumpeng.co.uk Web: www.pumpeng.co.uk

PROCESS INDUSTRY INFORMER January-February 2014

Talking turbine pumps Malcolm Walker, Centrifugal Product Manager for AxFlow takes a practical look at turbine pumps, how they work, their pros, cons and what they offer the process engineer. Of all the liquid pump types used in process and off shore applications, turbine pumps are perhaps the least well known. As a result of this general ignorance, turbine pumps present a vastly underutilised solution in the liquid engineering toolbox. One of the main reasons for the general ignorance of turbine pumps is caused by the fact that they fall between two stalls; being something of a hybrid sharing characteristics akin to both centrifugal and positive displacement pumps. This definition difficulty has left them as outsiders in both the Centrifugal and Positive Displacement (PDP) camps - the “Billy No Mates” of the pump world. We cannot even agree on their name, variously describing them as turbine, peripheral turbine, regenerative turbine or even centrifugal. As a consequence we do not use them because we do not understand them, which is a shame because they are in fact quite straightforward and have many advantages. The basic operational principle of the turbine pump is simple, working in a way that many of us believed a pump functioned before we were initiated into the mysteries of radial flow centrifugal pumps. Simply put; in the centre of the pump chamber is a turbine containing multiple buckets around its “periphery”. These buckets carry the liquid round the chamber until it has to leave the pump at the “shut-off” point, making the turbine pump not dissimilar to an enclosed water wheel. The only slight complication occurs as the result of the liquid recirculating within the buckets as the turbine rotates. This constant circular “regeneration” of velocity produces increasing pressures that far surpass that of a radial flow centrifugal pump impeller of the same diameter (Fig.1). Importantly, there is no contact between the turbine’s surfaces and the pump chamber because they are separated by a thin film of liquid on their faces and outer edge at the shut-off point. This means that the liquid is not completely trapped and therefore turbine pumps are deemed to be using kinetic energy to shift the liquid and not “displacing” a fixed volume. Of course the key word here is “completely” as a thin film of liquid is not very much of an interface and consequently nearly all of the pump’s characteristics are the same as those of a positive displacement pump.

Characteristics In practice, turbine pumps behave pretty much like positive displacement pumps and do not share much in common with their Kinetic pump brethren. Most notably they differ from most centrifugal pumps as: 1. 2. 3. 4. 5. 6.

They have straight differential head – flow curves. Power increases with pressure not flow. They can handle viscous liquids better while being good with thin liquids. Their pump action is relatively low shear. They can pump liquids with up to 20% entrained gases. With no axial thrust loads they have lower NPSH requirements as much less damage is caused in such situations. 7. However, they are not so good with solids. 8. And they would not normally be used to deliver large volumes of liquid. When should they be considered? AxFlow supplies several ranges of turbine pump and have found a multitude of applications for them. These applications stem from either their hydraulic characteristics or the range of bespoke constructions and materials.

Low Flow – High Head The main use for turbine pumps comes from their low flow high head capability (Fig.2) which compares a single stage ISO 2858 centrifugal curve with that of a turbine pump. The centrifugal pump is fitted with a 5.5 kW motor and the turbine a 2.2kW. It’s pretty clear where the turbine pump excels. But what about multistage centrifugal pumps? Well, the truth is that if a mass produced

PROCESS INDUSTRY INFORMER January-February 2014

multistage centrifugal pump can be used, then it will invariably be less expensive. However, if there is anything slightly unusual about the application, be it a chemically aggressive liquid, an ATEX zone or high liquid temperature then a turbine pump will be the better option.

Difficult Liquids Taking Aturia turbine pumps (Fig.3) as an example; these are magnetically driven and are available in polypropylene, PVDF, 316 SS and Hastelloy which makes them chemically resistant. However, it’s their low shear capabilities and similarity to PD pumps which brings the greatest advantages. For instance, historically one of the biggest uses for turbine pumps was in pubs when thousands of them delivered beer from the cellars to the bar without thrashing it into undrinkable foam. This was decades before the advent of cheaper gas pumps.

Fig 3

Turbine pumps will handle viscous liquids up to 150 cP, and in fact they are better suited to viscous liquids as they become more efficient. This makes them good for caustic solutions as fluctuations in the flow are a great deal less than a centrifugal pump, particularly if the caustic is subject to varying temperatures. Lastly, their ability to cope with 20% entrained gas makes then very useful in situations involving turbulent flows and they can even be used to mix separate streams of liquid and gas together.

Technical requirements All Aturia turbine pumps, including the plastic and self-priming ranges, can be ATEX compliant. The STM pumps are available in several types of metals including Duplex, Hastelloy and Titanium, making them capable of withstanding system pressures of up to 350 bar. High temperatures can be accommodated, with long coupled models being able to handle liquids of up to 350˚C. They are available with self-priming chambers, can be configured to API 685, have polished internal surfaces and come with a range of connection types including tri-clamps.

Applications Although less well known than other pump types, turbine pumps have been in use for decades. The most commonly encountered are vertical multi-stage pumps used in the municipal water and off shore sectors pumping water at very high heads. However, their use is much more widespread. They can be found cooling all manner of equipment from x-ray machines to VSD assemblies, CIP duties, transferring small flows over long distances, as tanker off-loading pumps, vapour recovery systems, for filter systems where higher pressures are encountered, spray bar applications, soda re-circulation in fast food outlets, shower booster pumps and LPG distribution to name just a few. The list of industries in which turbine pumps can be found includes petrochemical, pharmaceutical, food production and food dispensing, medical, laboratory, military, nuclear generation and general chemical. To sum up, turbine pumps provide an extremely simple solution to a host of low-flow and challenging pumping applications. Their use should be more widespread and could be if engineers had a greater appreciation of the technology and were willing to look just outside their comfort zone more often. AxFlow Limited, Ealing, London Can be contacted on: Tel: 0208579 2111 E-mail: info@axflow.co.uk Web: www.axflow.co.uk

Digital valve control performance optimi Norman Render, Fisher Instrument Business Unit Manager, Emerson Process Management, explains how digital valve controllers fitted to critical process valves can help increase plant availability and efficiency and reduce maintenance costs across the valves’ complete lifecycle. Energy costs account for between 40-60% of total production costs - depending on the industry. Due to increasing energy demands, the UK’s Chemical Industry Association is predicting that electricity is expected to make up 70% of costs by 2020, up from its current 60%*. This means there is a greater need than ever to drive optimisation initiatives to reduce operating costs and remain competitive. Optimisation programmes tend to focus on high end initiatives such as advanced process control. Whilst the status and performance of control valves might not be at the top of the target list for engineers trying to reduce operating costs, valves are crucial to good final control and therefore provide one of the biggest opportunities to help drive performance optimisation programmes. Studies have shown that approximately two-thirds of the control loops in manufacturing plants are poorly tuned, malfunctioning, or operating in manual. Poorly performing control valves can be a prime reason for loops running in manual, resulting in less than optimal set-points. This can lead to out-of-specification product, increasing waste or rework and cause plants to run below capacity due to the increased safety margin needed. In addition, valves that are not performing correctly can cause process upsets that lead to unplanned shutdowns, resulting in poor plant availability. Poorly performing control valves also make it difficult to take advantage of advanced process control strategies.

3. Abnormal Situation (Trouble shooting) 4. Turnarounds (Corrective Maintenance) Within each part of the lifecycle the digital valve controller supports plant personnel in different ways.

Figure 1: Emerson’s Fisher DVC6200 Digital Valve Controller Emerson’s software is used to present information in a consistent, easy-to-interpret interface that provides the capability to configure, calibrate, and diagnose the instruments from a centralised location. Emerson’s software for example, is available in a variety of configurations and can be integrated into the maintenance systems of most DCS manufacturers. It is this flexibility, including the ability to be fitted to any control valve and be integrated into most DCS systems that brings value to end users in terms of standardisation and reduced inventories.

Digital valve controllers Digital valve controllers have been around since the mid 1990’s. Based on microprocessor technology, these instruments enable users to monitor valve performance on-line, to collect and trend performance data over time, and to better predict or plan valve maintenance. The information they provide can help improve process safety, minimise variability, plan smarter maintenance, and reduce process downtime - all aspects of an optimisation strategy. A single digital valve controller can replace three traditional instruments, namely the position controller, position transmitter, and open/close switches. Emerson’s Fisher® FIELDVUE DVC6200 Series Digital Valve Controller, for example, mounts to any make of pneumatic actuator and provides the valves actual position and operating characteristics. Performance diagnostics run continuously, analysing valve and actuator data while the process remains on-line. If a problem is detected, information is automatically directed to the appropriate personnel, allowing more informed decisions to be taken. That includes whether the process can continue operating or whether the problem is serious enough to warrant taking the process offline.

Figure 2: Emerson’s software presents performance information in a consistent, easy-to-interpret interface wherever it’s needed For applications in hard to reach areas of the plant, wireless adapters can be easily connected to provide access to the otherwise ‘stranded’ valve diagnostics available from the digital valve controller. WirelessHART technology also negates the need for upgrading nonsmart DCS I/O, putting valve diagnostics at the fingertips of anyone wishing to use them.

Whole lifecycle protection Digital valve controllers provide the opportunity to obtain an array of valuable diagnostic information that can be used to improve plant performance and maximise availability throughout the lifecycle of the control valve. The valve lifecycle itself can be divided up as follows: 1. Start-up & Commissioning 2. Normal Operation (Predictive Maintenance)

Figure 3: Typical Control Valve Lifecycle

Start-up & Commissioning When installing a new valve, the first step is to scan and record its baseline signatures, enabling the ‘as-shipped’ performance to be compared with the valve’s current operating condition. All device related maintenance – including repairs and configuration, is automatically recorded in an instrumentation database, providing an audit trail or history of events that can be tracked and viewed by tag number. Some manufacturers have secure access to a personal account that provides a database of valve information. These web-based tools can help with preparations for upcoming shutdowns, help follow up on the service history of a valve and assign documents and valve data to the secure, personalised database. When the valve has been installed, the commissioning engineer can validate that the valve is operating as intended with good dynamic response – for example, that it will fully stroke and can quickly and accurately respond to small input signal changes. Objectives are: • Ensure that the valve assembly is ready for start-up • Find and fix operational and performance issues prior to start-up • Optimise performance and set up meaningful alerts • Establish a baseline reference for future troubleshooting Application example – Start-up of polysilicon plant Digital valve controllers and diagnostic software helped with early identification of a valve problem at

PROCESS INDUSTRY INFORMER January-February 2014

llers help drive isation programmes a new polysilicon plant. This related to resilient-seated butterfly valves and related accessories that included EPDM-coated seats and disks, FIELDVUE instruments, and actuators that exhibited incorrect torque output.

down. Performing these tasks remotely avoids sending personnel into hazardous locations unless absolutely necessary. This drives improved teamwork between Process, Operations, I&E Engineering and Maintenance with the objective of increasing process availability & reliability through:

The valves were installed in lined piping that resulted in an uneven load on the flanged area of the resilient seat. This created pinch points, where the disk would catch and stick in the EPDM seat. When plant personnel bumped the air pressure to move the Fisher valve with digital valve controller and valves, the result was torn EPDM seats. The problem WirelessHART adapter enables quick, cost had not been identified effective access to until diagnostics indicated diagnostics increased friction during the valve stroke. Identifying the problem early enabled the valves to be repaired, verifying their performance and avoiding later problems when the plant was on-line.

Normal Operation During normal operation, control valves fitted with a digital valve controller can be continually monitored from a central control room. Performance diagnostics are used to monitor Key Performance Indicators (KPI’s) such as friction, deadband or mass air flow whilst the process is still on-line. They give a non-intrusive indication for valve, actuator and instrument health with trending capabilities to show how that health is changing over time. As control valve performance is key to the performance of the loop and therefore the whole process, knowing when performance worsens is key to maintaining operational efficiency. Application example – Control of oxygen to reactor at chemical plant As part of analysing the performance of a critical valve supplying oxygen into a reactor, its travel deviations were recorded to determine the cause of process variations. The performance diagnostics showed that vibration was the most likely cause of the process variations. Until these readings were taken and analysed, the plant piping group were unaware they had a vibration problem. By changing the mounting and strengthening the supports and expansion joints the problem was resolved.

Abnormal Situations Should a problem be detected, the diagnostic capabilities can be used to locate the source of the problem before it is necessary to shut the process

• • • • •

Problem detection Severity Identification Cause Corrective action

Application example – Cooling water valves at polyethylene production plant Emerson’s digital valve controllers monitor valve performance and deliver detailed information about the health of cooling water control valves. The software is used to quiz the devices for additional information or to run advanced diagnostic tests and these include Travel Deviation alerts which are a primary indicator of control valve problems. A Travel Deviation alert is triggered when the control valve has not moved to its required position within a certain period of time. This alert can indicate many potential faults, such as an increase in friction, air leaks, mechanical faults or a physical blockage within the control valve. In this particular example the control valves were required to move to within 5% of the desired position within five seconds. If this does not occur, a travel deviation alert is sent. In one incident, a travel deviation alert occurred on an 8-inch butterfly valve used to control the flow of cooling water to a reactor. The valve should have closed, but it remained open and unmoving. The maintenance team disassembled it and found a jagged, 8-inch-long metal fragment stuck inside that was preventing its closure. Without the diagnostics’ alert, the valve would have gone unchecked until the reactor was restarted, which would have resulted in a potentially long and costly delay to production. Worse, the fragment might have travelled downstream where it could have caused extensive mechanical damage to more expensive assets.

Turnarounds When a planned shutdown or turnaround occurs, the diagnostic capabilities can be utilised to: • Improve turnaround effectiveness & efficiency (can reduce number of valves pulled, and shutdown prework can pinpoint issues before plant comes down) • Ensure quality of repair • Re-establish performance benchmarks and validate that valve is fit for service (avoid false start-ups) Following a turnaround the lifecycle restarts as we are now back in normal operating mode.

PROCESS INDUSTRY INFORMER January-February 2014

Application example - Fluidised Cat Cracker Unit (FCCU) at refinery Maintenance personnel at a refinery found that many of the control valves that had been identified as ‘poorly performing’ and added to a priority fix list, were actually in good shape when they were pulled from the line and inspected. Adding digital valve controllers to the control valves on the FCCU enables plant personnel to remotely communicate directly with the smart positioners. Performance diagnostics provide on-line, real-time data about the valve’s status and operating condition. Using these on-line diagnostic tools, plant maintenance teams are able to accurately determine which of the valves on the priority fix list actually need to be pulled and repaired before the process came down. This meant that over the next three scheduled outages, only 28 of the 253 valves on the priority fix list were pulled for repairs. This saved the refinery more than 900 hours of labour (4 hours per valve x 225 valves) and an estimated £100,000 in labour costs alone. In addition, refinery team members saved about £1800 per valve in parts and labour for every valve not pulled. That represents an additional saving or avoided cost of £405,000 (225 valves x £1800) over the three outages.

Summary For most companies, process control valves should be categorised as critical assets and users should look to protect their investment across the whole lifecycle. Replacing traditional analogue valve controllers with digital valve controllers enables critical valves to be continuously monitored. When combined with performance monitoring and diagnostic software, startup and commissioning are simplified, safety is enhanced and process variability minimised. In addition, on-line performance monitoring and diagnostics enable problems to be detected early – enabling more efficient maintenance procedures to be established – reducing unscheduled downtime and providing maintenance savings. Most importantly, the additional functions provided by digital valve controllers can be used to support performance optimisation programmes - helping process companies meet their business objectives by improving plant availability, increasing process efficiency and reducing operating costs - all of which means being more competitive in the global market. Emerson Process Management Can be contacted via E-Mail: InfoCentral@EmersonProcess.com or visit www.Fieldvue.com References: *CHEMICAL INDUSTRY TELLS UK CHANCELLOR TO ACT NOW ON SPIRALLING BUSINESS COSTS, 29 Nov 2013 http://www.cia.org.uk/Newsroom/PressReleases/ PressRelease/tabid/114/pwnid/165/Default.aspx #Torres, B.S., Carvalho, F.B., de Oliveira Fonseca, M., and Filho, C.S., “Performance Assessment of Control Loops— Case Studies,” International Federation of Automatic Control conference, 2006

INSTRUMENTATION

ALICAT DEVELOPS FIRST BIDIRECTIONAL FLOW AND PRESSURE CONTROLLER MCD-Series dual-valve mass flow controllers manage flow both into and out of a process Alicat Scientific, Inc.’s new MCD-Series Bidirectional Mass Flow and Pressure Controllers precisely and rapidly control mass flow rate, volumetric flow rate and absolute pressure of gases in two flow directions. This flexible dual-valve design is the first of its kind, accommodating demanding process control requirements in gas analysis, leak testing and environmental applications. In laboratory settings, it allows researchers to replace multiple dedicated instruments and make rapid changes to experimental setups. With a dedicated inlet valve and a dedicated exhaust valve, a single MCD can control upstream and downstream flows, as well as positive pressure or backpressure in both open and closed systems. It’s ideal for processes that require bidirectional flow control and/or pressure control, as well as for pressure control in closed systems, while also monitoring mass flow. User-selectable control modes allow users to switch quickly between mass flow, volumetric flow and absolute pressure measurement and control for maximum flexibility. As a universal control element, it can be used to monitor or control a number of parameter combinations, making it useful in a variety of laboratory configurations. Alicat’s patented, internally compensated laminar differential pressure measurement yields linear results over a very wide flow range. To learn more about Alicat’s MCD-Series Bidirectional Mass Flow Control, visit www.alicat.com/mcd, or call +1 520 290-6060. To see an “Ask Alicat” video featuring the MCD, visit http://www.youtube.com/ watch?v=6jPHKCqh-iw.

Illustrated guide West Control Solutions to identifying the helps customers ideal small bore with more video tips liquid flowmeter Titan Enterprises has produced an informative illustrated guide to help simplify the process of identifying and selecting the best type of small bore flowmeter (< 0.5-inch / 12.5mm bore) for a particular application. Achieving optimal performance from small bore flowmeters has very different challenges to those faced when using larger diameter meters. As the flows are lower, less energy is available in the liquid to convert to mechanical movement. The liquid is often running in the laminar flow region and viscosity and boundary layer effects become very important. Generally speaking the smaller the meter the harder it is to make an accurate inline measuring device but the easier it is for the user to check the performance. Titan Enterprises informative guide discusses the ten main flowmeter technologies and provides an unbiased comparison between each based upon 5 critical operating parameters (cost, linearity, operating range, minimum flow and repeatability) using an easy-tounderstand pentagonal graphic illustration of their relative performance in these aspects. The guide concludes to find the ideal flowmeter for small bore applications that there are several options for any given low flow rate and that choice is likely to be a compromise between performance, price and operating parameters. To download a copy of this illustrated guide please visit www.flowmeters.co.uk/flowmeters-below-half-inchbore.php. To discuss the optimal flowmeter for your application in more detail please contact Titan Enterprises, Sherborne, Dorset Tel: +44-1935-812790 E-mail: sales@flowmeters.com Web: www.flowmeters.co.uk

SENSORS

HOW RELIABLE ARE YOUR Ph MEASUREMENTS? The vast majority of installed pH measurement systems still use analogue glass electrodes. Although such sensors are highly reliable, the issues with cables and the environment around the process means that your measurements could be out by several units. The answer to this problem is digital technology. Download METTLER TOLEDO’s latest ‘Pro Insight’ on the reliability of pH measurement. It discusses how 100% signal integrity can be achieved even when moisture is present. Find out more about the benefits of using digital Intelligent Sensor Management (ISM), including: • Digital signal is immune to interference • Fast, error-free measurement point start up • Predictive diagnostics for reduced maintenance To download the full ‘Pro Insight’ go to: www.mt.com/uk-chem-sn For more information contact Mettler Toledo, Beaumont Leys, Leics. Tel: 0116 234 5095 E-mail: enquire.mtuk@mt.com Web: www.mt.com/pro-chemical

West Control Solutions has released the third in its on-going series of video guides designed to help customers install and tune the most efficient possible temperature control solutions. The video series is the first of its kind in the industry, underlining West Control Solutions’ dedication to customer service and its reputation as the leading specialist in temperature control technology. The new video is entitled Different Types Of Control. Following on from the first video, On/Off v. Proportional Control, it offers a clear and simple explanation of options available within the field of Proportional Control. Users who watch the two videos in sequence will swiftly gain a basic understanding of these options and be able to programme equipment for best efficiency and performance in their given application. A number of options are explained, such as integral action, which when added to proportional action enables measurement of control deviation and the smoothing out of errors. This capability is useful, for example, when changes in ambient conditions or demand alter the heat input to the system, such as when users draw more hot water from an immersion tank during busy times of the day. The West Control Solutions video guide series is ideal for anyone who is considering the specification and installation of a control system but has not yet developed a full understanding of the factors involved. The videos can be viewed at the West Control Solutions YouTube channel: www.youtube.com/user/WestControlSolutions For more information please contact West Control Solutions, Brighton, East Sussex Tel: +44 (0) 1273 810116 Fax: 01273 609990 E-mail: chloe.garrettdyke@west-cs.com Web: www.West-CS.co.uk

VEGA GET INTERACTIVE ON WATER If you would like a brochure, or if you have an application you would like to discuss please To further support customers involved in the water sector, VEGA have launched an application based, interactive website about their innovative solutions for the water industry. Aimed at both experienced and inexperienced water instrumentation users alike, it covers aspects of sewage system monitoring, main treatment plant processes and open water gauging. It features their latest innovation: VEGAPULS WL61 non contact water radar level transmitter. The applications shown across the site are a perfect demonstration of the versatility of the radar level technology, along with other innovative techniques for process control solutions. Process animations feature alongside their written descriptions, application challenges, user benefits and click-through access to detailed product information, application data sheets and all related manuals and certificates. There is a printed brochure available to also support the new website for users who may prefer a paper version or if you would like a brochure or if you have an application that you would like to discuss contact VEGA Controls Ltd, Burgess Hill, West Sussex. Tel: 01444 870055 E-mail: info.uk@vaga.com or Visit: www.vega.com/uk/Waste-Water-Industry.htm

PROCESS INDUSTRY INFORMER January-February 2014

DRIVES & MOTORS

NEMA motors from ABB available for immediate European delivery NEMA standard motors, from fractional to 250 horsepower (HP), are available from ABB for immediate delivery across Europe. Using ABB’s central stock warehouse in Menden, Germany, the motors available include NEMA general purpose, ECP XEX severe duty, IEEE841 totally enclosed severe duty and speciality motors. Customers can order NEMA motors for immediate delivery throughout Europe, reducing the lead-time on these products to days rather than weeks. The Menden logistics centre in Germany is fully equipped to deal with all aspects of product export, and thanks to the secure storage facility, has access to fast-track air freight dispatch. ABB plan to add a CSA/UL certified “Mod Express” line into the Menden facility in order to make modifications to these stock motors such as D flanges (B5), space heaters, thermistors and other adjustments. The line is due to be operational in early 2014. For more information contact ABB Ltd, Warrington, Cheshire Tel: 01925 741 111Fax: 01925 741 212 E-mail: energy@gb.abb.com Web: www.abb.co.uk/energy

The AUMA Advantage Innovative actuator solutions: • Save tax: AUMA has the only ETL certified actuator Licence 03209 • For enhanced control capability: - Variable speed - Eliminate water hammer - Flow linearisation • With remote diagnostics: - Asset management - Planned preventative maintenance • Explosion Proof range: - Independently certified SIL DIN EN 61508-1/-2 capable up to SIL 3 - ATEX, IEC and FM certified - National Grid Gas Approved to T/SP/VA/2

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PROCESS INDUSTRY INFORMER January-February 2014

Water hamm - solutions

By Stork Erhard, Development Manager, ARI-Armaturen Albert Richter GmbH &Co KG.

Very strong pressure pulses or surges, also referred to as water hammer, often occur in fluidconducting pipes. The stresses on the pipes, valves and apparatus can be so high that the equipment concerned is damaged – or in extreme cases actually bursts. Before effective measures can be taken to combat this problem, it is important to analyse exactly which kind of water hammer is involved and what causes it. No matter how carefully a facility is planned and constructed, the risk of pressure surges cannot always be completely ruled out, particularly if the plant is modified or extended or the operating mode changes frequently. If the plant components are designed with sufficient stability, half the battle is won.

Water hammer in pipes can have a variety of causes. A basic distinction is drawn between hydraulic water hammer and thermal water hammer.

Hydraulic water hammer and cavitational hammer If a globe valve (e.g. a butterfly valve) is closed abruptly while liquid is flowing through a pipe, the fluid flow immediately comes to a standstill and the kinetic energy is converted to pressure energy. In other words a water hammer pulse is produced upstream of the valve. This pulse is propagated at sound velocity from the point of origin against the original flow direction and reflected at points of discontinuity (vessels, pipe ends, etc.). The shock waves generally travel back and forth several times; they gradually lose their intensity due to dissipation before finally fading away. The pressure increase downstream of a fast-acting valve can be approximated using the classic Joukowski equation [1]: (1) Pressure increase [Pa] Fluid density [kg/m] Sonic speed [m/s] Change in flow velocity [m/s] The pressure surge reaches its maximum height when: (2) Closing time [s] of the valve Length [m] of the pipe section in which shock waves can be propagated without being reflected Downstream of the valve, the pressure decreases due to the inertia of the trans-ported liquid. If it drops below the steam pressure, the liquid evaporates locally and a “cavitation bubble” forms [2]. The subsequent condensation process is usually very abrupt. The magnitude of the pressure peak, which is also referred to as “cavitational hammer”, varies according to the valve type and closing speed and can be much higher than the normal system pressure. Once again, the resulting shock waves may be replicated a number of times in the pipe before they come to a standstill due to friction.

is always a risk of water hammer if condensate with different temperatures collects in a header.

Measures to prevent water hammer The water hammer described can usually be prevented by designing the facility optimally; the measures that are suitable for avoiding hydraulic water hammer are totally different from those implemented to counter thermal water hammer. Since the intensity of hydraulic water hammer depends on the operating times of the globe valves, the starting and stopping times of the pumps and the flow velocity, water hammer pulses can be restricted – if not completely eliminated – by altering these parameters. Unlike water hammer pulses on the inlet side of the valve, the formation of a cavitation bubble can only be prevented by selecting a significantly higher closing time, which will probably be unacceptable in practice. If the parameters are fixed, water hammer can be damped – though not avoided – by installing bladder accumulators or air vessels and leveraging the compressibility of the gas volume in this apparatus. Other preventative measures are described in [2]. A good first step towards eliminating thermal water hammer in steam facilities is to ensure adequate drainage. A wise choice of steam trap, in combination with an optimal arrangement of the drain and condensate pipes, is crucial here [3]. The risk of water hammer is particularly great when a cold plant is started up because this is when there is most condensate. The measures that are required to prevent water hammer in conjunction with flashing, mixing and transfer of the condensate drained from steam pipes are also described in detail in [3].

Influence of water hammer on valves Since it is not always possible to exclude water hammer in a facility completely, the possible consequences for fittings – and especially valves – are depicted by the “FABA®-Plus” globe valve (Fig. 1). This shows the areas affected by pulsating pressure loads.

Thermal water hammer If hot steam meets large accumulations of condensate because the piping system is insufficiently drained, sudden evaporation (or “flashing”) occurs. The resulting changes in volume are a cause of water hammer – in many cases violent – with strong pressure surges that can easily exceed the operating pressure. Water hammer also occurs in condensate systems if subcooled condensate is fed into a condensate pipe that is partially filled with flash steam. A vacuum is created locally as the flash steam condenses. Strong pressure surges are like-wise produced by the subsequent inflow of condensate at high velocity. In other words, there

Fig. 1

PROCESS INDUSTRY INFORMER January-February 2014

mer in valves

to improve stability The dimensions and design of the valve body are based on the “pressure” and “temperature” sizing parameters plus the safety margins laid down in the relevant regulations. As the water hammer values that occur in a plant can be far higher than the permissible values for the valves concerned, there is a risk that the body could break – at least with brittle materials that do not have very high yield strengths (e.g. cast iron). The use of these materials is restricted by several regulations for this reason [5, 6]. The static sealing elements between the individual parts of the valve bodies are subjected to the same pressure and temperature loads as the body itself. If the maximum values for pressure and temperature stresses are exceeded here, the seals may develop leaks and fragments of them could even be “blown out”. Compared to the static body seals, the seals for the stem guide are additionally exposed to dynamic stresses caused by the movement of the stem, which can be axial, radial or a combination of the two. Manual valves tend to be only rarely operated while control valves are in action regularly, if not continuously. A gland packing and the PTFE V-ring unit are the two classic systems and if this kind of seal is already badly worn, water hammer can easily result in leakage. Gland packings do have the advantage here in that they can be retightened. A stainless steel bellows seal provides a permanently leak-proof and maintenance-free stem seal because wear is ruled out. The material most commonly used for the bellows seal is austenitic stainless steel, e.g. 1.4541 or 1.4571, with very thin walls to guarantee the necessary low rigidity. The resistance to water hammer is consequently limited because there is a risk of plastic deformation and possibly even cracks in the material.

Design measures If water hammer cannot be completely prevented in the facility, a good starting point is to only use body materials that are sufficiently ductile. The design of the body parts also has a crucial influence on a valve’s stability towards water hammer. Taking the optimised bonnet of a globe valve as an example, by optimising the design it is possible to improve stress distribution. The bonnet was revised during the development of the “FABA?-Plus”, resulting in a slight reduction in weight and approximately 60% better resistance; this has additionally been verified by means of tensile tests. The valve thus affords better protection against water hammer. It is a good idea to choose a grooved design in order to prevent gaskets from being damaged, or in the worst case blown out, due to water hammer. These seals generally consist of a shaped metal carrier and a soft seal. Once the seal has been installed and preloaded, the soft material, e.g. graphite or PTFE, is pressed into the carrier profile to give additional anchorage. Chambered gaskets are another possible alternative. The “FABA®-Supra C” globe valve (Fig. 2) features a double-walled bellows seal between the top and bottom parts; the inner web shields the seal against the fluid. If water hammer occurs, it is prevented from even reaching the seal. The outer web provides support

Fig. 2 as well as extra protection against leakage. If the seal is faulty, fluid jet cannot escape The movements of the bellows connectors due to water hammer have considerable influence on the stability of the body seal. If these metal parts are clamped between gaskets, the latter could fail if a defined limit value is exceeded. The bellows connector of the “FABA?-Supra C” is welded directly to the top part of the body for this reason. At the same time, the number of seals is reduced to one.

Bellows design To prevent water hammer from damaging metal bellows, the bellows must be designed with sufficient compressive strength, including appropriate reserves. As a way to increase the nominal pressure, multiwalled designs are preferable to single-walled bellows with thicker walls. The wall in contact with the fluid performs the sealing function while the other walls serve to support the bellows and give them a higher compressive strength. The resistance of bellows valves to water hammer can be further improved by shielding the bellows on the fluid side. The protective rim welded to the top part also acts as a plug guide. Pressure surges or water hammer never even reach the bellows and no plug vibration is excited by high flow velocities

Summary The water hammer that occurs in a facility’s fluidcarrying pipes generally has a variety of causes that can never be completely ruled out. This article has analysed the consequences for fittings, and especially valves, starting with the extremely diverse physical causes and

PROCESS INDUSTRY INFORMER January-February 2014

continuing with the engineering options available for prevention. The design measures described make the valves more resistant to water hammer and improve their stability. The effectiveness of the design details outlined is verified by the extensive trials carried out at the Fraunhofer UMSICHT Institute in Oberhausen [7].

6. References [1] A. Dudlik: “Vergleichende Untersuchungen zur Beschreibung von transienten Strömungsvorgängen in Rohrleitungen” Fraunhofer IRB Verlag [2] A. Dudlik, S. Schlüter, P.-M. Weinspach: “Druckstöße und Kavitationsschläge in Fernwärmerohrleitungen - Messung, Berechnung und Vermeidung” Fraunhofer UMSICHT, Oberhausen [3] ARI-Armaturen: A Practical Guide to Steam and Condensate Engineering [4] ARI-Armaturen: Manufacturer’s Catalogue 2010 (www.ari-armaturen.com) [5] EN 12953-2: Shell boilers - Part 2: Materials for pressure parts of boilers and accessories [6] AD 2000 A4: Accessory housings [7] Fraunhofer-Institute for Enviromental, Safety and Energy Technology UMSICHT, Osterfelder Straße 3, D-46047 Oberhausen (www.umsicht.fraunhofer.de)

Ari Armaturen (UK) Limited, Tewkesbury, Gloucestershire Can be contacted on: Tel: 01684 275752 Fax: 01684 275627 E-mail: inquiries@uk.ari-armaturen.com Web: www.ari-armaturen.com/

Sealing Piping Systems for Sustainability By Gerry Morgan - UK Sales & Marketing Manager of Garlock GB Sealing Technologies

Today’s industrial piping systems have a direct impact on the sustainability of the facilities in which they are installed. With numerous connections subject to failure, these systems have the potential to disrupt operations, resulting in damage, downtime, lost production, non-compliance penalties, and in some cases injury and even death.

Fig. 1 Analysis of 100 failed gaskets indicated that nearly 70% were attributable to insufficient load.

Most of the connections in industrial piping systems are flanged joints that usually fail from insufficient gasket load (Figure 1). Different gaskets seal at different loads, with minimums ranging from 100 psi for some types of rubber gaskets to 5,000 psi for spiral-wound and metal-jacketed gaskets. When service conditions and flange designs point to different types of gaskets, these conflicting specifications give rise to problems. However there are gasket materials and configurations available to bridge these inconsistencies for more sustainable piping systems.

Industries wide, leaks from flanged joints have been reduced significantly, and in some cases even eliminated. The performance of piping systems, including pumps, valves and other equipment, is a major factor in both their economic and environmental sustainability. As such, it warrants close attention to the flanged joints and gaskets that seal them. In the event of a leaking gasket, first identify its cause, starting with a determination that it was the proper gasket for the intended service, including temperature, media, pressure and other operating parameters. Look first at temperature because it will immediately narrow the options of suitable gasket materials. In addition the media, including fluids for flushing the system, must be chemically compatible with the gasket. Most systems operate at relatively constant pressure, but the gasket also must be able to withstand any spikes and surges that may occur. In reality, flanged joints rarely leak due to the gaskets being attacked chemically or subjected to temperatures and/or pressures that exceed their ratings. Such failures would clearly be the result of misspecification in light of common knowledge. More often gasket failures are caused by either too much or too little compressive load. Therefore it is important to know what type of flange is being used, including material and bolting information to determine available compressive force. Problems may result from uneven bolt loading, but far more often the proper load could not be attained given the flange design and available bolting. A flat-faced flange, for example, can not apply the same compressive force as a raised-face flange with its reduced compression area.

Note the significance of variations… Flat-faced flanges commonly found on valves, pumps and glass-lined equipment provide only low compressive loads Other typically flat-faced flanges include non-metallic flanges such as FRP, PVC, CPVC and HDPE, rolled angle iron flanges for ductwork, and flanges on tanks and vessels for vacuum service. Variations in available compressive stress are quite large. An ASME 150# raised-face flange, for example, will generate at least 4,800 psi of compressive load at a bolt stress of 60,000 psi. With standard ASME bolting, flat-faced flanges on pumps and valves will create compressive loads of 1,000 to 2,000 psi; if glass-lined, between 2,000 and 3,500 psi; if non-metallic, 150 to 500 psi; and if angle iron, 100 to 300 psi. In vacuum service, some flat-faced flanges will generate almost no compressive load.

Rubber-based gaskets with molded ridges are available to concentrate load in ultra-low-load flanges. These ridges make initial contact with the Fig. 2 Designed for use in nonflanges, allowing the gasket to seal at lower loads metallic flanges, this gasket seals (Figure 2). These ribbed elastomer gaskets are also with less surface contact and lower available with PTFE envelopes that wrap around their seating stress. inner diameters and a portion of the gasket face, improving chemical resistance and reducing the potential for contamination of the media. The PTFE envelope may be bonded to the rubber during vulcanization or with an adhesive afterwards.

Increasing the pressure capability… Some CPVC piping systems feature specially designed backing rings that permit more torque to be applied to the bolting without damaging the flanges; this arrangement in conjunction with the correct gasket has substantially increased the pressure capability of these systems. Also available are softer PTFE-based gaskets that can be compressed by as much as 60% to 80% of their original thickness, making them even more compressible than some rubber gaskets. However, they still require a higher minimum compressive stress than rubber to prevent leakage through the body of the gasket itself. These gaskets can be used to seal some of the flanges described above, but may not be suitable for sealing other types, notably non-metallic, flat-faced flanges.

Gaskets that swell in the presence of liquid also can be used to deal with lowload flanges (Figure 3). These fiber-based gaskets are less compressible than rubber gaskets, but can seal effectively under low loads and withstand stresses that would crush a rubber gasket. In addition, the fiber-based materials of which these gaskets are made are available in sheet sizes up to 150” square, making it possible to produce one-piece gaskets for extremely large flanges. Fiberbased gaskets are also more suitable for use in flat-faced flanges Fig. 3 This gasket swells where operating or test pressures may exceed the capabilities when exposed to liquids, of a rubber gasket. These gaskets are rated for service at creating its own load to elevated pressures, and their swelling action serves to seal seal low-load flanges. the joint.

It should be noted, however, that there can be significant variations even within these low-load flanges. For example, not all non-metallic flanges are flat-faced. Many have raised ridges to concentrate the load, while others feature stub-ends that limit gasket contact to within the bolt circle of the flange. Typically used with metallic backing flanges, these types of flanges have a contact area equivalent to that of a raised-face flange, allowing them to generate significantly higher compressive loads than flat-faced flanges. Due to their compressibility, elastomer gaskets are often the solution to sealing low-load flanges. However, while their compressive loads are significantly lower than for metal gaskets, rubber gaskets are usually too soft for glass-lined and stub-end flanges. In addition, elastomer gaskets may pose compatibility problems with system media. Conversely, PTFEbased gasketing provides chemical compatibility, but requires higher compressive loads.

The available compressive stress of a flange is a vital piece of information when selecting a gasket to seal it or determining why it is leaking. Following are some general guidelines that may prove helpful in this process. Available stresses of 600 psi to 1,200 psi, typically call for rubber gaskets. Below 600 psi, however, special gaskets might be required. Stresses above 1,200 psi can damage rubber gaskets, but may not be high enough to effectively seal harder materials, such as rubberbound fiber sheet and standard PTFE gaskets , which require stresses of 3,000 psi or greater.

Compressive gasket load is the single most important factor in the performance of flanged joints in industrial piping systems. Therefore available load from the flanges and bolting is critical in determining the type of gaskets and any special features to be used. Different types of flanges -- flat-face, raisedface, stub-end and others – call for different sealing solutions, including but not limited to rubber, PTFE, elastomer with PTFE and fiber-based gaskets. Matching gaskets to the flanges they are installed in can be a daunting task without the assistance of a reliable sealing supplier in the selection and replacement process. With such assistance, however, flanged joints can be optimized to deliver longterm, sustainable piping performance under a wide range of service conditions. Garlock GB Sealing Technologies, Elland, Yorkshire Can be contacted on: Tel: (0)845 450 4411 E-mail: uk-info@garlock.com Web: www.garlock.co.uk

PROCESS INDUSTRY INFORMER January-February 2014

FILTRATION

STAINLESS STEEL FLOOR DRAINAGE

NEW HARMER STEEL FLOOR Completely DRAINS EXPAND ALUMASC’S unique product for maintenance COMPREHENSIVE DRAINAGE OFFER engineers A “unique” new product called “Velum” to protect Robotics & Electronic Equipment used in a production environment; this is a low cost manual Air Filter System that fits over the Air Intake of any piece of electronically operated equipment. Unique is an often misquoted word however in this case it is correct; there is nothing currently on the market that is even similar to Velum, most peoples thoughts when they see it in operation are: “Why has nobody thought of this before?” The product is a bit like a toilet roll holder magnetically attached above the Air Intake Grill, a single piece of 10 micron flame retardant Velum mesh is pulled down to cover the grill (this is also held in place by two magnetic strips) the airborne contaminates are then collected by the mesh. By a quick visual inspection a Maintenance Engineer can see when it is full, he then simply tears off the old mesh strip and pulls down a replacement piece. Velum comes 3 in different widths; 200mm, 300mm & 400mm and each roll contains 90 sheets (use 1 per week and it could last you 18 months). Distributor Enquiries welcome

The new Harmer range comprises high-performance, highly versatile stainless steel floor drains, channel drains, shower and wet room drainage, capable of withstanding some of the most demanding applications. Boasting high flow performance, high sump volume, excellent corrosion resistance and integral waste baskets, this incredibly robust range is the perfect example of Harmer’s commitment to evolving its product offer to meet the changing needs of the drainage market. Harmer Steel Floor Drainage is available in both standard and compact drain sizes, either as a one or two part drain body with vertical or horizontal outlets. There is a wide choice of grate finishes to suit any application and load requirement. Wayne Willmott, Sales Manager for Harmer Drainage, said: “Our new Harmer Stainless Steel Floor Drains offer an unrivalled choice of point drains and channel drains for the most demanding applications such as food and drink processing, chemical and pharmaceutical industries. The complete range of new Harmer Steel Floor Drains will be showcased for the first time at the Foodex Exhibition at the NEC Birmingham from 24th-26th March 2014. Visit Alumasc at stand P380. For more details on Alumasc’s Harmer range contact Alumasc Exterior Building Products Ltd Tel: 01744 648400 Fax: 01744 648401 E-mail: info@alumasc-exteriors.co.uk Web: www.harmerdrainage.co.uk

For more information contact DPA Technologies, Paisley Tel: 0141 840 4946 E-mail: sales@dynapointautomotive.com Web: www.dynapointautomotive.com

Available on iPhone and Android devices

PROCESS INDUSTRY INFORMER January-February 2014

POWER MEASUREMENT YOKOGAWA LAUNCHES THE WORLD’S FIRST PRECISION POWER SCOPE: WHERE POWER MEETS PRECISION - Innovative PX8000 combines power-analyser and oscilloscope technologies to offer new dimension in time-based power measurements Yokogawa has combined its world-leading expertise in power measurement and its long heritage in oscilloscope design to create the world’s first Precision Power Scope: the PX8000. The PX8000 brings oscilloscope-style timebased measurement to the world of power measurement. It can capture voltage and current waveforms precisely, opening up applications and solutions for a huge variety of emerging power measurement problems. “As more and more innovation focuses on energy efficiency and the integration of electronics into power-based systems, more and more engineers are demanding accuracy and precision from their power measurement”, comments Terry Marrinan, Yokogawa’s Vice President, Test & Measurement, for Europe & Africa: “With the launch of the PX8000, R&D professionals need no longer compromise on their need for high-accuracy time-based power measurement: a need that conventional power analysers and oscilloscopes were never designed to meet.” The PX8000’s power measurement capabilities are supported by Yokogawa’s reputation for measurement accuracy, stability and repeatability. The instrument also offers ease of use and a short learning curve thanks to features familiar to users of Yokogawa’s existing families of power analysers and oscilloscopes. The new instrument has 12-bit resolution with 100 MS/s sampling and 20 MHz

bandwidth. This means that the PX8000 can be used for accurate measurement of inverter pulse shapes, which can then be used to fine-tune inverter efficiency. A choice of input modules covers voltage, current and sensor measurements at voltages up to 1000 V RMS and currents up to 5 A RMS (higher values are possible with external current sensors), with basic accuracy down to ±0.1%. To evaluate three-phase electrical systems, at least three power measurement inputs are required. The PX8000 not only has four inputs but also enables the simultaneous capture and display of voltage and current across all three phases. In addition to delivering precision power measurement to give true insight into energy consumption and performance, the PX8000 incorporates a number of innovative features that support the crucial measurement and analysis of transient power profiles. For further information about the PX8000 visit http://www.tmi.yokogawa.com/ px8000 or contact Yokogawa Europe BV, The Netherlands. Tel: +31 (0) 88 464 1811 Fax: +31 (0) 88 464 1111 E-mail: terry.marrinan@nl.yokogawa.com Web: www.tmi.yokogawa.com or search www.piimag.com to read the full release.

D3064_155x225mm PROCESS INDUSTRY INFORMER AD_Layout 1 08/01/2014 15:32 Page 1

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PROCESS INDUSTRY INFORMER January-February 2014

The BPMA gets off to a good start to 2014 It’s a busy edition to start this years’ series of “the News” with informative and interesting articles on subjects that are close the heart and the welcoming of 3 new members into the association. We keep on growing and it is indeed gratifying that the BPMA continues to attract companies of diverse activities into the fold, thereby broadening the areas of knowledge relevant to the variety of “pump related” products, services and applications, not to mention the opportunities for networking. On the subject of networking the 2014 Pump Industry Awards are in the offing – set for March 27th at the Chesford Grange House Hotel in Kenilworth. A new venue, but still with the flavour that makes it such a competitive and enjoyable evening and you still have time to vote and to book your place at this ever popular event. See pages 3 & 4.

Standardised

Customised

Systems-based

NEWS

FEBRUARY 2014

One provider

You choose. We supply.

As to the content… In this issue amongst items of interest are articles about the on-going concerns relating to Circulating pumps and “What to know about Pumps & Energy” plus information from a number of member organisations – all worth turning the pages for…

Our wide range of standard pumps and valves provides plenty of scope for individual demands. You can select the materials, hydraulic systems and drives. When you’re facing complex tasks, we’re with you from Day One – whether you want planning guidance, specially designed components or help with commissioning. But see for yourself. Test our products for quality and versatility and discover why KSB is so often first choice. www.ourtechnology.yoursuccess.ksb.com KSB Limited • 2 Cotton Way • Loughborough • Leicestershire • LE11 5TF • 01509 231872 • www.ksb.co.uk

Welcome to:-

Pumping Technology

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

A KSB Company •

Our technology. Your success. Pumps • Valves • Service

NEWS BYTES   Green Deal

guideline on circulating pump replacement

Introduction The purpose of this guideline is to present, in one document, the essential points that will be required to identify a less efficient pump installed in a domestic property and whether it should be upgraded to a more efficient one.

Scope Is to give adequate information to the assessor to easily identify if an installed stand alone circulating pump is of the old technology where its replacement with a product that complies with the Energy Related Product legislation displaying an Energy Efficiency Index (EEI) will afford the householder energy savings that meet the Green Deal guidelines.

Identification The easiest way to identify if a circulating pump is post 2013 legislation is to check the main body of the pump for a Energy Efficiency Index ( EEI ) . Legislation came into force January 1st 2013 and required all manufacturers to identify that all stand alone pumps are at least 0.27 EEI or lower.

If the existing circulating pump does not display an EEI rating it should be considered for replacement.

Energy Savings As referenced in the 2012 SAP document Table 4f, 90 kWh/year can be saved by the householder. The energy usage for circulators is estimated as follows; - 120 kWh/year for existing pumps (pre 2013) - 30 kWh/year for new pumps (2013 onwards) Installation costs will vary from one installer to another. The time taken to replace an existing pump would be approximately 1 hour. Circulating pumps have an estimated life in excess of 10 years and typically a payback on investment of 5 years.

Acknowledgements The BPMA wish to thank the following companies for their contributions to this guidance document; • Grundfos • Wilo • Smedegaard • Xylem Lowara

 BPMA

High Efficiency Circulating Pumps ALERT!!!

Back in January 2013 we were all waiting for the EU’s Energy Related Products (ErP) Directive to kick in and change the way circulating pumps were specified and installed forever. But would it have the desired effect? Would it make a huge dent in emissions across Europe and help the UK and other Governments to reach their, in the main, optimistic targets for energy efficiency and emissions reductions? And would everyone comply with these new regulations? You may recall that the EU Commission estimates that inefficient heating system small circulators alone are responsible for about a 20% share of household energy bills and removing them and replacing them with intelligent circulators could save several billion euros by 2020 across the 27 European member states – equivalent to the total annual electricity consumption of Ireland. The British Pump Manufacturers Association Ltd (BPMA) and its Council members including some of the top pump manufacturers such as Wilo, Grundfos, Xylem and Armstrong met with the National Measurement Office (NMO) recently to discuss how they could help to monitor the products that do not comply with the ErP regulations. The NMO are the UK Market Surveillance Authority in respect of Products in scope of the Energy Related Products Directive The new ErP Directive states that old uncontrolled pumps would need to cease being manufactured from the end of December 2012 and thereafter only the new high efficiency products would be distributed by all pump manufacturers., in compliance with the ErP regulations. However the BPMA and its members have seen a number of non-high efficiency pumps on the market and they are becoming increasingly concerned about the influx of non-Erp products imported from countries such as China. They are concerned that these pumps, although cosmetically looking like the new high efficiency models, in some cases, do not meet the requirements of the ErP regulations. In their discussions with NMO the BPMA presented a number of products which they deemed to be non-compliant. The NMO are responsible for enforcing the Energy Related Products Directive within the UK. They operate direct enforcement and this can be in the form of the education of the manufacturer through to court action if they believe that any company are ignoring the clear guidelines set out in the ErP Directive. The NMO confirmed that they were aware of concerns in regard to Circulators and informed the BPMA that they will initially be testing 20 circulators across 3 member states including the UK and also 10 water pumps across 2 member states again including the UK, to ensure that all regulations are being complied with. Accordingly, BPMA will continue to work with the NMO to monitor the situation.

 Pump Technology Training We have had a very successful 2013 calendar of was cturer le e le lecture based- training presented both abroad and h b t “ gea nowled ld” in the UK with almost 40 courses taking place both very k his fie within in-house and at our facility in West Bromwich and over 200 delegates attending the various modules we are currently able to provide. Feedback from both delegates and companies give us great encouragement that BPMA are definitely providing the right sort of knowledge-based modules created to arm the student with a sound technical ability to enable them to either progress further in their chosen career in the pump industry or for those wishing to widen their expertise. In-house bookings taken for 2014 are already well ahead of schedule. Courses are held throughout the year at the National Metalforming Centre and dates already fixed for 2014 are as follows:11 February 2014 – Module 001 Part 1, Pumping Fundamentals

12 February 2014 – Module 001 Part 2, Pump Selection “Lecture 4 June 2014 – Module 001 Part 1, was frie r nd knowle dgeable ly, Pumping Fundamentals and too time to k explain 5 June 2014 – Module 001 Part 2, Pump Selection ” 16 June 2014 – Module 007, Pump Testing 17 June 2014 – Module 008, Pump Systems 23 June 2014 – Module 009, Hydraulic Design of Centrifugal Pumps For further details on costs or availability please contact Jeanne Page at j.page@bpma.org.uk

“the course catered to all levels”

NEWS BYTES  Pumps and Energy – did you know? Pumps are involved in nearly every aspect of modern living. They are used to move fluids such as liquids, slurries or gasses. In businesses, buildings, households and industries, pumps exist - in some form or another. They are key components in maintaining comfort levels in buildings. They deliver and distribute clean drinking water from water treatment plants throughout cities, while at the same time removing wastewater. And, they are highly present within a wide range of industries. The world depends on them, but many pumps are also serious energy wasters, leaving behind a significant carbon footprint. This is because today’s pumps account for no less than 10% of the world’s electricity consumption and because the majority of electricity is still produced using fossil fuels. Pumps and the world’s electricity consumption Today pumps account for no less than 10% of the world’s electricity consumption. • Two third of all pumps use up to 60% too much energy. • If every business switched to a high efficiency pump system there could be global savings of 4% of the total electricity consumption- comparable with the residential electricity consumption of 1 billion people. The surprising truth about pumps • Pumps currently account for 10% of the world’s total electricity consumption There is no doubt that pumps are important, but they are also a major source of energy wastage. However, with optimised pump technology available today, it is possible to reduce their electricity consumption immediately and start to reduce this figure NOW. • You cannot go through a day without using pumps Pumps are involved in all kinds of processes and everyday practices: taking a shower, drinking a cup of coffee, cooling off production equipment, ensuring the right temperature in office buildings and transporting wastewater to sewage plants. All of these routines require pumps. • Switching to energy efficient pumps could make savings equivalent to the residential electricity consumption of one billion people If every inefficient pump were replaced with one that is energy optimised, it

could result in savings of 4% of the world’s total electricity consumption. This is equal to the residential electricity consumption of one billion people • 2 out of 3 pumps are wasting energy In two thirds of pumps and pump systems currently installed, it is possible to save up to 60% energy by switching to pumps with high-efficiency motors and variable frequency drives. • In the chemical industry there are more pumps installed than there are employees A chemical industry study conducted in Germany revealed that for every employee, chemical companies had an average of 1.25 pumps installed. • Buildings today account for 40% of the world’s energy use This means that the resulting carbon emissions are greater than those from flights, trains, buses and cars combined. By optimising current pump installations in buildings this number can be significantly reduced. • On average, pump optimisation has a payback time of 1 to 5 years Needless to say, switching to energy efficient pump systems involves certain investment costs. However, as the payback time is remarkably low, you will experience considerable savings for many years to come. • More than 20% of all the power used by motors in Europe is used to drive pumps • Most pumps waste energy 95% of the time In many pump installations, the motors run at top speed, regardless of actual requirements. This means the pumps are needlessly inefficient. In fact, most pump motors only need to run at full speed for 5% of the time. So What Should You Do???? Simple – Make Sure You Operate The Correct Pumping System By Regularly Undertaking A Pump System Audit And You Do That By Retaining The Services Of A Certified Pump System Auditor (Cpsa) SEE www.bpma-cpsa.co.uk or contact The British Pump Manufacturers Association at www.bpma.org.uk

 2014 EUROPUMP

Europump to visit Scotland in 2014 for its Annual Meeting The British Pump Manufacturers Association, host of next year’s Europump Annual Meeting, has recently announced the launch of its dedicated website –

http://europump2014.com Providing full details on the event, which is being staged at the luxurious Fairmont St Andrews Resort in Scotland from 22-24 May, the website offers a ‘one stop shop’ for all those pump executives looking to attend this important industry event. A comprehensive programme of meetings, workshops and presentations has been configured to allow all matters pertinent to European and American pump companies to be addressed. Topics such as directives, standards, market reports and other business initiatives, along with the latest appraisals on energy efficiency across the sector will be covered. Full details on the venue, the programme, the pricing and the registration procedure can be found within this online provision. Further information regarding the event, including specific details on the associated ‘National’ and ‘Gala Evenings’, will uploaded over the coming weeks. Next to the many meetings and workshops, an extensive ‘partner programme’ has been produced, including award winning afternoon tea overlooking the Old Course at St Andrews, a trip to The Hill of Tarvit, one of Scotland’s finest Edwardian mansion houses, lunch at the world famous Sea Food Restaurant, a cocktail master class and a fantastic Falconry Display. Additionally, following the General Assembly there will be the opportunity to participate in a golf competition, sponsored by WEG Electric Motors and hosted on one of the hotel’s championship courses. Please ensure you book your place(s) early, as onsite accommodation cannot be guaranteed for any reservations received after 31st March. For further information, contact: Andrew Castle - Touchwave Media, andrew@touchwavemedia.co.uk, T: 07785 290034, www.europump2014.com

 New Members We are pleased to welcome 3 new members into the BPMA: Apex Fluid Engineering Ltd, Bristol - Apex Pumps design and manufacture a wide range of centrifugal pumps for industry, building services, petrochemical plant and similar demanding applications. Mid-Kent Electrical, Sittingbourne, Kent – MKE have two divisions“. Electrical and Mechanical, as well as specific Power and Water divisions and if you have an electric motor, pump, gearbox or an engineering problem then MKE will have a solution to meet your needs. Smith and Loveless Ltd based in Camberley - manufacture and market the diverse water and sewage handling technologies from transcontinental affiliates Smith & Loveless Inc. / Kalsep UK Ltd.

 PIA

Awards 2014

It’s decision time to cast your votes in the 2014 Pump Industry Awards Have your say in who will be the stars of the show at the 2014 Pump Industry Awards being held this year at Chesford Grange Hotel, Kenilworth on 27th March. Check the list of nominations to ensure that the companies you believe are worthy of being winners - then cast your votes at www.pumpindustryawards.com where you can also “book your place” at the pump event of the year…

Reducing Red Tape Sealless Pumps from HMD Kontro Reduce Administration Time and Cost

Three Good Reasons To Choose a John Crane A Series Coupling ZERO MAINTENANCE No relative moving parts hence no lubrication or routine maintenance required

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

INSERT REPLACEMENT Can be replaced without moving the associated machines

Rely on John Crane for lower cost of ownership, guaranteed reliability and improved productivity. To learn more, please contact us at: John Crane UK Ltd, 31 Nash Road, Trafford Park, Manchester, M17 1SS. Tel: 0161-872-2484 Email: enquiries@johncrane.co.uk

www.johncrane.com

In these days of increasing legislation and litigation, plus appropriately higher health & safety considerations, the resulting red tape can tie you up in knots. In fact, it usually means lengthy meetings and long documents that need to be completed as an integral part of any engineering project. However, this all takes time and, as a result, money. In particular the completion of HazOps (Hazard and Operability) studies and Job or Task Hazard Analysis processes often result in time-consuming meetings involving many senior personnel. Also, the associated amount and cost of necessary documentation has also soared. Sundyne HMD Kontro, the pioneer of the magnetic drive pump technology, claim that their sealless pumps can save considerable time and money because the HazOps study and the resulting paperwork to be completed is much more concise. This allows engineers and other important staff to focus on other aspects of a project or similar. Because the HMD Kontro pumps are sealless, there is no risk from a leak or emission to atmosphere. Also, there is minimal ancillary equipment such as seal support systems. This significantly reduces the hazards involved and hence the time necessary for risk evaluation and assessment. In addition to quelling health and safety concerns, HMD Kontro pumps also have environmental benefits. Here the absence of any potential for leaks from the pump or support system ensures that the risk to not only staff but also the wider public and the environment is almost completely eliminated. For a free guide to the latest know how about sealless pumps, please contact HMD Kontro on +44 (0) 1323 452000. Alternatively, for further information please see their website at www.hmdkontro.com

E-mail: enquiries@johncrane.co.uk

It’s decision time…

www.pumpindustryawards.com hannah@touchwavemedia.co.uk

E-mail: hannah@touchwavemedia.co.uk

Grundfos take the biscuit With a history dating back to 1830, the manufacturing process has dramatically changed since Robert McVitie opened his first shop in Edinburgh. Today McVitie’s are part of United Biscuits and operate from a total of five sites across the UK. At their largest site in Harlesden in London alone, they produce an incredible 23 million biscuits a day making this the largest biscuit factory in Europe A production process involving very abrasive liquids that have a very high viscosity puts pressure on the process pumps involved within the production procedure. Older traditional solutions often mean frequent leakages that require extensive maintenance work. This was the position for McVitie’s back in 2009 when the incumbent pumps were frequently experiencing leaks that required extensive repairs every 6-7 weeks. So when Grundfos Pumps initially established contact with McVitie’s and introduced them to the Grundfos NOVAlobe concept, they were very interested as they needed to find a solution to this problem. The NOVAlobe family are rotary lobe pumps that are specifically designed to provide reliable, efficient and hygienic operation even under the most demanding condition. These pumps have been designed to pump very viscose media and also meet the highest hygienic standards including achieving EHEDG accreditation. Today McVitie’s are continuing to replace pumps with Grundfos NOVAlobe pump options and the company continues to be very pleased with this pump solution. For more information contact Grundfos Pumps Ltd, Leighton Buzzard, Buckinghamshire. Tel: 01525 850000 E-mail: grundfosuk@grundfos.com Web: www.grundfos.co.uk

SPP protects Europe’s tallest building SPP Pumps, leading manufacturer of centrifugal pumps and systems, knows more than most about the importance of considering fire safety and protection in large construction projects. With more than 130 years’ experience in providing critical performance pump solutions into demanding environments, SPP is an expert in overcoming the challenges faced by its customers. Alex Playfair, Business Unit Manager, Fire and Safety Divisions at SPP explains how the company went about providing fire protection solutions for Europe’s tallest building, The Shard, which recently opened its doors to the public. “There is no doubt about the fact The Shard is one of the most spectacular skyscrapers in the world. Standing at 309.6 metres tall on London Bridge’s skyline it is quite possibly the most recognised building in Europe” said Alex. As well as being a feat of modern architecture however, The Shard has a huge responsibility to play in keeping its inhabitants safe. And that is where SPP Pumps comes in to the picture. Alex continues: “This was a prestigious project win for SPP. The unusual design of the building demanded the highest performing fire safety pump sets as well as the most efficient water supplied for the whole building, and this provided a unique challenge.” While many pump manufacturers can offer equipment designed to the various locally

applicable fire rules and registrations, SPP is one of the select few who have had its sprinkler and wet rise pumps subjected to the stringent performance and reliability tests of specialist fire approved laboratories worldwide. Alex goes on: “We were aware that European Sprinkler regulations don’t allow the use of pressure reducing valves due to their unreliability, so zones had to be created to limit pressure on the sprinkler heads in lieu of the valves. “This concept had never been applied to a building over 300m before, and so we had to work with Arup (the consultant) to create a solution that produced a quality, reliable water source, at the same as satisfying the strict regulations.” For the sprinkler pumps, SPP supplied two off CD12K 10 stage pumps with seven take

off outlets to supply seven sprinkler zones in the building. The pumps were driven by 200 KW motors, and each zone has its own jockey pump to maintain pressure. Pumps for the hydrants then provided a totally different challenge. Three pump stations were installed at various levels in the building. At base level SPP supplied 2 BU06 split case pumps with 315kW motors to produce 4500 L/M at 24 Bar. The mid and high level pump houses were equipped with CD10K 4 stage pumps with 132kW motors producing 3000 L/M at 24bar. As the first company to achieve fire pump approval and listing by the internationally recognised Loss Prevention Certification Board, SPP has more pumps approved by the LPCB than any other manufacturer. Manufactured in the UK, SPP’s Pumps meet the requirements of all major international standards, particularly NFPA 20. Approved for use in many markets, including Europe, the Middle East and Africa, SPP provides world class protection technology. For more information contact SPP Pumps, Reading, Berkshire. Tel: 0118 932 3123 Fax: 0118 932 3302 E-mail: enquiries@spppumps.com Web: www.spppumps.com

E-mail: sales@wilo.co.uk Wilo_BPMA Magazine February 2014_print 16 January 2014 16:16:35

WRAS Certification Granted

for the Smedegaard EXE range of Cold Water Booster Sets At Smedegaard Pumps Limited we are continuously working to improve our product ranges. The results of this are clear to see with the recent launch of our new technologically advanced and highly efficient Magneta range of

circulating pumps. Now the latest success at Smedegaard is the award of WRAS (Water Regulations Advisory Scheme) certification 1312078 to our tried and tested EXEFLEXX range of cold water booster sets.

It is important to note that rigorous mechanical testing was carried out for this approval to be granted ensuring that these complete booster sets comply with various strict byelaw regulations & requirements as they currently exist in the UK today. It is worthy of note that this certification has been awarded for the complete booster set assemblies not just for the component parts. The EXE range now includes such features as single outlet manifolds to eliminate any deadends and the use of flow-through vessels throughout the entire range. Furthermore, included in the same certification are the EXEDOL direct on line cold water booster sets and EXETRAN water transfer booster sets. Smedegaard have always been known for supplying booster sets of the highest standards & with the extra assurance this approval provides it reiterates the benefit of choosing Smedegaard.

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

Atlas Copco extends breakthrough GA VSD+ compressor range up to 37kW With this strategy, Atlas Copco wants to contribute to a more sustainable industry. Koen Lauwers, Vice-President Marketing of Atlas Copco’s Industrial Air Division comments: “Since the launch of the VSD 7-15 VSD+ range, we have succeeded in selling more variable speed drive units. With the introduction of the larger GA VSD+ units (18-37 kW), we expect even more VSD sales, more Atlas Copco Compressors has extended its innovative range of GA VSD+ oil-injected screw compressors, launched in 2013, with the introduction of new models from 18-37 kW. With the expansion of the range up to 37kW, Atlas Copco is now able to offer its breakthrough VSD+ technology, which provides industry-leading energy savings of 50% on average, a 13% leap in Free Air Delivery and a canopy less than half the size of traditional fixed speed compressors, to 75% of oilinjected screw compressors users worldwide. The introduction of the GA 7-15 kW VSD+ range in 2013 led to a significant increase in the “VSD ratio”: the relative number of Variable Speed Drive units on the total number of compressors sold worldwide. With the extension of the GA VSD+ compressor range up to 37kW, Atlas Copco expects to raise this ratio even further, benefiting not only customers but also the

Available on iPhone and Android devices

environment in general thanks to the increased energy savings on offer. In addition to expanding the GA VSD+ range, Atlas Copco has also introduced its new “condensation prevention cycle” for Variable Speed Drive compressors.. Variable speed driven compressors adapt the speed of the compression element to exactly match the compressed air demand: for a standard VSD compressor, this means an energy saving of 35% on average. The new, in-house developed VSD+ takes that figure even higher: an

integrated permanent magnet motor drives the VSD+’s screw elements, realising energy savings of 50% on average, compared to fixed speed models. For more information contact Atlas Copco, Hemel Hempstead, Hertfordshire. Tel: 0845 6010001 E-mail: ac.cmtuk@uk.atlascopco.com Web: www.atlascopco.co.uk

Motors | Automation | Energy & Distribution | Coatings

The flameproof W22X. Ultimate safety. Ultimate efficiency.

Historically, hazardous area motors have been a compromise between safety and efficiency. Not any more. Our new W22X flameproof motors are IEC compliant for use in hazardous areas. They’re also the only flameproof motors rated IE3 for energy efficiency. So your customers get flameproof protection and money saving efficiency, too.

To learn more about our new W22X, the ultimate hazardous area motor, visit www.weg-ie4.com/hazardous

One year on from circulator legislation It is one year since legislation changed the circulator market in Europe forever. This change has meant that all glandless standalone circulators, with the exception of those specifically designed for primary circuits or thermal solar systems and heat pumps need to have an energy efficiency index (EEI) of less than 0.27. With other ever stricter changes scheduled to take place in 2015 and 2020. The Grundfos domestic circulator range delivers an energy efficiency index as low as 0.15 and runs on as little as 5W. The benefit of fitting these very efficient pumps is something which is becoming increasingly clear with recent, and seemingly ongoing, energy price hikes and the huge numbers of households now recognised as being in fuel poverty. The energy saving opportunities that these products offer have recently received an important acknowledgement, as following on from extensive and lengthy pump industry lobbying - the BRE

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

Mr/Mrs etc:........ Initials:..... Surname:..................................

have agreed to include circulator pumps in the government’s Green Deal scheme. The Green Deal has been designed to help consumers make energy-saving improvements to their homes without having to pay the costs in advance. Instead the associated costs of the improvements can be paid back over time with the resultant savings covering the repayment costs.

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

John Crane A Series couplings – a powerful way to reduce maintenance costs Ever tighter budgets and increasing uptime requirements have again highlighted the need for reliable rotating equipment products from a trusted supplier. Backed by an impressive track record in a wide variety of industrial applications, Powerstream A Series couplings from John Crane feature a compact design and a simple construction which allows new inserts to be installed without removing either the prime mover or the driven equipment. They are available in either close-coupled or spacer configurations, both of which are designed to allow easy installation. The coupling has no relative moving parts, and hence requires no lubrication or routine maintenance. Large bore and high torque requirements can be accommodated, and the couplings can be mounted horizontally or vertically using standard inserts and retaining rings. Standard or high temperature insert options up to 150°C/300°F are available, further extending the versatility of these couplings and making them suited to a huge range of applications. For more information contact John Crane EMEA & APAC, Trafford Park, Manchester. Tel: (+44) (0)161 886 5993 Fax: (+44) (0)161 872 1654 E-mail: enquiries@johncrane.co.uk Web: www.johncrane.com

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

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

Goulds Pumps ISO Process Pumps now come with a

5 YEAR WARRANTY

What would give to spot a pump failure sooner? With the Goulds iFrame you could. The iFrame features on Goulds ISO and ANSI process pumps, incorporating the iAlert, vibration and temperature are constantly monitored on your pump to ensure your process runs at its optimum condition with strong visual indication in the form of three flashing LED’s, its never been easier to see how a pumps performing. When the iAlert is first activated at startup it sets an operating benchmark for temperature and vibration of your pump, with any change in either of these conditions outside of acceptable limits the iAlert notifies you by green flashing LED’s turning red. So when you’re on the morning walk around the plant it couldn’t be easier to see how things are running. As the iFrame with iAlert is fitted to Goulds ANSI and ISO process pumps which come with a 5 year warranty you’d have to ask yourself, why not? We just believe it’s better. For more information contact Goulds Pumps, Axminster, Devon Tel: 01297 630473 E-mail: www.gouldspumps.com/Contact-Us Web: www.gouldspumps.com

It pays to invest in refrigerant leak detection as part of your overall maintenance strategy, but which one offers the best solution? Jim Bishop from A-Gas looks at the options available With plant and process managers under pressure to contain leaks and minimise the environmental impact as well as the cost of lost refrigerant, leak detection has now become more of a priority than ever. All sealed systems leak and every pressure system has leaks because every joint seam or weld may contain flaws that are too small to detect.

being added to the air conditioning or refrigeration plant. The dye then mixes with any lubricant and circulates throughout the system. When the refrigerant leaks so does the dye and it can be detected by scanning the system with an ultraviolet or blue lamp.

A leak can be present as a result of a weakness in the weld or a small groove between pipe fittings. Even the tightest of systems which may have operated for years without a top up charge will still have leaks, but so small they do not show up on a gauge and performance will be largely unaffected.

This is a relatively simple and low cost technique, but the test results can be influenced by environmental factors, or where parts are hotter or colder than ambient temperatures as a result of a welding operation. Small pressure decays can also be impossible to see on a pressure gauge.

If regular testing and detection is not carried out these leaks can soon become larger detectable leaks and could have a detrimental effect on your plant’s performance. Repairing leaks is not the problem, but with many techniques and technologies available, using the most appropriate method for your system to find them, can be confusing, as there are many common leak detection methods available.

As the industry focuses on compliance with the F-Gas regulations and customers demand leak reduction, refrigerant users are constantly searching for more effective solutions.

With a greater focus on implementing EU directives, F-Gas Regulations and pressure from trade bodies, leak detection is now a mainstream issue. It is estimated that as much as 30% of refrigerant is lost annually through leaks in refrigeration and HVAC equipment. The environmental impact, refrigerant replacement costs and tightening legislation means that end users now give leak detection a very high priority.

Leak detection methods

Pressure decay testing relies on the principle that when a leaky part is pressurised with nitrogen, then isolated using valves, a loss of pressure over time will be apparent and the pressure decay rate will be converted to a leak rate according to the equation Q = (P1-P2) V/t Q = leak rate P1-P2 = the change in pressure over the test period V= test volume T = test period (The temperature is assumed to be held at a constant)

One of the latest solutions is a ‘next generation’ precision leak detection gas that not only addresses environmental concerns and provides customers with an effective solution for detecting leaks right down to less than five grams per year. Called Trace-A-Gas® it is a 5% Hydrogen and 95% Nitrogen mixture which is non-flammable and nontoxic. Hydrogen is a light element and is the smallest molecule, so it moves quickly through a system and will pass through even the smallest leak. Its’ low viscosity makes it easy to flush out and vent away. Leak detection devices with high levels of sensitivity are able to detect even ‘pinhole-sized’ leaks, which are far more problematic to locate. Developed to focus on the difficult- to-find leaks, this method has been proven to be far more effective at detecting smaller leaks than traditional methods such as the bubble soap spray or pressure decay. Following extensive testing, Trace-A-Gas® was subsequently trialled on a pilot site using a supermarket refrigeration pack. Using Trace-A-Gas® a pinhole leak which had gone undetected by a bubble soap spray and a further four tiny leaks were highlighted including one on a joint covered by Armaflex. None of these had shown up during an overnight pressure decay test at 27.5 bar.

- Real time results, which ensures less time is spent on site If unchecked, leaks can have a detrimental effect on plant whilst compromising company’s legal obligations. They can impact health and safety requirements, increase running costs as well as servicing costs and have a detrimental impact on the environment. Considering the high cost of refrigerant, repair of equipment and the time it takes to locate leaks, it makes good business sense to have in place a preventative maintenance programme. Taking a proactive approach and ensuring that leak detection is a part of your overall maintenance strategy will help pinpoint leaks quickly, accurately and minimise refrigerant losses. To help plant and service engineers there is a wealth of information in, FETA’s Code of Practice for Refrigerant Leak Tightness which can be found at www.feta. co.uk Information and advice can also be found on the Institute of Refrigeration’s website www.ior.org.uk/ Trace-A-Gas® Fast Facts • • • • •

Ability to detect small leaks Suitable for testing all areas of a system Compatible with a standard nitrogen regulator Available in portable 10 litre cylinder size 30 litre cylinder size available for workshop applications

A Next Generation Solution TRACE-A-GAS™ 5% Hydrogen and 95% Nitrogen • Non flammable • Non Toxic • Environmentally friendly Hydrogen has a number of properties that make it an excellent tracer gas: • Low viscosity • Finds and passes through a leak faster • Lightest element • Easy to flush out and vent away • With the use of an electronic leak detector engineers are able to locate even the smallest of leaks

The trials also confirmed that this method was up to 100 times more sensitive than soapy bubble spray and that combined with a suitable electronic hydrogen detector, offers a very valuable tool in the battle to eradicate leaks. There are various methods of leak detection available, one of the oldest methods is the bubble spray. A soapy solution is applied at the suspected area and in theory the escaping refrigerant will produce bubbles indicating where a repair is required. It is simple enough but the disadvantage is that with small leaks or if conducted in a draughty or exposed environment it is not accurate. Fluorescent leak detectors rely on a fluorescent dye

All leak detectors require a level of skill in using them and their effectiveness and ease of use are important considerations by service engineers when selecting a leak detection system. Consideration should be given to the size of plant and accessibility is of equal importance. A good leak detection kit will offer the following: - The ability to test all areas of the system, including insulated or difficult to access pipework where a spray device cannot easily be used

PROCESS INDUSTRY INFORMER January-February 2014

A-Gas (UK) Limited, Bristol, Avon Can be contacted on; Tel: 0127 537 6600 Fax: 0127 537 6601 E-mail: info.uk@agas.com Web: www.agas.com

HMI MO The benefits of remote access for manufacturing operations are widely known and accepted. This article details how modern SCADA systems are providing this access in a variety of ways to all manner of fixed and portable computing platforms and other devices. Human Machine Interface (HMI) has evolved significantly from the days in which operations staff had to sit in front of a single screen to monitor a machine or a process. HMI /SCADA (Supervisory Control and Data Acquisition) applications now not only monitor and help control equipment and processes, but also provide a huge range of information regarding machine and plant operations. Since many people consider HMI to be a low-end panelmounted apparatus, the term SCADA will be used to refer to the more advanced applications discussed in this article. Table 1 lists the various ways in which HMI and SCADA systems provide remote access to users. At the most basic, a panel-mounted HMI with built-in web server capabilities provides some limited degree of remote access via a web browser. This access is often only one-way, allowing remote users to view information, but not to make changes.

TABLE 1: Remote Access Methods 1. 2. 3. 4. 5.

HMI server-browser SCADA server-browser SCADA server-mobile phone app SCADA server-thin client Cloud-based SCADA server-multiple

Modern SCADA systems generally provide server-thin client remote access, allowing any type of PC or other similar device to remotely access the main SCADA system. This type of access is often virtually identical to local SCADA system access, providing a full range of features, albeit at a higher cost than browser or app access. The next step up is again server-browser access, but this time via local SCADA software, generally running on a PC installed locally at the machine or the process. Although the remote access is still via browser, in most cases this access is more full-featured than with a simple HMI, allowing remote users to view more information in a wider variety of formats. SCADA server-browser access also usually provides two-way access, allowing for remote adjustments and corrections. Many SCADA software packages also allow server-mobile phone app remote access. As with SCADA server-browser access, remote users have full-featured two-way access. But mobile phone app access can provide other advantages, namely easier and faster loading of the remote application, and faster response to and from the SCADA system.

Finally, cloud-based SCADA servers can provide multiple means of remote access at very low cost, and are an ideal fit in many applications. This article will discuss all of these remote access methods in detail, focusing on more advanced SCADA-based remote access solutions.

The Move to PC-based Systems Whether it’s a plant manager checking the latest Overall Equipment Effectiveness (OEE) performance or an operator reacting swiftly to an alarm, the ability to access data quickly from multiple remote locations makes manufacturers more efficient and flexible. Table 2 lists some of the advantages of remote access, which are well known to most manufacturers and won’t be covered in detail in this article.

PC-based SCADA systems opened the way to laptops, mobile phones and other remote appliances that enable operators and managers to view information from anywhere, enabling plants to run more effectively. For example, when remote SCADA software became available for the Microsoft Windows CE operating system platform, it allowed developers to more easily implement remote access on a wider variety of hardware platforms. Remote SCADA packages optimized for mobile and embedded operating systems were developed to deliver many of the tools and functionality found in a local PC-based SCADA system to a wide variety of smaller capacity remote devices.

SCADA Data TABLE 2: Remote Access Advantages 1. Provides faster operator response to alarms and events 2. Allows personnel to leverage their knowledge across multiple facilities 3. Improves quality by enabling continuous process improvement 4. Cuts costs by reducing or eliminating travel expenses 5. Allows quick comparison of operations across multiple facilities

Not so long ago, operator interface meant a local HMI for control of a single machine or process. Today, HMI has morphed into full featured SCADA systems that often serve as an important component of plant automation by collecting and archiving huge amounts of data. This has increased the need for easier and less expensive remote access, as more personnel want and need access to this expanded amount of data. Operators, engineers and managers are expected to respond faster to events, even though total staff counts are the same or lower. Fortunately, remote access tools are enabling greater efficiency, allowing personnel to operate more effectively over a wider geographical area (Figure 1).

Over the years, various technical advances have provided the required remote access to enable improved operations. As SCADA systems evolved from simple local HMI functionality and became more advanced, they had to move to open standards and networking protocols to communicate with diverse equipment and systems. This opened access to a wide variety of devices that could remotely access SCADA information from just about anywhere and at any time. Starting in the 1980s, SCADA systems migrated from proprietary hardware to PCs, generally Windows-based. This offered many advantages in terms of graphics, alarming and trending that improved control and overall plant performance. Many people remember and are keenly aware of the advantages PC-based SCADA brought to local users, both in terms of cost and performance. However, one often forgets how the move to PC-based systems made possible the changes in SCADA information portability and remote access. The first HMIs were designed only to interact with local human operators, and not with other systems or with remote users. As SCADA systems began to be integrated with other nonproprietary control systems, they started using Microsoft standards to facilitate connections. SCADA information could then be downloaded easily into programs such as Microsoft Word and Excel, the types of data representation that appealed to a broader range of users. As a corollary benefit, remote access was much easier to implement with these PC-based Windows SCADA systems, particularly as compared to older SCADA systems based on proprietary hardware and software operating systems. The introduction of networking standards along with the increasingly open SCADA architectures have enabled this and other types of SCADA-based information to be accessed by a growing number of remote devices.

Figure 1: OEE dashboard. Plant managers and executives can now access important OEE measurements remotely to improve quality and efficiency. For example, a recent expansion of SCADA system functionality has been to include more enterprise data, such as OEE dashboards that present Key Performance Indicator (KPI) data (Figure 1). This type of data has a great appeal to plant managers and executives. By studying a plant’s KPIs with respect to factors such as throughput, quality and availability, plant managers can remotely determine the machines or parts of the process that need improvement. If a machine’s throughput is at 100 percent with acceptable quality of finished parts at only 80 percent, a plant manager knows that improvements can be made.

Browsers versus Apps Since operators, engineers and managers must monitor more processes in more places, they need the ability to access SCADA information from mobile devices. In response to those needs, SCADA suppliers have designed their products to provide a wide range of remote access methods.

PROCESS INDUSTRY INFORMER January-February 2014

OBILITY

By Fabio Terezinho, Vice President of Consulting Services/Product Manager, InduSoft

Now, authorized users can remotely access data using a variety of devices including PCs, iPads, tablets and smartphones. Remote access to SCADA systems by mobile devices is typically achieved via a web browser or an app. There is a debate over which method provides better access, but in both cases the access must be optimized for the smaller screens found on remote devices as compared to PCs. Users need screens that are correctly sized for their iPhones and Androids, as too much graphical information will slow download speeds, and often result in excess data charges from cell phone providers. Incorrectly sized screens also make remote access cumbersome as excessive scrolling is often required to view text and graphics information. Apps are designed specifically for smartphones and other handheld devices, so screens are generally designed correctly. But care must be taken when designing browserbased remote access from SCADA servers, as information must be presented in a format consistent with the hardware limitations of the platform (Figure 2).

In addition to eliminating the expenses and problems related to the hardware layer of IT infrastructure, cloudbased SCADA enables users to view data on devices like smart phones and tablet computers, as well as through SMS text messages and email. Cloud computing is utilized by SCADA application in two ways: 1) the SCADA application is running on-site, directly connected to the control network and delivering information to the cloud where it can be stored and disseminated; 2) the SCADA application is running entirely in the cloud and remotely connected to the control network. Most cloud-based SCADA systems use the first method. The automation functions of the SCADA application are entirely isolated to the control network, with no interface to the cloud. However, the SCADA system is connected to a service in the cloud that provides visualization, reporting and access to remote users. These applications are commonly implemented using public cloud infrastructures (Figure 3).

depend on a single Internet provider. Cloud-based computing also poses some new security challenges, as the data in the cloud is generally stored in a shared environment. Users must trust the long-term stability and the security measures of the cloud provider, and must be confident that they can take control and ownership of their data if the provider isn’t performing to expectations. With respect to security, it’s important to remember that reputable cloud providers are aware of the new security challenges, and have entire departments devoted to learning about the latest possible threats and implementing necessary precautions. There is also reason to believe that existing Internet law on the ownership of data will be extended to protect cloud users. Whether remotely obtaining information using networking protocols, enabling more authorized users to access the SCADA system from their smartphone, or even moving their SCADA IT infrastructure to the cloud—more and more manufacturers are benefiting from the remote access capabilities of their SCADA solutions. In the majority of cases, remote access has increased flexibility, improved overall efficiency and reduced operating costs. Less staff is required to operate plants, plant managers can make informed decisions to improve productivity, and workers don’t need to drive to distant locations to retrieve data. Not all manufacturers are ready to move to cloud-based SCADA, but most have benefited from the move to advanced SCADA solutions that have ushered in the era of access to data anytime from anywhere via a wide variety of platforms.

Figure 2: Handheld device with SCADA screens. With modern SCADA systems, operators can access more information from handheld devices, in formats tailored for smaller screen sizes. Since the programming languages used for iPhones and Androids are different, apps and browser-based applications typically had to be written by SCADA suppliers separately for different devices. This meant that users often had to wait months for their smartphone application to be developed or upgraded. However, many SCADA suppliers are now developing their remote access applications in HTML5, taking advantage of this open standard to develop a multitude of web applications for multiple types of devices at the same time. Thin clients overcome the issues involved with designing remote access for smartphones and other similar devices, as the thin client is generally a PC or a related device with a relatively large screen size, and with accompanying supporting hardware. But thin clients are more expensive to deploy, as the hardware costs more up front, and as connectivity generally must be provided by means other than existing cell phone networks. In addition, some SCADA suppliers charge for each thin client software license, while most provide virtually unlimited smartphone browser or app access at little or no extra cost.

Figure 3: Cloud Network. Cloud-based SCADA can dramatically cut costs while offering more robust remote access from a wider variety of platforms.

From the Web to the Cloud

With cloud-based SCADA, all of the computing power, storage and redundancy required for remote access are provided by the cloud providers’ servers. This makes every user a remote user, with no additional effort required by the end user after establishing a connection from the local SCADA system to the cloud. It also reduces deployment time from weeks or months to a few days, or even a few hours.

One of the latest developments in remote access is hosting the SCADA system in a cloud-based environment. This enables users too significantly reduce costs and achieve greater reliability, while gaining the ability to remotely access data from a very wide variety of hardware platforms over many types of networks ranging from hard-wired to cellular.

Since the IT layer is removed from the plant, all updates, security measures and patches are performed instantaneously across the system without any input required from the end user. System availability for remote users is improved because the cloud provider usually offers multiple, redundant Internet and other connections, whereas most traditional SCADA environments generally

PROCESS INDUSTRY INFORMER January-February 2014

Indusoft, Austin, Texas, USA Can be contacted on: Tel: 001 512 349 0334 E-mail: fabio.souza@indusoft.com Web: www.indusoft

HEALTH & SAFETY

SFC’s key

CROWCON’S MODULAR GASMASTER CONTROL PANEL MONITORS UP TO FOUR GAS DETECTORS Crowcon’s new Gasmaster control panel has a modular design meaning users only need purchase the required number of input modules. It can easily be extended by adding more modules at a later date. Gasmaster monitors up to four gas detectors or four fire zones, all from a single location. Simple to operate, the large multilingual LCD display shows gas levels from all detectors simultaneously and allows quick and easy system adjustment and testing from the control panel. It can operate as a stand-alone unit or interface with any alarm or visual warning devices and control systems. In addition to standard 4-20mA-type gas detectors, Gasmaster can also be used with mV pellistor-type flammable gas detectors, which are significantly lower in cost than 4-20mA-types as they have no internal electronics. Sensor calibration is performed via the Gasmaster user interface: once commissioned, mV pellistor-type

detectors do not need to be accessed until the sensor needs replacing – usually 3-5 years after installation. In addition, power to mV pellistor-type detectors is automatically cut if the gas reading exceeds 95% of the gas’ LEL (Lower Explosive Limit) to prevent sensor damage. Gasmaster provides as standard a wide range of analogue, relay and Modbus outputs and a ‘calibration due’ warning informs the user when a service is due on a gas or fire detector. An IP65 enclosure also means the control panel can be installed in potentially wet areas without requiring the additional cost of high-IP enclosures. Key industries include: • Refineries • Petrochemical, chemical and pharmaceutical plants • Water and wastewater treatment • Gas storage and distribution • Power generation • Manufacturing processes (e.g. car manufacturing plants) • Universities and research facilities • Local authorities For more information contact Crowcon Detection Instruments Ltd, Abingdon, Oxon. Tel: +44 (0)1235 557700 Fax: +44 (0)1235 557718 E-mail: sales@crowcon.com Web: www.crowcon.com

SmartKey+ Securely Manages Safety Interlock Keys In Real Time SmartKey+ is an extension of Smith Flow Control’s Key Management Systems. Key cabinets provide a safe and visual way of storing interlock system ‘initiating’ keys. SmartKey+ has been developed to provide all the features of SFC’s Visual Alert Key Cabinet, along with the ability to record movements of keys in real-time, providing complete accuracy. SmartKey+ uses RFID (radio-frequency identification) technology which allows a key to be tracked with complete confidence, providing operator and control room personnel with information on interlocked processes and their status. Full transaction history is available, revealing details of key insertion/removal. The unit is designed to support a remote web interface, without any specific licence. SmartKey+ has enhanced levels of system security. All keys are trapped in the cabinet until authorisation is granted; a user is identified by a pin code. SmartKey+ highlights specific key positions that the operator is authorised to use. The user selects the appropriate key from the panel and removes the key as the selected key position is unlocked. The SmartKey+ Cabinet is configured around a central control panel capable of running a system with over 500 keys. SFC’s SmartKey+ provides a unique solution to key management, combining innovative software and smart technologies. For more information, contact Smith Flow Control, Witham, Essex Tel: +44 (0)1376 517901 Fax: +44 (0)1376 519720 E-mail: sales@smithflowcontrol.com Web: www.smithflowcontrol.com

management system ensures safe operation of interlocks

To complement its key interlock system, industrial safety company Smith Flow Control (SFC) offers a high quality key management system. SFC has designed a range of horizontal key cabinets to hold operational keys and ensure safe application under secure supervisory control. Each interlocked system has a dedicated, engraved tag location within the key cabinet to ensure total integrity and all keys are visually displayed inside the cabinet during periods of normal operation. Once the initial key has been retrieved from the central key cabinet, an operator can begin the sequence of key transfer events that allows dangerous machinery and critical valves to be operated in a safe and pre-determined way, eliminating human error. To facilitate this, key cabinets should be located in a secure place, typically a control room. Initial keys are typically issued by the Permit Officer. Key cabinets have fully lockable doors to prevent unauthorised access. Key cabinets vary in size, but utilise a new horizontal design which allows greater capacity and storage for up to 280 keys. SFC offers the units in a choice of carbon or stainless steel. For more information contact Smith Flow Control Ltd, Witham, Essex Tel: +44 (0)1376 517901 Fax: +44 (0)1376 519720 E-mail: sales@smithflowcontrol.com Web: www.smithflowcontrol.com

A SIMPLE YET EFFECTIVE WAY OF MONITORING STATIC GROUNDING POINTS The Bond-Rite® REMOTE is a static grounding solution that prevents the dangerous accumulation of static electricity on plant equipment located in hazardous areas. The Bond-Rite® REMOTE achieves this by grounding the plant equipment, like barrels or IBCs, with Intrinsically Safe electronics that monitor the integrity of the ground path between the object being grounded and the plant’s reference grounding point. When the operator connects the Bond-Rite® REMOTE grounding clamp to the object that requires static grounding protection, a green LED located in the wall mounted indicator station pulses continuously, provided the resistance between the object and the plant’s reference grounding point is 10 ohms or less. A resistance of 10 ohms or less demonstrates compliance with the recommendations of IEC 60079-32 and NFPA 77, the primary industry guidelines for preventing fires and explosions caused by static electricity. Unlike traditional basic grounding clamps and cables, with the Bond-Rite® REMOTE, when the operator gets the green light they know that the equipment is grounded and can start the operation. Each indicator station can be powered by a single 9V battery or by a certified 230 / 115 V AC driven external power supply that can power up to 10 indicator stations simultaneously. Bond-Rite® REMOTE indicator stations can be mounted in hazardous areas as high as Zones 0/20 and Class I, Div.1 locations. Bond-Rite® REMOTE external power supplies can be mounted in Zones 2/21 and Class I, Div.2 locations. IECEx / ATEX / cCSAus certified for gas, vapour and dust atmospheres. For more information contact Newson Gale Ltd, Colwick, Nottingham Tel: 0115 940 7500 Fax: 0115 940 7501 E-mail: groundit@newson-gale.co.uk Web: www.newson-gale.co.uk

PROCESS INDUSTRY INFORMER January-February 2014

HEALTH & SAFETY

FlexiDrive Valve Actuators Assist Paper Plants Equipped with two stations and joined by a unique linear drive cable, the Smith Flow Control FlexiDrive tool offers paper and pulp plants a cost-effective remote device to safely control valve operations. The FlexiDrive valve operator is constructed of stainless steel, and holds up well in corrosive, industrial environments. Typical paper and pulp applications can include inaccessible overhead valves, valves in pits and valves in hazardous zones. FlexiDrive allows a user to locate a point of operation in a safe and convenient place in the plant. It is adaptable to most valves with no modifications needed. The patented flexible linear drive cable effectively delivers rotary torque for distances up to nearly 100 feet depending on the output torque required. The system can be passed through and around walls, bulkheads and floors, and is completely sealed and permanently lubricated for maintenance-free, continuous loop operation. For more information, contact Smith Flow Control, Witham, Essex Tel: +44 (0)1376 517901 Fax: +44 (0)1376 519720 E-mail: sales@smithflowcontrol.com Web: www.smithflowcontrol.com

WIRING SYSTEMS Wiring system for Rittal’s Ri4Power with internal compartmentalisation Rittal’s wiring system for Ri4Power facilitates vertical and horizontal cable routing in conjunction with internal Form 2-4 separation. Where vertical cable routing is required pre-punched cut-outs are provided in the mounting brackets for compartment dividers, which can easily be knocked out and used to install a vertical wiring channel. Horizontal cable routing occurs behind the front trim panels. This entails fitting a wiring trim panel suitable for accommodating a wiring channel while, at the same time, concealing the busbar system. Rittal’s wiring trim panel consists of an inner front cover of the main busbar system with the option of mounting a wiring channel size 40 x 20 mm (W x D). For use in Ri4Power switchgear with 300 mm high front trim panels, the wiring trim increases the flexibility of the Ri4Power system and makes control gear cabling easier. For more information contact Rittal Limited, Rotherham, South Yorks. Tel: 01709 704000 E-mail: information@rittal.co.uk Web: www.rittal.co.uk

ENCLOSURES

READY FOR WINTER? RITTAL CAN HELP Enclosure heaters can prevent the temperature of delicate electronic equipment from falling to a level at which condensation occurs and is arguably as important as providing cooling during warmer periods. Rittal’s enclosure heaters with fans have capacities in the range 250 W to 800 W and the smaller heaters, without fans, have an output range of 10 W to 150 W. Providing a high level of energy efficiency due to the incorporation of self-regulating positive temperature coefficient (PTC) technology, the heaters benefit from a development using computational fluid dynamics (CFD) and a compact physical size that belies their heating performance. Positioned anywhere inside the enclosure, Rittal heaters may be fitting being either by snap-fastening onto 35mm support rails or direct screw-fixing onto TS 8 punched frame sections. Quick and easy assembly is completed using clamp-type wiring terminals. Control is effected simply by the inclusion of a thermostat or hygrostat in the supply to the heater, ensuring that either a minimum temperature is maintained or maximum relative humidity is not exceeded. Rittal’s enclosure heaters are now available with CSA approval and can be installed on systems for export to Canada. For more information contact Rittal Ltd, Rotherham, South Yorks. Tel: 01709 704000 E-mail: information@rittal.co.uk Web: www.rittal.co.uk

Partial doors for Rittal TS and Ri4Power Systems Suitable for 400, 600 and 800 mm wide TS enclosures Rittal’s new modular partial door can be used instead of a door or rear panel. Flexible for use with Rittal’s TS 8 and Ri4Power systems, the new partial door enables a wider choice of handles plus for Rittal’s Ri4Power, a new optional viewing window as standard. Optionally hinged on the left or right, the partial door is attached to the TS enclosure without drilling. To finish off the modular design in each case, a trim panel is required at the top and bottom. The cross member required for mounting is included with the partial door. The front trim panels may be removed from the outside by unscrewing. Accessories, such as monitor frame, lock inserts (standard double-bit lock insert may be exchanged for lock inserts), comfort handles and perforated mounting strips for retrospective external mounting are available. Perforated mounting strips with a 25 mm pitch pattern of holes may be used for individual mounting of cable ducts, hose holders etc. on the rear side of the door. For more information contact Rittal Limited, Rotherham, South Yorks. Tel: 01709 704000 E-mail: information@rittal.co.uk Web: www.rittal.co.uk

CALIBRATION

NEW GUIDANCE ON IMPROVING EFFICIENCY WITH TEMPERATURE CONTROLLER CALIBRATION A new white paper released by West Control Solutions provides valuable and practical guidance on using temperature controller calibration to improve process efficiency. This latest paper from the global specialist in process and temperature control explains the basics of input calibration and sets out some of the benefits that can be achieved. Calibration features on temperature and process controllers are often underutilised. However, if used correctly, controller calibration can achieve significant improvements in system efficiency and product quality in a range of industrial applications. The right calibration can ensure that legislative requirements are met as well as providing additional benefits, such as reducing waste and driving higher throughput on the production process by optimising the whole control system. The paper provides a useful guide for those that have not used input calibration before and reveals the deeper level of benefit that it can bring to the system for more experienced users. To download the full white paper visit: http://www.west-cs.com/lp/whitepaper-improving-efficiency-withcontroller-calibration/ For more information please contact: West Control Solutions, Brighton, East Sussex Tel: +44 (0) 1273 810116 Fax: 01273 609990 E-mail: chloe.garrett-dyke@west-cs.com Web: www.West-CS.co.uk

PROCESS INDUSTRY INFORMER January-February 2014

The right chemistry The importance of managing chemicals safely within the workplace is a major challenge to both employees and engineering companies. Providing the right equipment – such as sorbents, pads, rolls and Personal Protection Equipment appropriate to the application – will minimise the danger and damage caused by chemical spills in the workplace, thus preventing many potentially dangerous situations from escalating, says Paul Skade, ERIKS. specification can have the opposite effect, especially if these items must be worn simultaneously but are incompatible. After ensuring that the right PPE is worn, identify the source of the spill and use minibooms to surround and contain the spill to prevent further spreading or leakage into the drains. If the area of the spill is small enough for you to deal with, you need to use the appropriate types of sorbents to adsorb the liquids and make the area safe and clean once more. For smaller spills, the most important thing is to clear it up as quickly and effectively as possible, to leave a clean and spill-free area. Absorbent granules have been commonly used to manage chemical spills but these can leave as much mess as they remove, as well as posing potential dangers to the health of employees and equipment from dust and silicates. The cleaner and more effective are Melt Blown Polypropylene (MBPP) Sorbents such as ERIKS RX. ERIKS article JF 2014These sorbents are able to adsorb up to 25x its own weight, compared with granules’ adsorbent capability of just 0.5 to 1x their own weight, MBPP adsorbs faster than granules, as well as being easier to clean up afterwards. They can also be used as a preventative - placed under a joint that’s being undone, for example - rather than just reactively once a spill has happened. In addition, chemical pads and rolls, with a spunbound layer on one side, are ideal for use where a spill creates a slip hazard as in a walkway. Perforated pads are now available to minimise waste, while static-resistant products offer greater safety when handling flammable liquids. Increased demand for chemicals in the production of products spanning all industries places even greater demands on business to establish safe and efficient practices that govern their use. This must be achieved while working to comply with stringent standards and codes designed to protect people and the environment. Take, for example, the storage of chemicals and oils. This is governed by the Pollution Prevention Guidelines: Safe Storage of Drums and Intermediate Bulk Containers (IBCs): PPG 26. The main points of the legislation concern inspection of primary containers for leaks, rust and damage; provision of secondary containment; inspection of secondary containment; and repair or replacement of secondary containment if damaged. Legislation such as this is vital in minimising risk for employees but however closely companies adhere to the guidelines, accidents will happen. The result may be something as minor as a slip on an oily floor, or as major as an injury or health risk from contact with hazardous materials, to wider contamination of a large area or a watercourse. The results can be dramatic; at the beginning of 2014, about 300,000 people in the US state of West Virginia were warned not to drink tap water after a chemical spill into a river near the state capital. Schools and businesses were closed in nine counties after a foaming agent used in the coal preparation process leaked from a tank. Officials were unclear how dangerous the spill was but such was the risk that Governor Earl Ray Tomblin told people affected by the spill not to drink, bathe or cook with the water. On such a large scale the outcome of a chemical spill can be extremely hazardous to health and damaging to profits but, whatever the size and scale of the leak, the incident must be dealt with quickly and methodically to avoid a spread that may lead to further problems. In the event of a spill, best practice is to follow a series of steps to control the situation. First, identify the type of liquid that has been spilled. Second, if the spill is too large to handle, notify all relevant parties (fire brigade, safety manager, environmental officer, etc). Thirdly, make sure that correct PPE (Personal Protective Equipment) is worn. Using PPE is vital when dealing with chemical spills. Despite the plethora of legislation that is now prevalent in western economies not a day goes by without a preventable tragedy at the workplace. Quite aside from the dreadful effects that these preventable losses have on the families (and even communities) in question, there are also serious financial and reputational aspects that are often overlooked by companies.

Be safe – be covered… Since many engineering operations function in the presence of some particularly aggressive elements – not only chemicals but also molten metals, high pressure fluids, dust, gas – PPE therefore covers a wide range of product areas, from the more complex (for example, breathing apparatus) to the more common, such as eye, foot and hand protection. Here, even a better specification of an item as simple as a glove can enhance safety; for example, gloves must be flexible enough to allow the engineer to manipulate tools with dexterity while still offering adequate protection against hazardous substances. Similarly, goggles, ear defenders and respiratory protection can improve an engineer’s ability to concentrate and work effectively, while a poor

Clean-up and take account... Once the spill has been dealt with, you then need to ‘clean up’ your clean-up operation. Dispose of the spill as contaminated waste, in appropriately labelled bags, and remember to replenish kit with absorbent materials and other safety equipment for the next incident. When the dust has settled, make time to review procedures and contingency plans based on the recent incident. A review should be scheduled before a further incident occurs and if there are any suspicions that the equipment provided to deal with the chemical spill was inadequate then it is important to review the specification and establish that any replacement is capable of meeting application conditions. It is safer to establish proactive, rather than reactive, maintenance to support safety as well as efficiency and it is crucial that operators make regular checks in all applications. Providing the right equipment will minimise the damage caused by chemical spills in the workplace, thus preventing many potentially dangerous situations from arising. Ignoring the issues and failing to train staff in emergency procedure is swiftly punished by downtime costs and the far greater human cost of injury. When chemical fluid leaks onto the ground, the result is not only a potentially costly clean-up operation but also a fire hazard, risking the lives of workers and, depending on the application, the public and the surrounding environment. The importance of integrating chemicals safely within the engineering workplace online more quickly is a major challenge to both plant owners and engineering companies. This is where working with a specialised supplier with in-depth application knowledge can pay dividends. By ensuring that equipment for handling and dealing with chemical spills is correctly specified, operators can provide safe and reliable conditions for everyone concerned. And by maintaining good training practices to support best practice, including appropriate training to raise awareness of safety risks and establishing a set of simple rules to follow when a spill occurs, uptime and productivity can be maximised. ERIKS UK, Halesowen, West Midlands Can be contacted on: Tel: 0121 508 6008 Fax: 0121 508 6009 E-mail: tradeline@eriks.co.uk Web: www.eriks.co.uk

PROCESS INDUSTRY INFORMER January-February 2014

SOLIDS HANDLING PROCESSING

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including SHAPA News

JAN/FEB 2014

THE BIGGER PICTURE

Collective expertise Clearly no single person or even company can be expert at everything, but within the manufacture and use of solids handling equipment a vast range of expertise is needed. SHAPA offers valuable resources to enable to enable all members to widen their knowledge and experience. Within any major processing enterprise, the supplier of each element of the flow process system will be both a supplier and a receiver – or “customer”. Each supplier will need to know the characteristics, mass and volume flow of the material delivered to their part of the equipment. Similarly, they will need to pass on appropriate data about the discharge of their product to the next part of the plant. Such communication is essential. Coincidentally, many SHAPA member companies are either suppliers to or customers of each other, often within the same project.

experts from member companies as well as key figures from organisations such as HSE and standards institutions. Development of new skills for upcoming engineers is always high on the SHAPA wish list. To this end special seminars with an educational technical theme followed by an entertaining event, such as kart racing, are arranged from time to time. Continuity is important. Our industries need new blood keen to learn from “old hands” to enable clearly driven progress.

Steady evolution drives quality In many areas, development in solids handling industries is steady rather than revolutionary; step changes in control technology may be an exception. Notwithstanding the desirability of steady progress, from time to time new regulations and standards, perhaps at national level or from the EU, impose changes. Health and safety issues or moves towards the mythical “level playing field” may instigate these. SHAPA members collectively have access to all such changes, with the Association having good links with HSE and key engineering institutions. Quarterly general meetings, in addition to fostering the earlier mentioned networking opportunities, also provide forums for new knowledge and ideas. These are fed to the two main sub-committees dealing with marketing and technical issues and as appropriate become agenda items for the General Council. Thus SHAPA is able to develop and present cogent events and papers to meet new challenges head on.

Incisive technical seminars... A recent example of SHAPA’s listen and learn approach is the valuable co-operation between HSE and our Association to promote good practice in the design, installation and subsequent regular inspection and testing of local exhaust ventilation (LEV) – or dust control – equipment. A number of member companies design, manufacture and install dust control, whilst several others specify and make provision for this in their own equipment. Examples of such equipment include conveyors, vibratory feeders, sieves and many others. HSE requirements, guidance notes and principles of good LEV practice were

Communicating for success This is just one facet of the SHAPA community that leads to profitable networking between members at the regular Association general meetings. In fact, the high level of attendance at these gatherings is almost unique amongst engineering trade associations. By their own enthusiasm and efforts individual members have willingly contributed to the success of SHAPA, secure in the knowledge that this application will help their own companies as well as other members and little by little improve the quality and reliability of all projects offered to end user clients. It has been mooted that solids handling and processing was originally a “black art” – maybethis was true in the misty past. But not now. The cooperative work of technical research institutions and associations such as SHAPA, through the commitment of skilled engineers and other professionals has ensured that knowledge based progress has prevailed. Disseminating expertise So how is this nectar spread? The Association is well known for holding regular interactive seminars for members and increasingly, for other industry professionals. Speakers include

WESTINGHOUSE

the subjects of a very successful seminar held at the end of 2013 during which a number of incisive papers were presented to SHAPA members and other key players from industry. More seminars on equally important themes are, of course, being planned.

...and commercial and marketing ones too Whilst technical development reflects solid worthy progress, to underpin installations that are efficient, reliable, long lasting and cost effective, the world of marketing changes at a much faster pace. In particular, marketing is moving more and more towards the internet, with a huge presence possible at minimal cost to the savvy marketeer. Of course, whilst face to face communication and the printed word remain vital and accessible tools, marketing via the internet is becoming an essential adjunct. SHAPA has held a series of seminars to keep delegates up to date with the latest methods together with the relative merits of each. Professional speakers have offered training and valuable tips in these exciting areas. Again, this subject will recur in SHAPA seminars as new internet marketing possibilities emerge. A browse through the pages of this supplement will demonstrate the comprehensive expertise available to industry from companies who have chosen to become part of the SHAPA family.

Commitment to the future So, SHAPA may well have celebrated more than thirty years’ valuable service to our industries, but our keen members will ensure that the future is assured and therefore any company involved in the supply of solids handling equipment and services should really consider membership. Clearly, we thank those companies who have joined us over the years – today’s membership stands at over 110 companies! They have already tapped into these benefits. Vitally, however, companies and consultants involved with new projects or updating existing process plant should head first for the Product Finder on our website – just a click or two away at www.shapa.co.uk, or email to info@shapa.co.uk.

ss e c o r p r u o y d e e F

Hygienic Rotary Valves

Hygienic Diverter Valves

• Drop through and Blow through versions available • All product contact parts  Stainless Steel and  grit polish versions available • Clean in place (CIP) suitable • Explosion containment up to  bar • Standard Easy Detachable rotor, MZC rail system option available • Enlarged inlet option available • RID (Rotor Interference Detection) option available

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SOLIDS HANDLING AND PROCESSING

All product contact parts  Stainless Steel and  grit polish Tube diverters from  to  ports Clean in place (CIP) suitable plug diverter Ability to diverge or converge product Explosion shock resistant DMN UK Ltd. T +44 1249 818 400 dmn@dmnuk.com

COMPONENTS FOR BULK SOLIDS HANDLING

Last year was very much a year of consolidation and subtle change – at least for many parts of the UK economy, and indeed for many at an individual level. Trends such as “on-shoring” – or the reverse of “off-shoring” - started to emerge. Many “low cost” economies had begun to lose their pricing advantage in manufacturing. As an example, labour rates in industrial parts of China were beginning to chase those of USA. Furthermore, increasing transport costs from far flung places were allowing home grown industry to compete more robustly on the home market. An example of this “balancing” comes from the automobile industry, where net exports are now close to matching the value of imports. Now, almost everything that is manufactured or is a “processed” product, for example foodstuffs, has some materials that are supplied and used in bulk solids form, which is where SHAPA plays its part in this thankfully improving situation. Indeed, the Solids Handling & Processing Association was initially set up to help like minded companies share knowledge and increase their sales and marketing effort. For more than thirty years a wealth of knowledge and experience has been accumulating within the Association, offering technical standards and legislation data as well as sound commercial and marketing advice. Of course, all of this vital material is updated as and when new intelligence comes along.

By Gus Bishop – Solids Handling & Processing Association

www.dmn-shop.co.uk

www.dmnwestinghouse.co.uk

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SPIROFLOW SHOWCASING AT FOODEX, MARCH 24-26, NEC BIRMINGHAM, STAND Q340

Shifting millions of tons of ingredients is part and parcel of the production process for many food sectors, which is why Spiroflow Ltd will be showcasing the latest in bulk handling and conveying equipment during the FoodEx Show. Transferring food powders and granules from one area of a factory to another for packaging and distribution requires a system that is fast, easy to route, has few moving parts, empties the system of product with minimum residue and provides a dust-tight operation -– essential when dealing with potentially combustible material. Flexibility and totally secure handling is required if products have to be conveyed dust-free over long distances and complex routes within an operating plant. Spiroflow, a world-leading manufacturer of ATEX approved conveying and bulk handling systems, will be demonstrating a range of solutions for food materials where the most rigid standards in hygiene and containment need to be met and maintained. Sure to attract visitors will be a working flexible screw conveyor along with a bulk bag discharger, ideal for the totally hygienic discharging and distribution of food ingredients, including sugar, flour and spices, within a factory environment. This exceptional equipment fulfils the very highest levels of hygiene and dust control, whatever strict operating parameters are in place. The main advantage of Spiroflow’s flexible screw conveyor is its simplicity, which results in short installation times and low maintenance – the whole system can be stripped down for cleaning in minutes. It can transport powdered, granular and flaked materials with a bulk density up to 2.5kg/1 and carry material to a maximum distance of 20 metres, although

multiple units can extend to greater distances as required. All of Spiroflow’s conveying and bulk handling equipment adhere to the European Union’s ATEX Directive 1999/92/E, implemented by the Dangerous Substances and Explosive Atmosphere Regulations 2002 (DSEAR) act in the UK. Food manufacturers and processors visiting FoodEx - possibly agonising over which conveyor not only best suits their product but also meets the stringent regulatory safety requirements - need look no further than Spiroflow’s stand Q340, says the company’s Marketing Manager, Ben Ayrton. He said: “Sourcing the right conveyor can be a daunting task for the buyer, who may not be aware of the advantages of the individual systems available on the market, which is why we are delighted to be showcasing flexible and totally secure handling systems at FoodEx. It is the ideal stage for demonstrating to food professionals the proven advances Spiroflow has made in bulk bag discharging and conveying systems.” Finding the right conveyor will depend a lot on finding the right supplier. The key for food companies is to find a conveyor provider that understands your business, proves it can meet your requirements and who will give a performance guarantee – just like Spiroflow. Visitors to FoodEx at the NEC in Birmingham on March 24-26 will be able to see for themselves some of the high-quality conveying and bulk handling equipment on offer from Spiroflow on stand Q340, but if you can’t get there or would like more information on the company’s products and services visit www.spiroflow.com or call +44 (0) 1200 422525.

Size Reduction NEW Ad (114x160)_Layout 1 25/11/2013 14:17 Page 1

SIZE REDUCTION TECHNOLOGIES Hosokawa Micron offer one of the widest range of size reduction equipment and systems, capable of handling even difficult to mill and sensitive materials

• • • •

Coarse grinding, lump crushing, medium grinding Fine grinding, micronising and nano-milling Accurate repeatable particle size reduction Wet and dry milling equipment and systems

Contained Milling Systems Isolator systems delivering single or multi-cell process containment product, environment and operator protection. Uniquely designed equipment for installation in bespoke isolator systems.

Rivington Road, Whitehouse, Runcorn, Cheshire, England. WA7 3DS. Tel: +44 (0) 1928 755100 Fax: +44 (0) 1928 714325 E.mail: info@hmluk.hosokawa.com www.hosokawa.co.uk

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PROCESS TECHNOLOGIES FOR TOMORROW SM

PRECIA-MOLEN LAUNCH NEW 20TPH HOPPER SCALE WITH ATEX CERTIFICATION Weighing specialist Precia-Molen has extended its range of hopper scales to include the ABS-X00 available in capacities from 5 to 20tph. Designed to fit into factory process areas the new addition to the range comes complete with EC certification to meet the requirements of the applicable machinery standard, and includes EX certification allowing installation within ATEX areas. The new ABS-X00 range offers potential precision of +/- 0.1% and is designed for internal use, sheltered from the effects of wind with an operating temperature range from -10C to +40C. The ABS-X00 can also be used to weigh a wide range of free flowing granular products which can be adapted to individual requirements, including cereals, cake, wood pellets, waste and many derived products. Built to last, being robust and reliable the ABSX00 is manufactured using ISO components ensuring long life, with all main parts surface mounted and requiring little maintenance. The entire electronic I400 ABS range can also offer functionalities enabling the use of the new ABS-X00 hopper scale with local or remote operation by computerised or automatic control systems. The I400 ABS terminal enables up to four hopper scales to be connected to supervision software via a dedicated PC which can be installed either locally or remotely. Further more information contact Precia-Molen UK Ltd, Redditch, Worcestershire. Tel: 01527 590320 Fax: 01527 590301 E-mail: sales@preciamolen.co.uk Web: www.preciamolen.co.uk

WINKWORTH MACHINERY MAKES A MOVE... Lindor’s Owner and Managing Director, Bastiaan Soeteman, acquires a controlling shareholding in Winkworth, the UK’s largest industrial mixer manufacturer. In acquiring the shareholding from James Winkworth, grandson of the founder Frank Winkworth, the exchange ends 90 years and three generations of control and share ownership by the Winkworth family. Lindor, producer of gentle touch rotating drum blenders, and Winkworth will remain operating as two separate entities, each with their own factories and management. The two companies offer complementary product ranges, which will be beneficial and available globally throughout their respective worldwide sales and distribution channels. Grant Jamieson, who remains a shareholder and Managing Director of Winkworth, is delighted with the transaction adding “The Winkworth family has given a great legacy and opportunity to many people past and present, including me. My role now is to take the new era and opportunity to the next level with the support and vision offered by Bastiaan.” “Winkworth is a company that has a proven track record in the industry for nearly 90 years and is a great example of solid and thorough British engineering. We are very much looking forward to working together and sharing learning and insights to further develop the best process solutions for our current and future customers.” Bastiaan Soeteman For more information contact Winkworth Machinery Ltd, Reading, Berkshire. Tel: +44 (0) 118 988 3551 E-mail: info@mixer.co.uk Web: mixer.co.uk

SOLIDS HANDLING AND PROCESSING

SPARE CENTRIFUGAL SIFTER SCREENS AND FILTER BAGS Process Components Ltd (PCL) has its own in-house sewing facility where it manufactures and supplies a wide range of sifter screens for a number of centrifugal sifter machines, as well as filter bags. New investment in sewing machinery and personnel has meant that Process Components Ltd has not only increased its production capacity and capabilities, but also offers its customers an improved level of service. Benefits of working with Process Components Ltd; • Quality products produced from and OEM manufacturer • Competitive prices • Quick response to customer requirements • Process and application knowhow / expertise Nylon Screens PCL has a large and varied catalogue of screen dimensions and micron sizes that can be utilised to suit applications in many diverse industries. In addition, custom screen modifications can be requested. For example; • Sewn seam for oil based ingredients • Both ends of the screen can be ‘corded’ to allow easy mounting and fitting of the screen to the basket. • Double skin screens offer increased screen longevity in fine sieving applications. • Sifter screen aperture sizes are available from 53 – 5000 micron • FDA approved coloured nylon screens are available for efficient traceability and visible checks. Filter Sock / Bags PCL is able to produce a range of Filter Socks / Bags for Centrifugal Sifters and Mixers in a range of materials to suit a wide variety of applications. All PCL products are manufactured to customer specifications to ensure maximum filtration efficiency for each and every application requirement. Engineering Capabilities In addition to the manufacture of spare parts for Centrifugal Sifters and Mixers. PCL engineers are available to provide CAD support in order to design non-standard customer specific filters and screen templates. For more information contact Process Components, Macclesfield, Cheshire Tel: +44 (0) 1625 412000 E-mail: sales@pro-components.com Web: www.pro-components.com www.mucon.com

EFFICIENT PARTICLE CAPTURE? – THE ANSWER SHOULDN’T BE BLOWING IN THE WIND The removal of particles from gas flows can be achieved through a variety of equipment types. A major challenge for many industries when a plant is subject to expansion or re-design, is that it is often the case that the dry particle filtration system is unlikely to be adequately assessed for its capability to operate with either higher transfer rates or radically different bulk particle properties. Failure to take these factors into account can lead to an increased tendency for filter blinding or more frequent cleaning cycles. In either case the end result can cause interruption to process efficiency and hence loss of profits. The Wolfson Centre for Bulk Solids Handling Technology has developed a comprehensive suite of pilot plant scale equipment for evaluating filter performance and the effects of changes in bulk particulates on filter life. For more information The Wolfson Centre for Bulk Solids Handling Technology, Chatham Maritime, Kent. Tel: +44 (0) 20 8331 8646 E-mail: Wolfson-enquiries@gre.ac.uk Web: www.bulksolids.com

SOLIDS HANDLING AND PROCESSING

DID YOU KNOW There are approximately

50 reported dust explosions in the UK each year.

Keep reading to see more facts...

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Getting to Grips with ‘Waste’ By Richard Farnish – Mphil CEng MIMechE – Consultant Engineer – The Wolfson Centre of Bulk Solids Handling Technology

many types of materials can be diverted for use in other applications. Such applications may work directly with the reprocessing of plastics and cardboard, or take material for combustion in order to generate heat and power. A common issue to most types of scheme to extract value from waste is that the materials to be worked with are invariably defined by their particle irregularity and ‘difficulty’ in handling.

Glassware

Broken Bottles

The impact of handling problems is compounded by the low value nature of the materials being processed – any stoppage in the process operation frequently translates very rapidly into a direct impact on the profitability of the plant. For this reason there is a very strong impetus to adopt best practice when designing plant for these ‘difficult’ materials. Many types of recyclable bulk materials tend to exhibit a very strong ‘nesting’ behaviour which can result in flow stoppages caused by material forming self-supporting bridges over quite substantial distances. This is particularly an issue where such materials are being handled through bunker or silos that were originally conceived for more uniform particle types or freer flowing bulk materials. Generally, the use of convergences or reductions in cross-sectional area for bulk storage vessels or bunkers should be avoided – this will compound the inherent bridging behaviour. By virtue of the irregularity of particle shapes and sizes found in many ‘waste’ materials the packing of these particles (and subsequent load transfer when stress is applied – i.e. head of material) results in substantial gains in strength. This is partially where the pronounced ‘bridging’ characteristic originates from, which is compounded by the effect of geometry and internal construction features of the storage equipment.

Take account of the distinguishing features of the material… If the extraction system used to draw material out of storage is not capable of activating the entire cross-sectional area of the outlet (assuming at this point that no convergent sections or ledges are present) then it is highly likely that the discharge of material will be both erratic and head dependant. A common example of such a discharge arrangement would be the use of multiple screw sets, which typically utilise constant pitch and shaft diameters. The use of a design (as described) will result in an active draw down of material only at the far end of the screw set – which will drag material underneath material ahead of the flow channel. This will lead to extended storage time (indefinitely, if the bunker is never totally emptied) and give rise to the potential for bio activity or selfheating – depending upon the nature of the material being handled. Some installations of screw sets will attempt to introduce additional draw down capacity along the length of the screw through either an increase in pitch spacing or a reduction in shaft diameter.

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The use of a ‘shuffling’ floor has the potential to achieve a full cross-sectional activation for a bunker – but even with this approach it is important to take into account the size/shapes of the material to be extracted and also, critically, the elasticity/compressibility of the bulk. The latter bulk characteristics should be used to inform on the slat spacing and stroke length – such that the combination of the two aspects can capture and drag the bulk material beyond the point that it shears from the bed of material above and transports forwards. Failure to achieve this effect can result in very poor extraction rates and some rather large ‘nests’ of material! In summary, this article can only hope to highlight a few issues to consider in troubleshooting or designing plant. The key to success lies in taking the time to fully understand the bulk characteristics of the material being handled and to translate this knowledge into practical design options. The Wolfson Centre for Bulk Solids Handling Technology, University of Greenwich, Central Avenue, Chatham, Kent Can be contacted on: Tel: +44 (0) 208 331 8646 E-mail: r.j.farnish@gre.ac.uk Web: www. bulksolids.com

Broken Steel

of what actually constitutes ‘waste’ – with the effect that

Varying Shapes

conserve land fill resources has driven a broad reassessment

Recycled Materials

in a consumer orientated society. Increasingly the need to

Although, in principle, such designs have the potential to provide an increase in transport capacity along their length, the inclusion of these design details must take into account the bulk characteristics of the material to be extracted. If the pitch spacing is too close relative to the size/length of the particles to be handled ‘logging’ of the screw may occur which will result in a lack of capacity at that point in the screw (potentially supporting a static region above). If the change in shaft diameter does not fully take into account the gain in capacity achieved through the change in pitch spacing, then extra capacity may be too great too early in the screw volume progression – resulting in poor draw down or high contact stress/wear on the face of the flights.

Pet Bottle Flake

The reference to ‘waste’ is, as many are aware, a relative term

SOLIDS HANDLING AND PROCESSING

BESPOKE PADDLE BLADE MIXERS FROM JR BOONE PERFECT FOR CLAN CERAMICS John R Boone have developed a bespoke mixer solution for investment casting specialists Clan Ceramics for their global ceramic core process and material supply business, including high-temperature, multi-stage mixing with vacuum processing. In such a technical arena, the choice of machinery is critical. Clan needed a partner with whom they could work, and whom they could trust to supply equipment to fit their production lines globally. JR Boone produced a horizontal paddle blade mixer (HPBM) for Clan. The mixing process is complex, forming a paste at high temperature (140ºC) over a number of stages, finally de aerating and discharging under vacuum to make sure that a homogenous, bubble-free ceramic material is produced for the casting process. JR Boone produced a variation on their standard HPBM, incorporating an insulated jacket, heating system and a vacuum pump for the final part of the process. John Morris, Clan’s Technical Director, said: ‘The amount of testing we were able to do with JR Boone helped tremendously. We have been able to reduce mixing time by 25%, for example. We also found that the profile of the Boone paddles means that, despite the very abrasive materials we use, they wear far less than other mixers we have tried; improving product quality and ultimately reducing cost.’ The Control System was designed specifically for Clan, with temperature, speed and time all being selectable and monitored parameters within the easily operated menu system on the HMI. Boone mixers are specified to third party manufacturers, so JR Boone have manufactured them to be as far as possible ‘plug and play’, easily installed and operated so that operators worldwide can produce the very high quality ceramic cores that have rightly built Clan Ceramics’ reputation. For more information contact John R. Boone Limited, Congleton, Cheshire. Tel: 01260 272894 Fax: 01260 281128 E-mail:sales@jrboone.com Web: www.jrboone.com

VRIECO NAUTA DRYER DELIVERS MULTI PURPOSE PROCESSING FLEXIBILITY IN ONE MACHINE Now developed to be more than just a dryer, the Vrieco Nauta Vacuum Dryer, available from Hosokawa Micron Ltd is capable of performing a range of processes including filtration, high temperature and vacuum sterilisation, steam stripping, chemical and crystallisation reactions and vacuum drying – all in one machine. This additional flexibility can be further enhanced to include mechanical dewatering, prior to drying with the installation of a filter directly on top of the dryer or even inside the vessel. Developments of this well respected piece of equipment offers maximum flexibility with minimum operator intervention. Using smart process engineering methods the original multi-purpose sequences have been rearranged to deliver a 50% reduction in processing times which also delivers potential energy savings too. Process time is reduced by mechanical watering, prior to drying then by heating the extracted water which is then recirculated back to the dryer, reducing the process heating time. Alternatively the heated water is available to other processes. Crystallisation can also be carried out in the vacuum dryer where the reactants can be first dissolved and reacted. The efficient mixing within the dryer accelerates dissolution and temperature control. Cooling of the liquid then initiates the crystallisation process. The crystals formed can be dried under vacuum, all in one machine. Chemical reactions including those where solids react with gases or liquids can be handled very effectively with the high efficiency of the mixer ensuring an homogenous result in product conversion, while the reaction energy is efficiently removed or supplied by the efficient heat transfer within the dryer unit. For more information please contact: Hosokawa Micron Ltd, Runcorn, Cheshire. Tel: (01928) 755100 Fax: (01928) 714325 E-mail: info@hmluk.hosokawa.com Web:www.hosokawa.co.uk

SOLIDS HANDLING AND PROCESSING

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DID YOU KNOW

Which ONE company prevented approximately

potential dust explosions in the UK last year.

Keep reading to the answer...

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Keep up with ATEX and stop dust fires Most of us are aware that devastating explosions and fires can be caused by explosive gases and vapours but are perhaps not so aware that fires caused by dust can be equally as destructive. This has now been addressed by the recently defined ATEX zone 20 to 22 dust conditions. To avoid liability, companies are advised to use suppliers and repairers who correctly certify machines to comply with the new legislation, says ERIKS. The trend for many years now has been to tighten up Health & Safety in the workplace. Engineering companies have a responsibility to their employees, and engineers themselves have a responsibility for their own safety and those around them. Statistics at a recent H&S course illustrated the point that over 90% of all industrial accidents are attributed to complacency. At H&S courses, attendees are encouraged to think about what they would miss most if they lost their sight or the ability to walk, even temporarily, and suddenly the wearing of safety glasses

doesn’t seem such a chore. Understanding and appreciating the risks to workers and establishing the most effective and efficient practices by which to minimise them can be a complex task but one that looks set to become more urgent than ever. A new Health and Safety Executive (HSE) cost recovery scheme for inspections and interventions is now in force under the Health and Safety (Fees) Regulations 2012. These Regulations put a duty on HSE to recover its costs for carrying out its regulatory functions from those found to be in material breach of health and safety law. A material breach is defined by the HSE as a contravention of health and safety law that is serious enough to require them to notify the person in material breach of that opinion in writing. When it comes to machine safety, legislation is particularly thorough and far reaching. Since moving machinery is capable of causing fire in hazardous environments, designers and engineers have invested a lot of time and energy in trying to minimise the problem. The fact that so much is at stake as a consequence of failure has driven the development of a range of tools and practices to defend the workforce from such hazards and their consequences, and routine maintenance procedures have enabled engineers to minimise the development of faults. Indeed, components themselves are continually being refined and upgraded to prevent, or offer greater resistance to, hazardous environments. To achieve a consistent and efficient management of plant safety, an awareness of ATEX-approved components is vital and, in many process and manufacturing applications, plays a major part in enabling operators and maintenance engineers to ensure that plant is observing all current legislation. Compliance with ATEX has always been a challenging, step-by-step process. Even in traditional ATEX industries, such as petrochemical processing facilities, there have been some challenges that have proved particularly hard to surmount, such as providing sensors that can perform reliably in the presence of the high pressures found within applications such as wellhead automation, gas distribution and gas compressors. In these applications, safety is critical and component failure could result in a serious accident. These hazardous conditions present complications to engineers, not only in ensuring safety but also in carrying out installation and replacement of components, which can be extremely difficult. However, solutions have been developed and engineers in these applications are now well used to conformity. Now maintenance operatives in a much wider section of industry need to make sure that repairs and maintenance meet the latest ATEX dust regulations.

Newly defined regulations determine the need to select suppliers more carefully… The recently defined ATEX zone 20 to 22 dust conditions present a new challenge and companies are advised to use suppliers and repairers who correctly certify machines, if they are to avoid liability. Most of us are aware that devastating explosions and fires can be caused by explosive gases and vapours but are perhaps not so aware that fires caused by dust can be equally as destructive, and this is reflected by the new legislation. The regulations have

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been influenced by the fact that there have been several large explosions investigated in recent years, in areas such as crop storage, food processing, coal processing and plastics that have been attributed to dust, either atmospheric or settled. So, with both these dust conditions covered by the regulations, and with the dangerous substances and explosive atmospheres regulations (DSEAR) 2002 also requiring employers to control the risks from fire and explosions, it is time for engineers to be sure that they understand what constitutes a risk to safety and consider carefully how to address it. Key to achieving conformity is to consult a leading supplier with expertise in a wide range of parts and components such as motors, belt drives and couplings – all of which are included in the regulations. Any party with responsibility for certification of supplied equipment, including product manufacturers, can be held legally responsible for accidents due to non-conformity with the new directives. The newly defined zones will affect many new operations, so if you are in any doubt about your responsibilities, conformity or the best way to achieve it, you should talk to a supplier who understands your industry, the legislation, and the machinery to which it applies. ATEX compliance – indeed, plant safety at large – has thankfully become an established part of the business processes for most industrial and manufacturing companies. It has moved beyond a simple assessment of risk to comply with and exceed the requirements of legislation and the welcome growth of this more responsible culture will make it easier for most firms to adjust. Indeed, the more enlightened companies are already recognising that by getting in line with legislation as early as possible, they can both comply with legislation and improve their productivity and profitability, while also presenting an impressive set of credentials to their customers.

Don’t take chances… Understanding and appreciating the risks to workers and establishing the most effective and efficient practices by which to minimise them can be a complex task. So, it may be advisable to work with a partner such as ERIKS that can help you to cost-effectively and efficiently review and renew your plant to comply with the regulations. Take, for example, the requirements for motors that operate in hazardous areas. The ATEX labelling scheme provides a vital indication of the level of protection offered and the zones in which the motor is suitable for use but the judgement as to whether a repaired motor remains ATEX-compliant is more complex and may require help from a specialist. To maintain safety, operators must be sure that a repaired motor is as safe as a new one, so it is important to enlist the help of a partner that offers an accredited repair service. The recently defined ATEX zone 20 to 22 dust conditions present a new challenge but also an opportunity to maximise safety and minimise plant shutdown, which will benefit people as well as profitability. ERIKS UK, Halesowen, West Midlands Can be contacted on: Tel: 0121 508 6000 Fax: 0121 508 6255 E-mail: marketing@eriks.co.uk Web: www.eriks.co.uk

SOLIDS HANDLING AND PROCESSING

LATEST DEVELOPMENTS IN CONCRETE MIXING TECHNOLOGY Mixer manufacturer EIRICH are well known in many sectors of the concrete industry such as roof tiles and block paving. Their high shear intensive pan mixers have become synonymous with high quality end products. Since their originally invented rotating pan mixer design of the 1920’s, EIRICH have continuously developed their products according to customer demand. At the UK Concrete Show (2728th Feb 2014 – NEC, Birmingham) EIRICH and Orthos Engineering, their UK partner of almost 60 years, will exhibit examples of the latest developments in concrete mixing technology, designed to achieve mix quality superior than other styles of mixer. During the show’s seminar program, Dirk Heuer from EIRICH will make a presentation on Mixing Technology for high grade concrete. EIRICH and Orthos are on stand A13. Read more at www.eirichmixers.co.uk or contact Orthos Engineering Ltd, Market Harborough, Leics. Tel: 01858 464246 Fax: 01858 434480 E-mail: sales@orthos.uk.com Web: www.orthos.uk.com

Which statistic would you prefer to be part of for

2014?

In 2013 Fike EPACO® systems prevented 21 potential dust explosions from occurring in UK factories alone. In the UK the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) require employers to control the risks to safety from fire and explosions.

Fike offers: ■ Conventional & Flameless explosion vents ■ Full range of passive isolation devices ■ Active explosion isolation & suppression systems ■ Full-scale explosibility testing facilities

SOLIDS HANDLING AND PROCESSING

Fike UK, 35 Earl Street, Maidstone, Kent, ME14 1PF, United Kingdom T: +44 (0) 1622 677081 E: info@fike.co.uk www.fike.co.uk

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Chain Conveyors are an essential part of many bulk handling systems, where they are used to convey bulk materials such as powders, grains, flakes, pellets … etc. Many of these conveyors use drop forged chains with flights as a means of conveying the material being handled. This “en-masse” conveying system is very popular as it is a simple but highly efficient system of moving material. When it comes to purchasing a chain conveyor, it is easy to look just at the one-time purchasing cost and the quality of the components. The problem with conveyors is that they are exposed to a lot of wear and tear, and even the best chains can fail after a certain period of time. But this can be many years depending on the conveyor use and maintenance. If we look at the lifetime cost of an en-masse chain conveyor, we’ll find that a big part of this is the maintenance: the cost of replacement chains and links, the cost of the labour and finally the cost of the downtime. For each and every user of chain conveyors, it is of vital importance to have the conveyor running to full capacity for as long as the equipment can allow it. Maintenance and repair can cost a lot of money and time, usually requiring the services of a team of engineers and considerable amount of resources. So how does the en-masse conveying system work, and where does the chain failure occur?

The True Cost of En-Masse Chain Conveyors By Cedric Tchatchouang, Sales Engineer at 4B Braime Elevator Components In the case of a minor incident, such as the flights breaking, although the chain does not require to be changed, it is still necessary to order new chain links with flights welded or grind the sides of the failing links and weld new flights onsite. In both cases, a lot of resources and time are needed to complete the maintenance procedure. Having new links with flights welded is only the first step of the maintenance process: the chain needs to be slackened, the circlips must be broken in order to take out the links where the flights have failed, new links with welded flights need to be put in, and finally the chain has to be tensioned again before the conveyor is at last operational or the whole chain removed from the conveyor. One of the other major causes for concern with this traditional assembly is the fact that the circlips can sometimes come loose due to poor installation, not only causing the chain to collapse therefore again stopping the conveyor, but also contaminating the product that was being conveyed and risking pollution and obstructions in the plant process. Engineers have been working hard at suppressing and minimising the different problems encountered within a chain conveyor as much as possible with solutions such as more frequent maintenance checks, metal detectors… etc. - Whilst this has helped to reduce the number of unexpected break-downs, it hasn’t removed the need for conveyor shut downs when the chains or flights need to be replaced.

In En-Masse conveying, the flight height can be as low as 12.5% of the material being transported in the chain conveyor. The material is fed into the conveyor from the top and falls through the moving chain to the bottom of the box. Because the particles interlock, the material moves as a single stream at the same speed as the chain. This highly efficient conveying process allows nearly the entire conveyor cross section to move as bulk. Traditionally, the flights are made of steel and welded onto the links. The links with flights are then assembled in many different arrangements using pins and circlips, headed pins and circlips or headed pins with collars and a roll pins. The whole assembly is very robust and works well until general wear, operational errors, material build up and many other reasons can cause maintenance shut down.

A new system represents a solution to this problem: it is a new flight assembly system that gets rid of the need for welded flights and pins and circlips assemblies which are quite costly and time consuming in terms of manufacturing. The system minimises conveyor maintenance downtimes and overcomes a lot of the problems encountered when using drag chain conveyors. The system includes:  A set of Nylon flights that can be cut to accurate lengths depending on the desired overall width. These nylon flights are very strong and wear resistant but remain lightweight, therefore reducing the amount of power required to drive the chain.

no longer required to take the tension out of the chain and take the chain out of the conveyor before changing the flights; the old flights can be taken out and new ones fitted while the chain is still tensioned inside the conveyor. Since a shorter amount of time is required to assemble the Nylon flights rather than welding steel flights onto links, all the flights can be delivered very quickly thus eliminating the need to stock a lot of spare parts; or they can be kept in stock on site at low cost, since they are not welded to the chain. It will also enable the full use of the links since it is not necessary to change the links every time new flights are needed. Once again this represents a major saving for facilities using this system. This system has been used successfully in many facilities across the world, in a wide range of applications including agricultural, wood chips, sugar, animal feeds, etc. All these products have been used in conveyors of various length, angles and high capacity applications.

 A hollow pin made of alloy steel (the same material as the link) and case hardened to C57 - C62. This pin will take the load in the assembly. It is very strong and can be supplied in stainless steel for applications in a corrosive environment.  Bolts, nuts and washers are used to hold the flights onto the link and assemble the links together. Lock nuts are used to secure the whole system.  At no point does the bolt take the load or is in contact with the pin. It merely holds and secures the flights.  The system uses 4B drop forged chain links that have special lugs on the sides onto which the flights are fastened, giving the assembly extra stability. The system is extremely easy to install, yet very robust and has a long lifespan It will save a precious amount of time and money when conducting maintenance work. With this system, it is

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4B Braime Elevator Components Leeds, West Yorkshire. Can be contacted on: Tel: +44 (0) 113 246 1800 E-mail: 4b-uk@go4b.com Web: www.go4b.com

SOLIDS HANDLING AND PROCESSING

AMBROSIA DESSERTS KEEP FLOWING For Premier Foods it was no longer feasible to maintain the existing ingredient vacuum transfer system due to its age and excessive down time compromising critical production line performance. Piab’s involvement consisted of completing vacuum conveying trials of the six ingredients at our East Leake facility, witnessed by Premier Foods to vacuum transfer these product ingredients from 1 tonne FIBC bags. The decision was made to replace the existing complete mechanical pump powered system with a more efficient Piab Premium Conveyor which provided Premier Foods with the following benefits:

• 10-25% transfer rate performance gain • 50% reduction of maintenance downtime • 14-36% reduced energy consumption • A simple maintenance regime For more information contact PIAB Ltd, East Leake, Nottinghamshire Tel: 01509 857010 E-mail: info-uk@piab.com or visit our website www.piab.com

SOLIDS HANDLING AND PROCESSING

The Serious Pipe* *No side splitting comedy guaranteed High-volume manufacture means high-quality pipework that’s reliable, flexible and easy-to-maintain but costs less than custom-built sheetmetal ductwork.

Jacob (UK) Ltd T: +44 (0) 1694 722841 E: sales@jacob-uk.com W: Jacob-uk.com

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The UK’s largest manufacturer of aluminium silos • 30 years supplying the food and plastics industries • Fully ATEX compliant • Aluminium or stainless steel silo construction • Dual tower silo manufacturing facility

GLOBAL FLOORING MANUFACTURER USE RUSSELL COMPACT SIEVES® TO GUARANTEE CONSISTENT PRODUCT QUALITY A close relationship between Russell Finex and Altro helped ensure that six Russell Compact Sieves® were supplied and fitted to safeguard the quality of their final product.

Founded in 1919 Altro is a family owned manufacturer that supplies safety flooring and wall cladding solutions worldwide. Altro pioneered the world’s first safety flooring recycling system, and with sales subsidiaries across the globe, produce over 5.4 million square metres of safety flooring each year. Altro have been expanding their Hertfordshire operations for a number of years, allowing them to increase the manufacturing capacity of their flooring T: 01275 845901 production. With a new product range of safety flooring being developed a new sieving machine was required. E: sales@bartonfabs.co.uk Having worked with them previously, Russell Finex W: www.bartonfabs.co.uk provided Altro with a sieving solution to meet their exact requirements. Altro pride themselves on providing high quality, high wear flooring materials which maximize durability and life bartonFabAdvert86x124.indd 1 11/07/2013 10:46 of the flooring. Recycled glass granules are one of the materials used to increase the hardness of the flooring whilst adding to its robust safety features. In addition, the use of recycled glass conforms to Altro’s sustainability plans to remove fewer resources from the Earth. Before the glass is fed into the flooring, it is passed through a sieving system via a hopper where oversize particles are removed, leaving the fine material needed. The material of the correct particle size is then added to the product line. Having purchased two Finex Separators™ from Russell Finex 8 years previously, Altro have formed a strong relationship with Russell Finex and therefore when a new sieving solution was required it was the natural choice. After a short consultation, an onsite trial was arranged for a 600mm diameter Russell Compact Sieve® to be installed within the new processing line where staff could monitor the effectiveness and suitability of the machine. Sieving recycled glass during the trial proved very successful and it was decided that the Compact Sieve was the machine needed to meet the production demand. “It was important for us to be able to trial the sieve at our facility prior to purchase. It allowed us to put the machine through the toughest conditions and it needed to succeed to ensure that product quality would not be compromised,” says Richard Holt, Manufacturing Shift Team Leader. The Russell Compact Sieve® is a versatile check screener ideal for high capacity screening of a wide range of materials. One of its key features important to Altro is the ease of dismantling the machine. “We needed a system that would allow our operators to easily dis-assemble the machine for cleaning,” explains Holt. The slim-line straight through design of the Compact Sieve enabled Altro to mount the sieve below the hopper, with material passing straight through to storage once sieved. Deblinding discs were also fitted underneath the mesh of the sieve to eliminate blocking of the sieve mesh which has also prolonged the mesh life. “Our long relationship with Russell Finex has been cemented with excellent high quality machinery and aftermarket support they provide. We would certainly recommend them to others in the industry” concludes Holt. For more information contact Russell Finex Limited, Feltham, Middlesex. Tel: +44 (0) 20 8818 2000 Fax: +44 (0) 20 8818 2060 Malvern, Worcs WR14 1JJ, UK E-mail: sales@russellfinex.com Tel: +44 (0) 1684 891371 Web: www.russellfinex.com

PULSAR GUARD 2010 PROCESS PROTECTION MONITOR

Senses changes in flowrates of bulk solids in pipes, chutes and supply lines to ensure accurate process protection of foodstuffs, cement, powder, plastic pellets or animal feeds in flight. l IP68 ingress protection l ATEX I.S. option l Non invasive l -40 to +125°C

info@pulsar-pm.com www.pulsar-pm.com

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SOLIDS HANDLING AND PROCESSING

DURABLE ROLLER CRUSHER NOW FULLY CONTROLLABLE USING PLC TECHNOLOGY FOR REMOTE MONITORING Glen Creston - ‘Leaders in Size Reduction’ have improved the design and function of their Roller Crusher. OPERATING PRINCIPLE /CONSTRUCTION The wear resistant steel crushing cams are mounted on the roller shaft in staggered positions, accurately spaced so that they pass between the crushing and stripping combs which are mounted laterally on opposite sides of the inner housing. The roller Crusher Mill is only one machine from our range of laboratory and pilot scale/light industrial equipment. From our Jaw crusher, for primary sample breakage prior to further processing, to the McCrone Mill, which will grind to analytical fineness, these machines can cope with a wide range of materials from rocks to edible grains For preparation of larger laboratory samples or for light

It can be supplied with a new control box with PLC which allows remote monitoring and control of the crusher in process applications. The largest single shaft unit is now 800mm long by 500mm wide internally and designed for crushing lump coal up to 250mm. High temperature versions are available for crushing power station ash at up to 250 degrees centigrade This rugged, slow-running mill is equipped with either a single or double roller shafts fitted with crushing cams which rotate between crushing and stripping combs. Different shaped crushing elements are available depending on material. This machine is particularly suitable for de-agglomeration of materials from sacks or silos, pre-crushing softer minerals and for granulating coarse lumpy, caked or compacted materials. Features include: • Robust construction • Minimal maintenance • Compact design allows retro-fitting into existing process lines. • Parts easily removed for maintenance/repair Suitable for: • Pigments and Resin • Food and Pharmaceutical • Coal • Waste materials and Ash • Minerals

industrial applications, Glen Creston offers a range of machines that can cope with higher throughputs whilst still producing reasonable particle sizes. Glen Creston also manufactures special machines for sample processing production needs. These machines are designed for processing anything from small samples to larger scale continuous flows for industrial applications. For more information contact Glen Creston, London. Tel: +44 (0) 208 545 9140 E-mail: enquiries@glencreston.com Web: www.glencreston.com

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Schenck Process UK, based in Doncaster, incorporate the brands and technologies of Redler and Clyde Process. For more information on how we can improve your process efficiencies contact: Schenck Process UK Limited Carolina Court, Lakeside Doncaster, South Yorkshire DN4 5RA Tel: +44 (0) 1302 321313 Fax: +44 (0) 1302 554400 enquiries@schenckprocess.co.uk www.schenckprocess.co.uk

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Oldie but By Matthew Hikade, UWT Level Controls, USA

For as long as there has been a need to store material there has been a need to know how much is being stored at any given time. Whether it is for inventory counts, loading out or in, or batching, there is always someone somewhere in a plant needing to know what is in a silo or other holding bin. Because there hasn’t always been the fancy high tech methods of measuring level in a bin we know today or even electricity for that matter yet still a need to know, this need has led to innovative methods of measuring how much material one has in a bin. From hitting the side of a bin with a hammer (or even throwing rocks up the side of a silo) while listening to the type of “bong” the hit creates to waking up extra early to see where the morning dew on the side of vessel begins or ends, there is no shortage of ways people have come up with to measure level. Probably the most tried and true method and maybe even the most common still used today is the plumb bob style or “weight and cable” method. 12 SP

There is evidence of the plumb bob being used for vertical alignment as early as ancient Egyptian times and somewhere along the way someone came up with the idea to use this concept for measuring the vertical depth of empty space in a bin and using that measurement to calculate how much material is in the vessel from the bottom up or percent full. Assuming human error is controlled, this method has proved to be incredibly reliable and repeatable, inexpensive, and easy to execute. This manual method of bin level measurement is still by far the most used today in modern plants by operators who have tied a rock to a tape measuring device and lower the apparatus into a bin while looking at how much tape has paid out when the rock hits something in the bin. The only downside is that someone has to climb to the top of a bin or silo to conduct this measurement which requires valuable resources and introduces a possible safety hazard. It is this issue that drove the development of the electromechanical plumb bob level system several decades ago. Early systems utilised several pulleys and large motors which resulted in bulky, complex machines which, without proper preventative maintenance applied, tended to fail due to a number of reasons. Failures included cables breaking or tangling, fouling of the electronics due to material being drawn up into the housing, motors burning up, and weights being caught under material as it fed into the bin. Measurements were conducted using a counting wheel which generated an electronic pulse with every turn of the wheel relating to a predetermined distance of cable fed out of the unit during the plumbing. These pulses were typically sent to a counter which interpreted each pulse as a distance and displayed the resulting value to the operator. Even with all of these initial challenges, the electromechanical plumb bob device was perceived to be an invaluable tool in the field of inventory management and as technology improved in electronics and materials, so did the plumb bob. We are now seeing fourth and fifth generation designs which employ microprocessor based electronics, simpler pulley designs, high-efficiency motors, and stronger cables (or tape in the case of a few suppliers) which address many of the issues the technology saw with its ancestors. Engineering controls which are built in to the programming of these units monitor cable and motor life and notify users if there is cable, pulley, and motor failure due to any number of reasons. Some manufacturers offer direct analogue 4…20mA outputs, relays, and digital MODBUS or Profibus communications which eliminates the need for an intermediate remote start unit (RSU) thereby eliminating significant cost. Today electromechanical plumb bob devices are the most prolific and widely used inventory measurement systems but they still hold a reputation for being less reliable and more maintenance intensive than the newer technologies such as microwave radar, ultrasonic, and laser. The following are five common arguments (we’ll be bold and refer to them as myths) against electromechanical plumb bob level devices and the industry response to those arguments.

Myth #1: Having moving parts makes the electromechanical system maintenance intensive. Yes, electromechanical devices by definition have both electrical and a mechanical components and yes, some of those parts have to move in order to function as designed. However, with advances in motor technology and with simpler pulley designs in use, the reliability and resulting life cycle of these systems has increased to match that expected for devices with no moving parts such as microwave and ultrasonic. It is not unreasonable to expect 3500 running hours with standard motors or unlimited lifetimes for systems that use high efficiency brushless motors. Users may expect at least 100,000 measurement cycles of a cable-based system or over 500,000 measurement cycles for a tape-based plumb bob device. For an operator making 24 measurements per day, that equates to an expected lifetime of 10 years for a cable or over 50 years for a tape-based system. In addition, any supplier worth considering will utilise on-board diagnostics to notify the user as to any potential failure so that it can be addressed before becoming a resource-consuming problem. A quality electromechanical unit will monitor and notify a user of motor/electronics failures, sensor weights being jammed or buried, broken cables/tapes, adequate supply current, and other functions for which the failure of each would cause downtime.

Myth #2: Electromechanical devices are not as reliable or repeatable as newer technologies such as ultrasonic or microwave radar. Aside from devices which provide weight measurements of a bin or silo, electromechanical plumb bob technology is the only inventory management system which is not adversely affected by most conditions one might see in a silo containing a solid material. The performance of

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SOLIDS HANDLING AND PROCESSING

t Definitely a Goodie ultrasonic, microwave radar, and laser all depends on how amenable the conditions are within the vessel. With each of these technologies, an instrument is projecting a wave and looking for a return signal strong enough to detect and analyse. Dust, steam, foam, high temperatures, low dielectric constant, low bulk density, and angle of repose can all seriously affect the quality and reliability of a noncontacting time-of-flight instrument. Because a plumb bob utilizes a mechanical measurement, all of the conditions just listed do not affect the action by which this instrument generates a measurement thereby improving the chances of a repeatable and reliable measurement. Because a plumb bob is a straight line measurement, each time it is activated it takes a reading from the same spot within the bin every time. There is no worrying about installation angles in order to catch the optimal surface area as would be the case with many of the non-contacting technologies. Accuracies of measurement differ depending on which manufacturer one is considering but it is reasonable to expect a measurement accuracy of 0.25% to 0.5% of measured range.

Myth #3: Electromechanical devices are not directly compatible with current control systems. Before the introduction of modern electronics, this statement held more credence. However, today most brands of electromechanical plumb bob devices will communicate directly with PLC control systems via an analogue 4…20ma signal or for some suppliers even a MODBUS RTU or Profibus digital protocol. If a supplier is still specifying an intermediate remote monitoring unit as standard in order to generate an analogue output, find another supplier.

Myth #4: The use of pulleys and cables is inefficient and makes the device prone to failure. One of the more common questions about this technology regards the perceived high rate of failure due to cables getting tangled in pulley systems. Whether it was a result of constant winding and unwinding or material getting drawn up onto the pulley system and causing interference with the cable setting correctly on the cable, this used to be a legitimate concern. Many plumb bob suppliers have recognised that less is more with pulley systems and have introduced designs which utilise two or less pulleys. One manufacturer has even introduced a single pulley design. Many designs also employ the use of a brush cleaning system or a spring-tensioned tape scraping apparatus which removes material from the cable or tape as it is retracted into the housing. Manufacturers of plumb bob units which use a tape instead of a cable claim to eliminate tangling completely because of the tape’s tendency to lie only on top of itself as it winds onto a pulley. Add to this the qualities of improved materials as previously stated and these improved features have resulted in a reduction of pulley/cable failures and have enhanced the reliability of plumb bob devices.

Writing that this is a myth is a bit of a stretch because this has been known to occur. A weight and cable is intrusive in that it does have to enter the bin in which it is measuring material; however it must be pointed out that most technologies have to intrude in some manner in order to “see” the material it is tasked with measuring. One should remember that the sensor weight and cable is not exposed to the material in the bin except only when it is in the process of taking a measurement, and then it is only touching material for an instant before it is retracted back into the housing of the instrument. A well-designed plumb bob device will seal itself during downtime so as to prevent material from blowing up into the housing. With regard to sensor weights breaking off and causing damage, this may be minimised with the advance of stronger cables and engineering controls designed to prevent conditions which could lead to this issue. Many systems now include minimum travel distances for weights in the case that the silo is empty to prevent weights from getting caught in the bottom of the bin. Many systems also have controls built in to prevent motors from continuously pulling on cables in the case that a sensor weight is buried, which itself is a rare occurrence if care is taken during the installation stage. For those prospects who still worry about sensor weights breaking off, most suppliers now offer breakable “digestible” bags which may be filled with the material which is in the bin so that if the weight does break off it will simply pass through the system. Is the electromechanical plumb bob system perfect for every application? No. Because it is only taking a measurement when asked to do so, it is not a true continuous monitoring device. If one absolutely needs a 24/7 measurement for process control, another technology may be a better choice. Also, as with any device installed at the top of a bin, plumb bob units are measuring linear level and not true volume. Volume or weight of material in a bin must be calculated using bin dimensions and bulk density which may lead to slight inaccuracies. Finally, because power is needed to drive a motor capable of moving a sensor weight and cable, plumb bob devices are not available with twowire 24VDC loop power as is the case with many of the electronic level systems. Inventory management is an important function in any plant environment. Choosing the best solution depends on application considerations, desired output, and of course, cost. When considering which level measurement solution best suits your needs, seek advice from a tank monitoring professional, and remember that sometimes an oldie is still a goodie.

Myth #5: A weight and cable device is intrusive. The weight can get caught in the material and can break off into the silo causing damage to components downstream.

SOLIDS HANDLING AND PROCESSING

UWT (UK) Limited, Dorrington, Shropshire Can be contacted on: Tel: 0845 4810463 E-mail: sales@uwtuk.com Web: uwtuk.com

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Assessing the need for dust suppression A new white paper written by Peter Guttridge, Chairman of Guttridge Ltd, and Ian Walton (CEO, DSH Systems Ltd).

Figure 1: The release of dust during bulk outloading can present a major health, safety or environmental hazard which can be addressed by using appropriate dust suppression technology. The dust cloud visible here consists of fine particles that are escaping from the bulk material flow. These may originate from the ‘as manufactured’ product, which may have a defined fines content, or may result from attrition during transit. Many grain feeds may be transported in an ‘as harvested’ state that includes significant quantities of fine dusty dirt. In each case, as the material flows, these fine particles escape from the bulk, spreading into the surrounding environment on air currents induced by the bulk flow, and any prevailing wind. The result is a dust cloud that can present difficulties for a number of reasons:

• Environmental contamination From an environmental perspective the release of dust is, most immediately, an issue of air contamination. This is an important and growing problem as the potential hazards of respirable dust are recognised, and population centres develop around facilities that may, in the past, have been some distance from a community of any size. However, fugitive dust emissions are also a potential source of watercourse degradation and their monitoring is becoming increasingly stringent for this reason too. Tackling environmental issues is becoming critical for facilities anxious to secure good community relationships and an on-going licence to operate in the face of tightening legislation.

flammable materials have explosive potential. The lowest concentration of dust in air that is capable of supporting an explosion1 (the “lower explosive limit”) varies from material to material but typically lies in the range 10 to 500 g/m3. While this figure may seem quite low, it represents a relatively dense fog of particles and so, in practice, is relatively rarely exceeded during routine loading operations.

• Operator safety Certain dusts are known to have a direct effect on health and consequently have well-defined exposure limits. Silicosis, for example, is an occupational lung disease attributed to the inhalation of crystalline silica which, as a result, carries a NIOSH recommended exposure limit of 50 µg/m3 (TWA (time weighted average) for a working day of up to 10 hours, 40 hour working week).[1] More broadly however, even non-toxic dusts may be associated with a decline in lung function [2] making it essential for bulk material handlers to install appropriate control and exposure prevention strategies.

• Damage to machinery Machinery that has to operate in a dusty environment may be prone to low reliability caused by, for example, inhibited lubrication and enhanced wear. The frequent change out of filters designed to protect equipment is also a time-consuming task in dusty environments. One way to prevent such problems, and to simultaneously improve the operating environment, is to adopt an effective clean-up policy, but this too is manually intensive, adding to the overall cost of operation.

• Loss of product Especially for a valuable product, the amount of material lost through fugitive dust emissions can be surprisingly high, and may justify expenditure in superior bulk handling equipment. Most bulk materials are relatively low cost but even with these products the annualised overall cost of losses can be significant. When it comes to tackling a potential dust control problem there are three possible strategies: prevention, isolation and/or control. Conventional technology is typically based on the second and third approaches while more modern, dust suppression systems tackle the problem at source. To read more about these alternative options and the economics driving their adoption, please refer to ‘The practicalities and economics of dust suppression.’, To access the white paper, go to www.guttridge.co.uk

• Explosion hazard:

References

The fine nature of particles present in a dust can, under certain circumstances, promote very rapid reaction/combustion, which is why dust clouds formed from

1. http://www.silicosis.com/niosh/ 2. http://www.iom-world.org/media/93355/ioms_position_on_oels.pdf

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SOLIDS HANDLING AND PROCESSING

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BARTON SUPPORTS SIX SILO SCHEME Six new aluminium and stainless steel silos have been installed by Barton Fabrications at IKO plc. The major contract awarded by the specialists in roofing waterproofing is part of a £2million+ plant investment. Capability in providing a single source of liquid and powder storage for IKO’s first silo installation, plus technical support provided during silo specification, helped Barton to secure the order. Three stainless steel and three aluminium silos have been installed at IKO’s Chesterfield site. The stainless steel silos each stand 9m tall with a capacity for 100,000 litres of liquid plasticiser. The 12 metre high aluminium silos are used for dry powders: these contain non-flammable materials in the form of PVC resin and calcium carbonate. The silos are all fitted with load cells, ladders and hand-rails for safety and ease of operation. Commenting on what impressed him about Barton’s service, Andrew McArthur Engineering Manager of IKO plc said: “Barton Fabrications were able to provide a single source of silos for both liquid and powder storage. They guided us through the specification process and liaised with our materials handling engineering company to ensure that the specification, installation and commissioning all ran smoothly. “As the site is close to residential housing, a key requirement of the plant design has been to minimise environmental impact. Barton Fabrications worked closely with us to keep the height of the silos to the level of the roofline. The construction quality of the vessels has also been impressive.” Barton Fabrications is the UK’s leading silo manufacturer for the food and plastics industries. The company regularly works closely with all the key European materials handling engineering contractors simplifying the silo specification process and ensuring trouble free installation and commissioning. For more details on Barton Fabrications’ silo solutions, contact Mark Barton:Tel: +44 (0) 1275 845901 E-mail: sales@bartonfabs.co.uk Web: www.bartonfabs.co.uk

SOLIDS HANDLING AND PROCESSING 18.10.13 12:29

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