Process Industry Informer Jan/Feb 2015 by Process Industry Informer

JAN/FEB 2015 Volume 11 No. 1

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

Spiroflow reach the heights by opening their new Technical Centre - See page 5

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

contents. 4-10 News & Events 10-14 Applications 15 Heat Transfer & Energy 19 Network & Communications 19 Test & Measurement 21 Health & Safety 21 Detection Systems 22 Process Measurement & Instrumentation 23, 24 & 33 Fluids & Liquids Handling (incl. Pumps & Valves)

34 Analysers 37 Maintenance 37 Air Compressors 37 Separation Lines For Processing Algae 37 Water Treatment 55 Product & Services Directory

The new era in Advanced Process Control

Editor Phil Black: philblack@piimag.com Publisher/Advertising Manager Peter Ullmann: peterullmann@piimag.com SALES & Marketing Manager Guy Ullmann: guyullmann@piimag.com Supplements Manager David Harling: davidharling@piimag.com Office Manager Diane Ullmann: dianeullmann@piimag.com Art Direction Talita Soncini talita@piimag.com

Human error is the weakest link for process industry

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Jan/Feb 2015

25 - 32 BPMA Supplement

39-54 SHAPA & Solids Handling Supplement Features: - Particulate Flow Rates from Vessels - Solids Level Measurement - Specifying Bulk Bag Fillers - Continuous Wet Agglomeration - Powder Storage Silos

Are you ‘foaming at the mouth’ over your process?

LOOK TO THE SEAS FOR EFFECTIVE STORM TANK

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

Feature: Centrifugal Pumps Offer Great Potential Savings

Monitoring the monitors

Manufacturers use asset optimisation to extract value

Heating & cooling systems –

the little things that count

whatsoever and however arising, whether due to inaccuracy, error, omission or any other cause, and whether on the part of the publishers of Process Industry Informer, or their servants or agents, or any other person. Although it is the intention of the publishers in general to run copy as supplied by advertisers, advertorial item headings, which are not charged for, will be selected by the Editor, and other minor changes may be made, at the Editor’s discretion, for the sake of clarity, to avoid offence, for legal reasons or to ensure conformity to house style. Copy supplied over length will be cut to the amount paid for. Units and abbreviations will be standardised in accordance with house style. No part of this publication may be reproduced or transmitted by any means without the prior written consent of the publishers.

NEWS & EVENTS BOGE ENSURES OPTIMUM QUALITY MANAGEMENT WITH ISO 9001 CERTIFICATION Compressed air specialist BOGE Compressors has once again achieved ISO 9001:2008 certification, confirming its commitment to providing the highest quality of production and service for compressed air customers. The implementation of ISO 9001:2008 is part of BOGE’s ongoing dedication to continuous improvement and consistently delivering the best possible service to meet the needs of customers. With less than 10% of businesses in the United Kingdom holding ISO 9001:2008, BOGE is at the forefront of quality service and customer care. ISO 9001:2008 is an internationally recognised quality management system standard that is implemented by leading global companies from across industry. It contains strict requirements that enable businesses of all sizes and across industry to effectively manage and control the quality of their products and services to ensure high levels of customer satisfaction. “I am delighted that BOGE has once again achieved ISO 9001:2008 accreditation, which reflects the hard work and dedication of the whole team,” said Mark Whitmore, General Manager, BOGE Compressors. “The use of such a recognised standard plays an important part in BOGE’s overall global strategy of offering the very best engineered products with reliable, non-bureaucratic, friendly customer service.”

For more information please contact BOGE Compressors Ltd, Brighouse, West Yorkshire Tel: 01484 719921 Web: www.boge.co.uk

HANSFORD SENSORS ACHIEVES GOST-TR CERTIFICATION FOR EXCELLENT QUALITY MANAGEMENT Hansford Sensors has achieved GOST-TR certification for sales within the Russian Federation. This accreditation confirms Hansford Sensors’ manufacturing process is of the greatest possible quality, ensuring the highest standard of performance from vibration monitoring solutions for customers across industry. The implementation of GOST-TR is part of Hansford Sensors’ ongoing commitment to continuous process improvement and delivering the best possible service to customers. GOST-TR is a quality management system standard in the Russian Federation that is implemented by both Russian manufacturers and foreign companies looking to import goods and products for sale. Product tests conducted by the Russian Governmental Standards Organisation (GOSSTANDARD) in accredited laboratories ensure manufactured goods are of a high standard that meets the needs and expectations of purchasing companies. Chris Hansford, Managing Director of Hansford Sensors, said: “Earning this quality certification has been a team effort and reflects the high quality solutions that we offer and will enable us to expand our service offerings to Russia to meet growing demand for our vibration monitoring solutions.”

For more information on the extensive range contact Hansford Sensors, High Wycombe, Bucks. Tel: 0845 680 1957 E-mail: sales@hansfordsensors.com or visit www.hansfordsensors.com.

MORE UK MANUFACTURING AS WEST CONTROL SOLUTIONS CENTRALISES EUROPEAN PRODUCTION OPERATIONS West Control Solutions, global specialists in advanced temperature control, has recently completed a major expansion of its UK manufacturing centre in Brighton, creating new jobs and increasing output capability by up to 25,000 units per annum. The new facilities are the completion of a project to strengthen the company’s European production operations in the UK, and form part of a long term programme of investment in continuous product and service development. Previously, West Control Solutions had operated two production centres, in the UK and Germany, with the latter being outsourced to a third party supplier. Following a fire at the supplier’s factory, the decision was made in December 2013 to bring the manufacturing in-house. The move would affect four production cells; manufacturing the PMA KS family of instruments and PMA Railine. West Control Solutions also decided to use the opportunity to update the manufacturing process of these products from batch processing used in Germany to adopt the ‘one-piece flow’ lean manufacturing methodology already in existence at the Brighton factory, thereby helping both to reduce inventory and improve quality control procedures.

For more information contact West Control Solutions, Brighton, East Sussex Tel: +44 (0) 1273 810116 Fax: 01273 609990 Email: chloe.garrett-dyke@west-cs.com Web: www.West-CS.co.uk

ABB APPOINTS NEW CHANNEL PARTNER FOR THE IRISH PROCESS MARKET ABB UK Measurement and Analytics is delighted to announce it is partnering with Hanley Measurement and Control to offer its expanding portfolio of products into the Irish process market. Established in 1981 Hanley has built a reputation for the supply of specialist solutions and expertise in process instrumentation, process analytical technology and gas detection. The company will be the official sales agent for ABB’s complete portfolio of instrumentation and analyser products for applications in the pharmaceutical, chemical, food and beverage and other related industries. ABB products available will include a full range of process flowmeters, devices and systems for the measurement of temperature and pressure, plus liquid, gas and air emissions, as well as valve actuators, positioners, recorders and controllers. The appointment of Hanley Measurement and Controls further expands ABB’s network of Instrumentation Alliance Partners in the UK and Ireland, which includes specialist suppliers of instrumentation products, services and expertise serving the water, power, process and oil and gas markets.

For more information about ABB’s Instrumentation Alliance Partners, E-mail moreinstrumentation@gb.abb.com or call 0870 600 6122.

PROCESS INDUSTRY INFORMER January - February 2015

NEWS & EVENTS NEW TECHNOLOGY CENTRE BRINGS SUPERIOR TESTING TO SPIROFLOW UK based Spiroflow Ltd, leading manufacturer of conveying and weighing systems for companies across the world, has celebrated the latest exciting stage of its expansion strategy with a launch event to mark the opening of its new state of the art Technology Centre. The Centre, which was officially opened by Cllr Michael Ranson, Mayor of Ribble Valley, houses a spacious machine demonstration area for the company’s conveying, weighing, bulk bag filling and discharge equipment, plus a unique powder characterisation and testing laboratory. The primary purpose of the Centre – as well as showcasing Spiroflow’s market-leading machinery – is to facilitate powder characterisation testing on sophisticated laboratory equipment, providing a fundamental insight into powder flow properties and helping to anticipate and thus prevent handling issues. The launch event was attended by customers, partners, local companies and trade associations, who were treated to tours of the Centre and an insight into Spiroflow’s history, its reputation for innovation and technical excellence and its expectations regarding the new facility. The Centre will provide major benefits to customers, not least the opportunity to conduct full scale system trials and significantly reduce the risk of expensive downtime in the handling process. The Technology Centre will operate under the watchful eyes of Dr Will Weston, Spiroflow’s specialist in materials science, and engineer Terry Mason. Together they provide a wealth of experience in solving materials handling challenges across a breadth of industries, processes and scales. Dr Weston explained: “Powders and granular materials are complex entities with vastly varied handling properties, so conveying solids is a much more complex task than it is for liquids. Testing in the material characterisation lab will allow us to fully understand each material in order to design the most efficient bespoke handling solution. The lab will also be invaluable for customers’development projects to test the feasibility of introducing a new product into their process – particularly vital if a prospective additive has the potential to be cohesive, or has a high moisture or fat content that could affect the flow of the powder in conveying pipework, weigh vessels or valves. Preventive testing can ultimately save thousands in processing downtime.” The new Centre, based in the North of England, will also free up urgently needed space at the company’s existing site on the same industrial park, facilitating an increase in machine production to meet growing demand from international customers which currently account for around 50% of total sales. The expansion is also expected to result in the creation of a number of new jobs. This latest announcement comes hot on the heels of further expansion of the company’s USA operation through a new factory in North Carolina serving the North and South American and Far East markets. Spiroflow’s Chairman Michel Podevyn said: “Spiroflow already has a well-deserved reputation for technical excellence and commitment to customer satisfaction, supported by our rigorous testing programme that weeds out potential handling problems at a very early stage. Demand for our conveying and discharging systems is continually increasing in both domestic and global markets and we’re delighted about the combination of experience, scientific expertise and testing facilities that makes our new Technology Centre unique in the sector and enables us to meet this growing demand with renewed vigour and confidence.” Among those invited to the opening was Process Industry Informer’s publisher Peter Ullmann who was most impressed with the spacious build of the new facility, the variety of customer services available that go beyond the norm, and the pride and enthusiasm that Michel & Cathy Podevyn, together with the whole Spiroflow ‘team’ have for the benefits that they are now able to offer their customers - it will surely serve them well over the coming years. Spiroflow designs powder handling systems, including specialised conveyors and bulk bag handling equipment for the food, chemical, minerals and other process industries. Spiroflow also manufactures bin activators, Aero Mechanical Conveyors, Tubular Cable and Chain Drag Conveyors, Vacuum Conveyors, Bulk Bag Fillers, Ingredients Handling and Weighing Systems. The company’s technical and engineering expertise has led to it developing an international reputation for an unrivalled range of products with state-of-the-art control systems.

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

FEG LTD PROVIDES CE MARKING FOR STRUCTURAL METAL COMPONENTS

ABB TO HELP TRAIN AZERBAIJAN’S NEW OIL AND GAS ENGINEERS

Due to new CE Marking legislation, from July 1st 2014, manufactured structural metal components or kits used in civil engineering for manufacturing and process plants must now comply with CE Marking requirements. With this problem in focus FEG Ltd are expanding their CE Marking services to include structural metal components. FEG already provide CE Marking for individual machines and assemblies of machines as found in production lines. This new legislation now requires companies building new facilities or refurbishing existing production facilities to take into consideration this new legal requirement for CE Marking. As part of FEG’s ‘we solve problems’ service, during a CE Marking project they consider the Basic Requirements for Construction work including. FEG’s skilled engineers will undertake CE Marking for existing or new plant, machinery and structures and assist companies with these essential matters that would normally involve the use of already stretched in-house resources.

ABB UK has signed an MoU with Baku Higher Oil School (BHOS) to develop training for oil and gas personnel in Azerbaijan. The Memorandum of Understanding (MoU) sets out the first steps of a longterm collaborative partnership that aims to give the university access to technology and engineering expertise. The office in Azerbaijan is supported by ABB’s UK operation. ABB’s involvement in the deal is aimed at raising the awareness among local graduates of the benefits of a career in oil and gas control and instrumentation engineering. Azerbaijan needs to increase its base of skilled engineers if it is to grow its engineering sector. The collaboration between ABB and the BHOS supports education by giving tomorrow’s engineers’ exposure to real, cutting-edge technology. Rustam Gasimov, ABB’s General Manager, Azerbaijan said, “ABB’s involvement in the project signals the company’s commitment to shaping the next generation of industrial engineers.”

For more information contact FEG Ltd, Team Valley, Gateshead Tel: 0191 4046830 Email: info@feg-global.com Web: www.feg-global.com

PROCESS INDUSTRY INFORMER January - February 2015

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

NEWS & EVENTS New e-Learning course “Vortex Flowmeters: Applications” released *Free of charge eLearning course on the most common uses of Vortex flowmeters in auxiliary and supply circuits *Learning module and test on basic applications with steam, compressed air and natural gas *Latest course adds to a growing number of courses on process instrumentation already on offer at the KROHNE Academy online Wellingborough, December 17, 2014: A new course on “Vortex Flowmeters: Applications” has been released on the KROHNE Academy online learning platform http://academy-online.krohne.com. The free of charge eLearning course deals with the most common uses of Vortex flowmeters in auxiliary and supply circuits. It covers the requirements for applications that involve steam, compressed air as well as natural gas, and how to solve them with Vortex flowmeters. The following sample applications are discussed in detail: • Steam boiler monitoring • Measurement of steam consumption • Steam distribution and billing • Gross/net heat measurement • Compressed air measurement • Gas burner measurement The course consists of one learning module with a corresponding test allowing participants to assess their knowledge. The course has been made available in English and German to date, however other language versions (e.g. Russian, Chinese) are planned to be released in 2015. This latest course adds to a whole range of courses on process instrumentation already available on the KROHNE Academy online. About KROHNE Academy online: KROHNE Academy online is an online eLearning training tool, focusing on various elements within the area of industrial process instrumentation. It consists of electronic learning content with full audio. KROHNE does not advertise any of its own measuring devices, but describes and explains measuring technology in an industry comprehensive way that is not related to specific manufacturers. Registration is free and easy by visiting: http://academy-online.krohne.com

For more information contact KROHNE LIMITED, Wellingborough, Northants. Tel: +44 (0) 114 243 1332 E-mail: t.mchugh@krohne.com Web: www.krohne.co.uk

DO PLe APPLICATIONS NEED TWO INTERLOCKS? Rob Lewis, Managing Director of Fortress Interlocks, looks at interlock redundancy There is a lot of interest in whether redundancy is required when it comes to interlock actuators. This debate has been going on for many years but really gained momentum in 2012 by the inclusion of a note in table D8 in 13849-2-2012: ‘For PLe a fault exclusion for mechanical (e. g. the mechanical link between actuator and contact element) and electrical aspects is not allowed. In this case redundancy is necessary’ Now that EN ISO 14119 (The Interlock standard) has been published, it adds to the debate with the following two paragraphs in section 8 with relation to ‘Assessments of faults’ and ‘Fault Exclusions’: ‘There should be a proper selection of the device ensuring that the holding force (Fzh – see 5.7.4) of the guard locking device is sufficient... In this case the use of fault exclusion for breakage of the locking element does not necessarily limit the PL or SIL for the guard locking function.’ So what exactly does this all mean? Clearly there is variability in what the standards say about fault exclusions, with statements ranging from ‘not allowed’ through ‘normally not justifiable’ to ‘not necessarily limit’. However the common thread is: The possibility of actuators breaking must be considered very carefully for PLe applications. With a typical interlock this is fully understandable, as it is not uncommon for actuators to break, leaving the interlock in a fail-to-danger condition. When designing the Fortress amGard Pro heads and actuators, the objective was to create an indestructible product to meet the interlock standard. With all loadbearing components manufactured from over-dimensioned cast stainless steel, the amGard Pro actuator absorbs more than 50 times the energy of a typical actuator, and the head remains attached beyond loads of 4,000 kg. The end result is a unit with strength beyond that of the hinges, fittings and even the guarding itself. It is this overdimensioning, rigorous testing and data from 3 billion hours of in-service use which allows Fortress to recommend the amGard Pro as a PLe interlock without requiring a secondary interlock. Conclusion For PLe applications careful consideration must be given to the actuator. If a normal pressed actuator is to be used then, in all but the lightest duty applications, a secondary interlock should be used. Alternatively an interlock which incorporates an actuator and a separate non-contact sensor could be used. The Fortress amGard Pro interlock, on the other hand, having an actuator that is stronger than the rest of the guarding, provides the simplest solution to achieving a PLe rating.

For more information contact Fortress Interlocks Ltd, Wolverhampton Tel: +44 (0)1902 349000 Fax: +44 (0)1902 349090 E-mail: sales@fortressinterlocks.com Web: www.fortressinterlocks.com

APPRENTICES INVITED TO EXPERIENCE ABB’S NEW ADVANCED LEARNING CENTRE

DEGRÉMONT WATER SCIENCES LABORATORY RETAINS ISO 17025 ACCREDITATION

Every week, between January to March this year, ABB is opening the doors of its Aberdeen facility to apprentices from the UK Upstream Oil and Gas Industry Technician Training Scheme (UOGITT). Groups of up to 10 apprentices will spend time at the facility learning how a major electrical and automation provider to the industry helps to improve operational performance through advanced technologies and services. During the visit the apprentices will spend time in ABB’s advanced learning centre which supports the development of the skills required now and into the future to operate, maintain and extend the life of automation systems. The centre includes ergonomically designed interactive control room screens which aim to improve the safety and efficiency of operators by providing detailed and timely plant information. UOGITT is recognised as one of the most successful apprenticeship schemes of its kind. The trainees are managed by OPITO; the skills organization for oil and gas.

The Degrémont Water Sciences Laboratory, part of Suez Environment, has successfully retained its internationally recognised ISO/IEC 17025:2005 accreditation. It received excellent feedback from the United Kingdom Accreditation Service(UKAS) following a recent assessment, further underlining the laboratory’s position as a leading water sciences service provider. Degrémont’s Water Sciences Laboratory provides tailored services to major food and beverage manufacturers that improve efficiency and ensure environmental compliance, providing process analysis capability which encompasses the whole industrial water cycle. The Water Sciences Laboratory delivers cost effective, routine and responsive analysis, as well as specialist analysis of water and wastewater systems. ISO/IEC 17025:2005 specifies the general requirements for competently carrying out tests and calibrations. It covers testing and calibration performed using standard methods, non-standard methods, and laboratory-developed methods.“We are very pleased to have retained our accreditation, which recognises our ongoing efforts to always deliver the highest possible quality of service to our customers,” said Laura Polwart, Quality Assurance Analyst, Ondeo Industrial Solutions UKAS is the sole accreditation body recognised by the Government to assess organisations that provide certification, testing, inspection and calibration services for food & water testing laboratories against internationally recognised standards.

For more information contact ABB Ltd. Aberdeen. Tel: 01224 592 123 Fax: 01224 592 690 E-mail: Arlene.hutchinson@gb.abb.com Web: www.abb.com/service

For more information contact Ondeo Industrial Solutions, Grangemouth, Tel : 0191 491 4274 Email : Sophie.ONEILL@ondeo-is.com Web: www.degremont-industry.com

PROCESS INDUSTRY INFORMER January - February 2015

NEWS & EVENTS TOMLINSON HALL MAKES ITS MARK – AT HOME AND ABROAD Pump distributor and manufacturer Tomlinson Hall & Co Ltd has topped a highly successful two months by winning a prestigious industry award. The firm, based in Billingham, North East England, was this month named SME of the Year in the North East Process Industry Cluster (NEPIC) Annual Awards. The awards recognise outstanding achievement in the process sector, with NEPIC – Colin Simpson, business development director the first cluster in the UK to receive the of Tomlinson Hall receives the SME of the Year Gold Label for Cluster Management award and cheque for £2000 from Wayne Excellence – boasting hundreds of Baxter, managing director of award sponsors member companies from across a wide range of industries. Haden Freeman Ltd. Tomlinson Hall is an approved global distributor for major industrial pump brands, including DEPA and ELRO, and manufactures its own pump, Liquivac – an innovative liquid ring vacuum pump which can handle combinations of liquids, gases and fine solids and can perform a huge range of operations. The firm, which has operated since 1919 and is a co-founder of the Pump Distributors Association, was recognised for its outstanding performance – increasing sales by a staggering 62% (2009-13) through new product development, exporting and regional collaborations. The firm was also commended for its support of apprenticeships, local community sport projects and has donated its £2000 prize fund to Priors Mills CE Primary School in Billingham. The award, sponsored by Haden Freeman Ltd, was presented to Tomlinson Hall at a glittering ceremony at Hardwick Hall, County Durham on January 16 and the awards triumph follows the successful December 2014 launch of its recently rebranded Liquivac pump in the Middle East. Last year, Tomlinson Hall was one of three winners in a special ‘Golden Ticket’ competition offering the chance to visit Dubai and explore business opportunities. Organised by UK Trade & Investment (UKTI) in conjunction with Dubai’s Department of Tourism and Commerce Marketing (DTCM) and the Millennium Plaza Hotel Dubai, the market visit saw Tomlinson Hallpromote Liquivac to end-users and potential distributors in the UAE. Liquivac has huge potential for use in many applications in the United Arab Emirates, as its design allows the transfer of liquids and combinations of liquids, gases and fine solids, and it can operate with long suction lines, meaning the a pump can be situated a long distance away from the source of the liquid or material it is transferring. Liquivac can be applied, for instance, in desalination – which provides most of Dubai’s fresh water - and in pumping water to aquariums and water features, which are popular in Dubai’s leisure developments. The pump’s flexibility means that it is ideal for use in the Middle East’s petrochemical related industries, for instance in spill recovery, chemical processing and in pumping bilge water from tankers. Colin Simpson, business development director of Tomlinson Hall & Co Ltd, said: “It’s a huge honour to be Colin Simpson, business development director of named SME of the Year in the Tomlinson Hall & Co Ltd (fourth from left), with NEPIC Awards, and a great Fahad Al Thani, Director, Investment Support Section, achievement for the company Dubai FDI (far left) and Shahab Abdulla Shayan, and its staff. NEPIC does Head of External Affairs for Overseas Offices at the incredible work for the process Department of Tourism and Commerce Marketing industry in the North East, and (far right) with members of the UKTI market visit its members are some of the most innovative and dynamic businesses in the UK, so to be recognised in this way makes us very proud. “In addition, we are committed to flying the flag for North East manufacturing abroad and our market visit to Dubai opened up many opportunities for Tomlinson Hall in the Middle East, where there is substantial demand for Liquivac. “The market visit, awards triumph and re-launch and re-brand of Liquivac have combined to make this a highly exciting time for the company, and we look forward to what the future holds.” Tomlinson Hall has won the UK Pump Distributor of the Year Award four times at British Pump Industry Awards, most recently in April 2014 and is also a finalist for the 2015 UK Pump Distributor of the Year Award, the winner of which will be announced in March 2015. To vote for us please go to www.pumpawards.com/voting/

For more information about Tomlinson Hall’s products please go to http://www.tomlinson-hall.co.uk or call Tel: +44 (0) 1642 379500

PROCESS INDUSTRY INFORMER January - February 2015

NEWS & EVENTS TRI-ARK LTD. NAMED A FINALIST IN ‘DISTRIBUTOR OF THE YEAR’ CATEGORY AT THE 2015 PUMP INDUSTRY AWARDS (PIA) The Pump Industry Awards (PIA) will hold its 12th annual event in association with the BPMA on Thursday 19 March 2015 at the Chesford Grange Hotel in Kenilworth, UK. The prestigious ceremony will celebrate the professional excellence of outstanding individuals and successful businesses operating within the pump industry. Tri-Ark Ltd., an Essex-based distributor, which supplies diaphragm pumps to the UK and Europe, has been shortlisted for an award in the ‘Distributor of the Year’ category at this year’s event. David Rozee, Managing Director of Tri-Ark is “delighted” with the news. “I’ve been watching the awards grow over the years into something quite impressive and to be recognised at this time is far more exciting than in previous years. This year the competition has been described as ‘fierce’ so I’m very proud that we’ll be rubbing shoulders with some of the UK’s pump elite,” he says. Please vote for Tri-Ark at http://pumpindustryawards.com/voting/.

For more information contact Tri-Ark, Burnham-on-Crouch, Essex Email: sales@tri-ark.com Web: http://tri-ark.com

PIONEERING PROJECT AIMS TO RECYCLE MORE FLEXIBLE PACKAGING Axion Consulting is leading an innovative collaborative project involving high-profile global brands aimed at significantly improving the recyclability of flexible packaging and diverting more of it from landfill. The two-year REFLEX project, funded by the UK’s innovation agency, Innovate UK, aims to create a circular economy for flexible packaging – from confectionery wrappers to detergent pouches - by involving the whole supply chain, from polymer production and packaging manufacture to waste management and recycling. Joining the Manchester-based resource recovery specialist are Amcor Ltd, Dow Chemical Company Ltd, Interflex Group, Nestlé UK Ltd, SITA Holdings UK Ltd, TOMRA Sorting Ltd and Unilever UK Central Resources Ltd. Flexible packaging such as plastic bags, confectionery wrappers, frozen food bags and pouches makes up nearly a third (32%) of consumer plastic packaging in the UK, however virtually all of this 556,000 tonnes produced annually ends up in landfill. By contrast 58% of plastic bottles are recycled. “This project aims to remove the barriers preventing flexible packaging being recycled, thus enabling recyclers such as Axion and SITA to change the supply chain, create a circular economy in flexible packaging and divert it from landfill,” explains Axion Director Roger Morton. “To achieve this, innovative recyclable flexible package designs and materials are required, where all the materials used can be reprocessed together. Recycling these materials is still very technically and commercially challenging.”

For more information contact Axion Consulting, Bramhall, Cheshire Tel: 0161 426 7731 E-mail: info@axionconsulting.co.uk or visit www.axionconsulting.co.uk.

HANOVIA’S HALIM MIRZA PRESENTING AT GLOBAL WATER & BEVERAGE TECHNOLOGY CONGRESS Halim Mirza, Hanovia’s MENA Regional Sales Manager, presented a paper entitled‘The Benefits of UV in the Beverage Industry’ at this year’s Global Water & Beverage Technology Congress in Dubai. The Congress is part of the Dubai Drink Technology Expo, which was held between 14-16 December. Hanovia also exhibited its PureLine PQ (Performance Qualified) UV disinfection system at the Expo through its local distributor Water Engineering Technologies FZC (WET). Why UV? The beverage industry operates under exacting safety and quality standards. Any microbial contamination in the process can cause discoloration, affect flavour and shorten shelf-life, not to mention potential health risks to consumers. Effective microbial disinfection of the whole process is therefore essential. UV is an increasingly popular non-chemical disinfection method as it eliminates all known spoilage microorganisms, including bacteria, viruses, yeasts and moulds (and their spores). It is a low maintenance, environmentally friendly technology which eliminates the need for chemical treatment while ensuring high levels of disinfection. PureLine PQ range Designed specifically to provide performance-qualified UV disinfection of water in the food, beverage, pharmaceutical and other high purity applications, the PQ system is guaranteed to provide the ultimate process security with performance validation from an authoritative third party. It provides realtime UV monitoring (including self-compensation for varying water quality), validated UV dose calculations and features simple to use controls, all adding up to maximum biosecurity for the production process and peace of mind for the operator. “By working with our local partner WET we’ve already had a number of successful installations across different industries in the United Arab Emirates, all with excellent feedback from the customers,” said Tim McDougle, Hanovia’s Sales and Marketing Director. “We’ve also noticed that, as production processes become more mature, the need for advanced UV technology also grows stronger. The Dubai Drink Technology Expo is therefore the perfect platform to introduce our state-of-the-art technology to a wider audience,” he added.

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

AUMA ACE Scheme Drives up the Standard AUMA UK Ltd is introducing the ACE (AUMA Certified Engineering) Technician Certification Scheme to drive up the standards of actuator installation and maintenance within the controls industry. The training and accreditation programme is targeted at actuator technicians working for both customers and independent controls contractors. The scheme, spearheaded by the specialists in modular electric actuation, addresses the fact that there are no formal standards for SQEP (Suitably Qualified and Experienced Persons) working on-site with actuators and valve control systems. The AUMA programme is set at three levels: ACE Technician Level 1 aimed at in-house technicians. ACE Technician Level 2 suitable for on-site installation and service activities and ACE Technician Level 3 which provides the highest level of qualification for those involved in communications protocols and systems integration.

For more information contact Auma Actuators Ltd, Clevedon, North Somerset Tel: +44 (0) 1275 871141 Email: mail@auma.co.uk Web: www.auma.com

PROCESS INDUSTRY INFORMER January - February 2015

NEWS & EVENTS PIONEERING PROJECT DEVELOPS NEW PROCESS TO RECYCLE FUEL CELL COMPONENTS A pioneering recycling process to recover high-value materials from waste fuel cells has been developed in a collaborative project between resource recovery specialist Axion Consulting, Johnson Matthey Fuel Cells Limited and Technical Fibre Products (TFP). Funded by the UK’s innovation agency, Innovate UK, the objective of the Recover project is to establish the technical and economic feasibility of recovery and re-use of high value materials from fuel cell membrane electrode assemblies and ultimately to establish the potential for a new UK-based global recycling business. Having proven the initial process steps, further research is underway on evaluating the viability for commercial operation and developing a take-back system for end-of-life fuel cells such as those from forklift trucks, mobile phone masts, electric vehicles and in small portable power packs for laptops and other products. The project involves Axion leading on the development of the primary recycling routes; TFP leading on the recovery and re-use of the carbon fibres and Johnson Matthey Fuel Cells leading on the re-use of materials in fuel cells and the final recovery and recycling of the precious metals. “It offers exciting potential using really elegant chemistry,” commented Roger Morton, Axion Consulting Director. “The ability to recycle fuel cells is important as they will be powering the vehicles and technology of the future, which needs to be cost-effective if they are to be acceptable to both consumers and manufacturers.

For more information contact Axion Consulting , Bramhall, Cheshire Tel: 0161 426 7731 Email: info@axionconsulting.co.uk or visit www.axionconsulting.co.uk.

HBM BRING YOUR MEASUREMENT TECHNOLOGY KNOW-HOW UP TO DATE Following on from a successful series of training and workshops in 2014, HBM – a market leader in the field of test and measurement – has announced the first dates for its 2015 training courses, which take place at the end of February. The first of the training courses is on ‘Data Acquisition’ and takes place on the 24-25th February. This course is suitable for all personnel who would like to plan and conduct measurements with transducers and measurement data acquisition systems. This two day seminar provides both practical and theoretical advice and covers topics such as: how to select the correct sample rates; how to avoid aliasing effects; how digital amplifiers work; the advantages and drawbacks of carrier-frequency supply; the impact of measuring leads; and how data processing works in modern measuring data acquisition systems. This is followed by the popular ‘Measurement Uncertainty’ training course, which takes place on 26-27th February and is aimed at all measurement engineers in charge of planning and taking measurements as well as users performing measurement data analysis. Offering delegates the opportunity to learn and practise the GUMbased approach, this course aims to provide an appreciation of the concept of uncertainty of measurement in a calibration or testing environment. The course takes attendees through the process of calculating uncertainties, by a combination of lectures and practical application exercises. Located at the AMP Technology Centre in Rotherham and presented by experienced lecturers, these two training courses will enable attendees to bring measurement technology know-how up to date with professional training that has a perfect mix of sound basic knowledge and practical guidance. The HBM Academy trainers have a wealth of knowledge in all aspects of data acquisition, strain gauge measurement and analysis of measurement data and have been successfully training engineers worldwide for many years.

To register or for further information on these training courses, contact HBM on +44 (0) 20 8515 6000 or via email: info@uk.hbm.co.uk or visit the HBM website at http://goo.gl/vLbpA3

PROCESS INDUSTRY INFORMER January - February 2015

NEWS & EVENTS AQE 2015 Conference details announced The organisers of AQE 2015, the international Air Quality and Emissions show, have announced a comprehensive conference programme for the event which will take place in Telford, UK, on 22nd and 23rd April. Organiser Marcus Pattison says: “The event could not have been better timed. Just before Christmas, the UK Government issued a consultation that, if adopted, could result in a dramatic reduction in ambient air quality monitoring, and this is causing uproar in the sector. The messages surrounding the enormous numbers of premature deaths resulting from air pollution are starting to gain traction in the mainstream media, so it is astonishing that Defra should propose less monitoring, and this is bound to be a hot topic at the Conference!” AQE 2015 is the 8th in a series of Air Quality & Emissions events, attracting visitors from all over the world, each with a professional interest in air quality. In common with AQE2013, this year’s event will focus on issues relating to the measurement of stack emissions to air on the first day, and on ambient air quality on the second day. Day 1: ‘Emissions monitoring challenges facing operators and manufacturers’ Wednesday 22nd April The first day’s conference will commence with David Graham from E.ON Technologies explaining how stacks are defined under legislation that aggregates units together. He will also provide a regulatory update on the Industrial Emissions Directive and the Medium Combustion Plant Directive. Jonathan Clark from Syngenta will then outline the challenges facing operators with small stacks in relation to periodic monitoring and compliance with standards. Continuing this theme, Dan Jones from E.ON Technologies will address issues facing the operators of large stacks, particularly in relation to Health & Safety, sample representativeness etc. In the afternoon: Derek Myers from REC will provide an overview of the challenges facing test laboratories and others, when sampling dust from wet stacks, and finally, Rod Robinson from NPL will explain the measurement and calculation of stack flow rate for mass emissions reporting purposes. Day 2: Air Quality - Latest developments and tools - Thursday 23rd April In the morning : Ambient air quality issues are of course extremely localised, and Stephen Stratton from Ricardo AEA will provide a summary of a study on exposure to pollution at buggy height, adult height and air quality station height. Jacqueline Barr from IBI/Transport Scotland will then deliver a presentation on a Sensor Rotation Project in which a network of new monitoring technologies has been applied to traffic management and control systems. In the final presentation of the morning, David Green from Kings College London will report on a series of PM Speciation Studies looking at the makeup of particulate matter measured across the UK and how it varies. In the afternoon: Martine Van Poppel from VITO Belgium, will explain the results of the CARBOTRAF EU Project which examined ways in which Black Carbon and carbon dioxide levels can be reduced by the latest monitoring technologies and effective traffic management. In the final presentation, David Carslaw from King’s College London will describe ‘OpenAir’ (open-source software) which is a free software tool for the analysis and visualisation of air quality data. Inevitably, many of the presentations will be coloured by Defra’s recent consultation, which bodes well for a lively debate. AQE 2015 ( www.AQEshow.com ) will take place at the International Centre in Telford and in addition to the Conference, visitors will also be able to attend Workshops providing practical advice and case studies, and an Exhibition featuring almost all of the world’s leading providers of monitoring equipment and services.

The charge for attending the Conference is £55 +VAT per day or £100 for both days. However, entrance to the exhibition and workshops is free and pre-registration guarantees free lunch, free refreshments and free parking. Online registration for AQE 2015 is now open, see http://tinyurl.com/lo7qt5m. For more information log on to www. aqeshow.com or Tel: +44 (0) 1727 858840 or E-mail: info@aqeshow. com

Applications JACQUET WESTON ENGINEERING PROCESS LINE HELPS PRECISION ENGINEERS MAINTAIN THE HIGHEST STANDARDS A dedicated and highly versatile acid-etching process facility and associated effluent plant have now been fully installed by Jacquet Weston Engineering (JWE) for one of the world’s major manufacturers of precision components. The factory at American-owned Symmetry Medical’s plant in Sheffield focuses on a range of products – from aerospace components to surgical instruments and implants – and is at the heart of a newly constructed building on the site. The Symmetry facility produces both cast and forged components, primarily on a subcontract basis for customers worldwide, using special performance metals including stainless steel, cobalt chrome and titanium. The installation comprises two cantilever transporter lines with a framework manufactured from 316 ST/ST, due to the aggressive process chemistry. Separated by a walkway, each line comprises 13 individual stations – an unload/offload facility and 12 individual process tanks. Significantly, a major part of the JWE installation also includes mixing and effluent handling stations – both of which are linked directly to the processing facility. The effluent treatment plant ensures that the process only produces clear water and filter cake – the former safely removed to drain according to authorisation requirements, whilst the latter is taken off site for separate disposal. Russell Robinson , Director at the Symetry site says “The facility will help us to maintain our excellent reputation”

For more information contact Jacquet Weston Engineering Tel: 01488 674400 E-mail:info@jweltd.com Web; www.jweltd

New waterworks facility is truly innovative As the 2nd biggest city in Denmark, Aarhus faces many of the same challenges that are seen in places with a high population density. This includes delivering clean water as effectively as possible and recently they have developed a ground-breaking solution to achieve this. At Truelsjerg Waterworks a new system, supported by Grundfos Pumps, has been installed that is a closed water treatment system that has changed traditional waterwork designs by pioneering a method that will deliver the highest possible water quality. This approach means that now there is an entire, enclosed above ground water treatment system. Which results in an end to open cascade aerators that are vulnerable to contaminates. This visionary solution utilises water systems at every point from source right through to delivery at the tap. Grundfos were chosen as the ideal partner as they had the perfect range of stainless steel pumps, motors with built-in frequency control and a wide range of sensors that work to support the system. In addition, Grundfos also supplied a range of pumps to support the centres full-scale test facility that will be used by staff and research workers.

For more information or literature request contact Grundfos Pumps Ltd, Leighton Buzzard, Bedfordshire. Tel: 01525 85000 E-mail: grundfosuk@grundfos.co.uk

PROCESS INDUSTRY INFORMER January - February 2015

FEATURE

The new era in Advanced Process Control Phil Black – Editor of PII had a Q&A session with Norbert Meierhoefer, business consulting director,

AspenTech about the recent introduction of their new Adaptive Process Control solution. PB: Why do oil & gas and chemicals companies implement Advanced Process Control technology? NM: Advanced technology delivers the most effective solutions for any process task

or problem. As modern process plants become more complex Advanced Process Control (APC), in particular, is a necessary deployment in addition to basic process controls to meet the operational targets and customer demands. Refineries and chemical companies are under constant pressure to improve throughput, save energy, meet operational constraints and improve time management amongst many others. By optimising their assets using advanced technology, industry leaders will see greater return on investment and truly maximise process profitability.

PB: What challenges do APC engineers need to overcome and what can they achieve using APC software tools to meet operational objectives? NM: Today, APC engineers need to exert tighter control of operations in order to squeeze out more production at lower cost from complex and demanding processes. Standard APC applications are typically built with an underlying assumption that the model developed by the engineer will always be accurate and properly structured. However, as process plant performance and economic objectives change, this may cease to be the case as the behaviour of the process changes over time. Although a controller may be accurate enough when implemented, at some point in the future it may not be, so the aim should be to automatically detect this occurrence and correct it on a continuous basis. When issues with model fidelity are detected, the tuning of the controller should also change to mitigate the potential negative impact. So, it is important that the engineer is equipped with valuable insight into process behaviour and understanding of process characteristics. Crucially, it is the ability to shape the properties of the controller across testing, operation, maintenance and enhancement phases that will improve benefits, reduce the cost of ownership and mitigate risks associated with model accuracy issues.

PB: What is AspenTech’s involvement in APC software? NM: For more than 20 years, AspenTech’s

Aspen DMCplus® software has been the industry standard for advanced process control software. Now, with a completely re-designed modelling environment and the introduction of AspenTech’s Adaptive Process Control solution, the process industries have a powerful new tool available to manage their operation with greater control that will deliver greater operational profitability – Aspen DMC3 software. This technology provides a complete range of economic trade-offs for managing step testing and model construction. Essentially, that eliminates the need to approach APC maintenance as a project and creates a continuous background process of assessing model quality, collecting current data and generating new models as the behaviour of the plant changes over time. The Adaptive Process Control initiative was born from a need to address the current problems associated with building and maintaining control applications. This smart software can detect, isolate and correct problems without increasing the burden on engineering staff.

PB: Can you describe further the benefits of AspenTech’s Adaptive Process Control capability NM: Adaptive Process Control capability helps organisations ensure controller

models are continually analysed for accuracy, poorly performing areas of models are identified, non-disruptive background testing collects new process data while units are being optimised; new data is monitored in real time and bad data automatically identified and removed. By making it easier to generate data, manage step tests and produce results, APC becomes more accessible and efficient. There is a crucial difference between the traditional approach to controller

PROCESS INDUSTRY INFORMER January - February 2015

maintenance (sustained value) and Adaptive Process Control capability. With sustained value, revamping the controller is typically carried out as part of a lengthy and costly project. Under Adaptive Process Control, however, the clever controller is modified over time in a background process that is not disruptive to plant operations. Adaptive Process Control improves long-term profitability by reducing process variability and allows plants to be operated optimally. Refiners and chemical companies have seen great value returns in product yield improvement and minimised energy costs with financial pay-back within short time periods. For existing controllers, keeping applications running at peak performance is a big challenge. We are all aware that quicker and more efficient control projects improve the return on investment and, therefore, Adaptive Process Control opens up new opportunities to implement APC with this clever approach. AspenTech control technology is distributed control system (DCS) agnostic, which is crucial in today’s environment of mixed DCS. The Adaptive Process Control functionality makes it possible to create high quality models without turning off the controller while significantly reducing time consuming jobs

PB: What Advanced Process Control innovations are shaping today’s industry? NM: Today, the technology game has been taken to a new level. AspenTech’s DMC3

software combines industry leading DMCplus technology with the most innovative tools for building and maintaining controllers – all in one place. Aspen DMC3 software provides the control engineer with key capabilities that modify the behaviour of the controller based on the lifecycle needs (i.e. lifecycle needs defined by changing process plant performance and economic objectives). The new gain constrained model identification in Aspen DMC3 leverages process knowledge to create more effective model predictive control applications. Innovation and economics go hand in hand. On the one hand Aspen DMC3’s Adaptive Process Control solution provides a complete range of economic trade-offs for managing step testing and model construction. On the other hand, the Robustness feature of Aspen DMC3 software provides the same ability to shape the performance of the controller when in optimising control mode. By setting the Robustness factor, the controller aggressiveness can be set by the engineer to mitigate the risk of poor model conditioning. Binary choices are replaced with a continuously variable scale giving fine control over the technical and economic trade-offs involved in APC. The benefits to companies are also significant and include better control to shape the economics of APC solutions to continuously meet changing business objectives. In addition, users can now shape the behaviour of the controller during testing, model construction and deployment phases.

PB: How does APC add value and impact the profitability of process plants? NM: Operating a process with greater control increases efficiency and safety

to improve product quality. Robust control provides risk mitigation against poor model conditioning. Innovative APC software allows plants to operate at the highest possible throughputs, maximise the yield of the highest value products and perform at the optimum energy usage possible. Aspen DMC3 software marks a new era in APC technology. By mitigating model errors and improving the performance of control over time, this ground-breaking innovation optimises the production process, eliminates waste and reduces the overall cost in the manufacturing process. With this latest APC technology, implementation and maintenance of APC is no longer an arduous project, but more of a continuous programme of improvement – the bottom line is that companies now have truly robust control and ‘cost-to-payback’ return on investment with dramatic and uplifting results.

Applications UK’S LARGEST PLASTIC RECYCLER INSTALLS BABCOCK WANSON HOT WATER BOILER Plastics recycling firm Jayplas (J&A Young) has installed a Babcock Wanson HEB 420 Hot Water Boiler and Heat Exchanger into its latest recycling facility in Loughborough, Leicestershire. The large-scale reprocessing facility has the capacity to process up to 25,000 tonnes per year of low density polyethylene film (LDPE) and is believed to be among the largest of its kind in the UK. Material for the plant includes back-of-store film waste from retailers, post-consumer polyethylene and plastic films from agricultural and construction sources. These are reprocessed into a plastic granulate for use in the production of new plastic film products, including refuse sacks and carrier bags. In line with Jayplas’ philosophy to invest in technology that enables the company’s recycling plants to operate in an efficient and environmental way, the Babcock Wanson HEB 420 Hot Water Boiler was chosen by Jayplas for its high efficiency – up to 96.2% - and long working life. Jayplas is a long standing Babcock Wanson customer, employing a range of equipment. Commenting on this latest contract, Jason Hall, Group Engineering Manager, stated: “Jayplas was pleased to give this second project to Babcock Wanson with confidence due to the reliability of the ESM Steam Generator installed at our Corby site PET washing plant in 2010”.

For more information, please contact Babcock Wanson, Borehamwood, Herts. Tel: 0208 9537111 E-mail: info@babcock-wanson.co.uk www.babcock-wanson.co.uk

SUCCESSFUL ONDEO INDUSTRIAL SOLUTIONS PROJECT IS ‘CHALK’ OF THE TOWN Ondeo Industrial Solutions, part of Degrémont Industry, has successfully completed a water mains diversion project at the UK’s leading independent lime and chalk supplier, Singleton Birch. The industrial water management company completed the project on budget, within a tight time frame specified by the customer of just six weeks. The project, which was completed on behalf of family owned civil engineering company Fox Ownby, required a 900 metre raw water diversion at the Singleton Birch site located near Grimsby. Singleton Birch, established in 1815, is a global supplier of lime products and services that are used in the production of steel, various chemical processes, and a wide range of applications in the construction industry. Following a comprehensive review of the site and a detailed planning process, Ondeo Industrial Solutions’ Site Services team excavated, installed and commissioned the water main, complete with wash-out stations, air valves and gate valves. “We are delighted with Ondeo Industrial Solution’s professional approach to the project and the high standard of the works carried out, especially taking into account such a tight time frame,” said Paul Wilson, Project Manager at Fox Ownby.

For more information contact Ondeo Industrial Solutions, Grangemouth Tel : 0191 491 4274 Email : Sophie.ONEILL@ondeo-is.com Web: www.degremont-industry.com

CASTELL SUPPLIES SAFETY INTERLOCKS TO TIANWAN NUCLEAR POWER PLANT FS interlocks and key exchange boxes provided for Phase II project Industrial safety specialist Castell is to supply interlocking systems to the Tianwan Nuclear Power Plant Phase II project under construction in Lianyungang, Jiangsu province, China. Tianwan is the nuclear power plant with the highest unit capacity in China. To date, it is the largest joint technical and economic project undertaken by China and Russia. Castell will provide multiple sets of mini FS industrial safety interlocks and key exchange boxes for the China National Nuclear Corporation construction project. These devices prevent the busbar earthing switch from connecting during maintenance on high-voltage switchgear, thereby guaranteeing the safety of maintenance staff. Since 2010, Castell has provided customised safety interlocking devices for six successive nuclear power projects in China. Project supporter ABB China recommended Castell to the China National Nuclear Corporation as part of this latest Power Plant Phase II project. Christy Zhang, Castell senior sales manager for the China region, said: “Once again, Castell has retained the trust of its Chinese nuclear power industry clients. The company continues to establish its products’ leading edge within the high-end field of nuclear power.” The unit capacity for the Tianwan Nuclear Power Plant’s Units 3 and 4, which are currently under Phase II construction, will be one million kilowatts. Units 3 and 4 are expected to be put into commercial operation in February and December 2018 respectively. Castell Safety International protects personnel, assets and the environment worldwide across the energy, industrial, manufacturing and transport sectors. Castell products are designed to work in the harshest environments, delivering safe and efficient solutions.

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

LANEMARK PROCESS GAS BURNER CONTROL HELPS MEET EXACTING CERAMIC PRODUCTION STANDARDS The excellent control characteristics associated with process gas burner technology from Lanemark International are increasingly being brought in to sharp focus at Stoke-on-Trent-based Ceramic Drying Systems (CDS). The company has a leading worldwide reputation for the manufacture of drying and curing systems that meet specific challenges associated with the ceramic and concrete production industry. It can point to a growing list of installations where Lanemark burner systems play a central role in its drying, curing and environmental control system designs. “It is a key requirement of the production industry – from concrete, bricks, heavy clay and white-ware to sanitaryware and tableware production – that the heating and curing process follows extremely tight parameters and guidelines,” comments Chris Johnson, CDS Group’s Operations Director. “By ensuring that operations are conducted in the optimum environment, the speed of drying and curing can be managed accurately while significantly reducing the risk of uneven curing or drying deformation. The role of the Lanemark burners in meeting this essential requirement is fundamental and, indeed, has now become a standard part of our system design.” For more information contact Lanemark International Ltd. Nuneatron, Warks. Tel : (024) 7635 2000 Email : info@lanemark.com Web: www.lanemark.com

PROCESS INDUSTRY INFORMER January - February 2015

Applications FULTON’S BOILER INSTALLATION ASSISTING IN THE DIVERTING OF FOOD WASTE FROM LANDFILL Refood’s state-of-the-art anaerobic digestion plant in Widnes is a firstclass recycling technology alternative. Diverting food waste from landfill, Refood is a trusted choice when converting commercial business food waste into green energy. In 2013, heat transfer specialist Fulton successfully tendered for the supply of a packaged hot water boiler system consisting of 12 FHE-250 modular hot water boilers

for the Widnes site. Commenting on the decision making process, Shane Murray, group project manager for Saria (Refood’s parent company) says: “Fulton presented a solution to provide multiple small hot water boilers which, additionally, gave us spare capacity during scheduled maintenance or if one of the boilers malfunctioned. The Fulton design was also considerably better than anything we saw from their competitors.” Fulton’s boiler installation at Refood is providing multiple functions. Its two primary functions are to provide hot water for the cleaning of the site and hot water for washing and sterilisation of the food waste bins. The boiler system also provides heat to the pasteurisers prior to the anaerobic digesters. To comply with ABP regulations, legislation dictates that pasteurised food waste has to be maintained at 70 degrees centigrade for one hour. Heat from the boiler system is also used for the under floor heating system in the offices and other ancillary processes on site. “We were so impressed with the design, installation and the fact that heat and hot water from Fulton’s boilers are used for so many functions, that we are also discussing maintenance packages with the company.” says Shane.

Further information on the products and services available from Fulton can be found at www.fulton.co.uk, by emailing sales@fulton. co.uk or by calling +44 (0)117 972 3322.

CASTELL SUPPLIES SAFETY INTERLOCKS TO LARGE HYDROPOWER PROJECT IN CHINA More than 5bn yuan invested in new plant in Xianju. In a first for the company, industrial safety specialist Castell is participating in the construction of a Chinese hydropower plant. Castell will provide multiple sets of FS industrial safety interlocks and key exchange boxes for the large project currently under construction in Xianju, Zhejiang province. These devices prevent the busbar earthing switch from connecting during maintenance on highvoltage switchgear, and so guarantee the safety of maintenance staff. Tian Xinhai, Castell China sales manager, said: “This is the first time Castell has entered the Chinese hydropower field, which is of landmark significance to Castell’s business in China. While maintaining our leading edge in the fields of nuclear and thermal power, we will use the experience gathered from those fields to provide quality products and services for our Chinese hydropower clients.” More than 5bn yuan (£535m) has been invested in the hydropower plant project in Xianju. The project will take five and a half years to complete. Upon completion, the system’s comprehensive thermal power peak load regulation range will be cut by 2.44%, reducing the system’s standard coal consumption by 155,000 tonnes. After being put into operation, the plant will participate in system frequency and phase modulation operations and act as an emergency system backup. It will improve power grid frequency and voltage stability levels, helping to ensure the grid’s safe and stable operation. The plant’s ability to receive large amounts of external power across long distances will be particularly important, and its installed capacity will increase the size of the East China and Zhejiang grids.

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

PROCESS INDUSTRY INFORMER January - February 2015

GREENCORE SLASHES GAS BILL BY £30,000 WITH A SPIRAX SARCO HEAT EXCHANGER SYSTEM Upgrading its domestic hot water system from two shell-and-tube calorifiers to a compact Spirax EasiHeat™ solution has enabled Greencore Food to Go to reduce its annual gas bill by £30,000. The EasiHeat steam-to-hot-water system provides crucial hot water for staff at the company’s production facility at Manton Wood in Worksop, Nottinghamshire. The site employs up to 2,000 people, who produce 3.5 million packs of handmade sandwiches, baguettes and wraps each week. Staff must adhere to a rigorous daily hand-washing regime, before they start work, after every break and every time they change from using one type of filling to another due to the risk cross-contamination poses to allergy sufferers. EasiHeat is based around a compact plate heat exchanger and provides instantaneous hot water at constant temperatures. Because it does not store water like a traditional shell-and-tube storage calorifier, which must store water at 60°C or higher to aid the prevention of Legionella growth, less energy is needed to heat the water. This enabled the Manton Wood site to reduce its annual gas bill by £30,000. Further savings will be achieved by reduced maintenance costs. Greencore’s two calorifiers needed to be stripped down regularly for insurance inspections, a task that typically took several days. The EasiHeat system does not need dismantling for insurance inspections, saving substantial time and maintenance costs. Greencore Food to Go has included the EasiHeat in its 24-7 priority response Service Contract with Spirax Sarco. This guarantees the company access to Spirax Sarco’s experienced engineers 24 hours a day, 365 days a year via a dedicated helpline. In the event a problem cannot be resolved over the telephone, a Spirax Sarco engineer will visit the site within 24 hours. “Hand washing is crucial in a food factory and we have to ensure that hot water is available 24 hours a day, seven days a week,” explains Chris Bassett, Services Engineering Manager at Greencore Food to Go. Mr Bassett says Spirax Sarco was the obvious choice for this project. “Spirax Sarco is the world leader in steam technology and its products always deliver. From conception through to installation, the technical support and advice we have received from Spirax Sarco on this project, and the interaction between Spirax Sarco, ourselves and the third party contractor used for the installation, has been second to none. I can’t fault a thing and would always recommend and use them for any steam project.”

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

THE SWEET SMELL OF SUCCESS? Babcock Wanson completes regenerative thermal oxidiser project for food processing company Babcock Wanson has completed a project for the design, construction, erection and commissioning of a Regenerative Thermal Oxidiser at Moy Park’s Grantham, Lincolnshire, facility to provide an effective odour abatement solution for the sites frying and oven based cooking processes. One of Europe’s leading food companies, Moy Park specialises in fresh poultry and complementary convenience food products. Its Grantham premises is a large further processing site for breaded and ready to eat produce featuring six production lines. Both frying and oven cooking methods are used at the site, which has grown rapidly over recent years. With this growth has come the need for improved odour abatement, especially important because of the site’s location close to the town centre. A customer of Babcock Wanson for more than 30 years, Moy Park turned to the company for an effective solution. An almost unique project in the food industry, the installation has proven to be very reliable with the bare minimum of maintenance or cleaning requirements to meet it’s ‘round the clock duties. Installation was completed using much of the sites existing ductwork to help minimise disruption to Moy Park’s busy schedule.

For more information contact Babcock Wanson, Borehamwood, Herts. Tel: 020 8953 7111 E-mail: info@babcock-wanson.co.uk Web: www.babcock-wanson.co.uk

Applications DOSING PUMPS ESSENTIAL TO MAINTAINING CHINESE SEMI – CONDUCTOR MANUFACTURING GROWTH Industry Overview China, one the world’s largest manufacturer of electronics and the largest consumer of semiconductor products, accounts for about 40% of global consumption. Many of the leading international semiconductor companies have transferred their production to China, making the country a key link in the international industrial chain. In 2014, sales growth in the IC (Integrated Circuit) industry had been estimated to exceed 18%, with an industry size of over 250 billion Yuan. Wastewater Treatment System The wastewater produced during semiconductor fabrication process, must be carefully handled to avoid harm to the environment. Verderflex® hose pumps are predominately used in the dosing process to treat wastewater. The source of wastewater can be divided into three categories, manufacturing wastewater, drainage from Ultrapure water based manufacturing, and washing exhaust. When classified by type of contaminants, it can be divided into acid-alkali wastewater, wastewater containing fluoride, cyanide wastewater, grinding wastewater and heavy metal wastewater. The most widely adopted method in wastewater treatment is chemical precipitation. Chemical precipitation uses chemicals to react with dissolved ions to produce indissoluble sediments. The treatment of wastewater containing fluorine involves calcium ions reacting with fluoride ions, creating calcium fluoride precipitate which is then removed. In order to reduce the residual concentration of fluorine ion, calcium concentration can be increased to achieve the expected treatment effect. The Verderflex® VF range of industrial hose pumps are widely used in this application for dosing lime, calcium chloride and other similar agents. Advantage of using VF peristaltic hose pumps Verderflex peristaltic pumps are the ideal solution for the pumping lime because: • The abrasive nature of lime, creates continual wear problems for progressing cavity pumps leading to ongoing high stator replacement costs and frequent maintenance downtime; • lime is relatively highly viscous, usually too viscous for diaphragm pumps, causing them to clog up resulting in continual maintenance requirements; • Verderflex pumps have a linear flow-speed characteristic, ideal for feedback control systems, allowing precise control of the chemicals being dosed, minimising chemical useage; • Verderflex pumps have a smooth liquid passage, there are no opportunities for product to settle and the peristaltic action keeps product in suspension rather than allowing settlement; • Verderflex peristaltic pumps are designed for ease of use, reduced downtime and to the low cost of ownership.

For more information contact Verderflex, Verder Ltd, Castleford, West Yorkshire Tel: +44 (0) 1924 221020 - E-mail: info@verderflex.com - Web :www.verderflex.com

MICRONICS CLAMP-ON FLOW METER PROVIDES RELIABLE WATER FLOW MEASUREMENT IN LEADING FOUNDRY The supply of cast iron plays a fundamental role in the production of brake discs and drums for vehicle manufacturers, the motor racing industry and replacement part distributors. When melting iron up to 1550oC, cooling water is circulated through an electric induction coil, it is therefore absolutely crucial that flow is monitored constantly because, if water is lost, the electrical coil could melt and safety would be seriously compromised. Furthermore, a replacement coil would cost £35,000, plus the costs of repairing any collateral damage caused by uncontained molten iron, notwithstanding the costs resulting from loss of production. Eurac Poole Ltd is one of the leading grey iron foundries of its type in Europe, supplying over 40,000 tonnes of cast product every year. Molten iron is prepared in four medium-frequency, coreless induction furnaces where cooling is a critical part of the process. Paul Sillence, Eurac Poole’s Maintenance Superintendent had used electro mechanical flow monitoring devices on previous occasions and had found them to be unreliable. He wanted an alternative that would constantly measure the flow in a closed loop cooling system through an evaporative cooling tower. In addition, he determined that to avoid costly and disruptive downtime the flow meter would have to be non-invasive and easy to fix without any need to break into the system. He had read about Micronics devices in a technical publication and knew that the Buckinghamshirebased company supplied non-invasive flow monitoring devices and contacted Micronics at the beginning of last year and their engineers recommended a Micronics U3000 Permanent Ultrasonic Liquid Flow Meter to be fixed on pipework serving the furnace cooling system. Because mechanical parts do not need to be inserted through the pipe wall or to protrude into the flow system, installation took just a few minutes and there was no need to shut down flow or drain the system, making it extremely cost effective and practical. The device uses non-invasive ultrasonic sound transmission and detects liquid flow velocity inside closed pipes; it is simple to operate and gives a flow measurement to an acuracy of 1.5%. Paul is completely satisfied with the purchase and the after-purchase support received from Micronics. “I would definitely use Micronics again and am seriously considering buying another Ultraflow 3000 for an identical furnace system in the near future.”

For further information on this project or the Micronics range call Micronics on +44(0)1628 810456, or visit www.micronicsflowmeters.com.

PROCESS INDUSTRY INFORMER January - February 2015

HEAT TRANSFER

& ENERGY

WEIDMÜLLER DC-UPS: SAFE POWER SUPPLY FOR AUTOMATION BRIDGES MAINS FAILURES FOR UP TO 30 MINUTES AT 40 A. Weidmüller’s new DCUPS uninterruptible power supply avoids costly machinery and system downtime during mains failure and keeps safety functions, process controls and communication up and running for a defined period of time. If a power outage occurs at the system input, the DC-UPS reliably provides 24V to the automated components without interruption for a pre-defined period of time. The maintenance-free buffer module is suitable for momentary interruptions in the range of several 100 ms, whilst the UPS controller in connection with a battery module bridges longer mains failures, supplying power of up to 40A for 30 minutes or 1A for 30 hours.

For more information contact Weidmuller UK, Leicester, Tel: 01162 823470 E-mail: sales@weidmuller.co.uk Web: www.weidmuller.co.uk

COOLING FAN RATED FOR USE IN EXPLOSIVE ENVIRONMENTS WITH 200,000+ HOURS RELIABILITY AMETEK Rotron MIL-901XP meets UL, NEC and ANSI hazardous use standards A high reliability cooling fan qualified for use in hazardous industrial applications has been introduced by AMETEK Rotron (www. rotron.com). The new MIL-901XP fan meets UL, NEC and ANSI standards for equipment that will not create an ignition source in explosive environments. It is designed for use in either indoor or outdoor installations where sufficient concentrations of flammable gasses, vapors, or dust are present. Applications include cabinet cooling, heat exchanging and air exchanging for equipment used in the oil, gas, chemical, mining and other industries. With a rated life in excess of 200,000 hours, the fan provides the reliability needed to assure continuous operation in critical situations. Construction features include thermal protection, advanced composite propeller material and permanently lubricated stainless steel ball bearings. Ambient operating temperature range is -54C to +70C. Applications: Oil & Gas production and refining • Chemical processing • Mining • Pharmaceutical • Military • Agriculture AMETEK Rotron is a division of AMETEK, Inc., a leading global manufacturer of electronic instruments and electromechanical devices with annual sales of US$3.6 billion.

For more information contact Steve Galloway at AMETEK Airscrew Ltd. Tel: +44.12.58.45.06.41 Email: steve.galloway@ametek.co.uk Web: www.ametekaerodefense.com

PROCESS INDUSTRY INFORMER January - February 2015

WEIDMÜLLER’S “PROmax” – SLIM AND POWERFUL FOR DEMANDING AUTOMATION APPLICATIONS The new “PROmax” switched-mode power supply units from Weidmüller are the ideal choice for users needing powerful power supplies for their machines and systems. With “PROmax” the switched-mode power supply units supply the power required for overloads, even at high temperatures. The units supply continuous overloads of up to 20% or transient peak loads of 300% with ease. The “PROmax” offers high boost capability (150% power boost for 4 s and 120% at ≤ 45°C) and full capacity in the wide temperature range of -25°C to +70°C. Thanks to their slim width and side-by-side mountability, “PROmax” devices save on installation space on the DIN rail.

For more information contact Weidmuller UK, Leicester. Tel: 01162 823470 E-mail: sales@weidmuller.co.uk Web: www.weidmuller.co.uk

FEATURE

Are you ‘foaming at the mouth

By Steve Gallagher MSc, MBA, MIET, CEng. – Technical Dir

Proven measurement technology leads to opti level. Proteins as long chain molecules have this effect by lying along the thin films between the bubbles, thereby preventing drainage. The stability of such foams clearly has a large impact on their life time. Additional factors such as poor system design and leaking pumps can exacerbate foaming problems. In all instances, in order to minimise the impact of foam, it requires to be effectively monitored, measured and controlled.

Controlling foam

Exciting new technology developments in foam measurement and control are bringing important benefits to a wide range of process industries. The accurate and reliable measurement of foam brings substantial savings to companies through the improved control of anti-foaming agents, improved process control, increased yield, reduced product loss and reduction in equipment failure. In certain processes, especially in the waste water sector, significant energy savings can be made through improved foam control. The patented measurement technique uses level measuring technology specifically developed for measuring foam levels and foam-liquid interfaces. Suitable for both aqueous and non-aqueous liquids, it already has a proven track record in a wide range of applications and industries. By comparison, alternative, less-effective, solutions use existing level measuring technology ‘adapted’ to measure foam. These tend to be inherently unreliable, inaccurate and adversely affected by process product build-up on the measuring probes.

“Measurement is the first step that leads to control and eventually to improvement. If you can’t measure something, you can’t understand it. If you can’t understand it, you can’t control it. If you can’t control it, you can’t improve it.” - H. James Harrington 1929

This principle is certainly true of the challenges presented by industrial foaming and its subsequent control. Foaming affects almost every industrial sector: from pharmaceuticals to brewing, from paint manufacture to waste water treatment, from oil & gas to food processing, from textiles to pulp and paper. Foam may be an integral and important part of a process or it may be an unwanted side effect. Foaming has the appearance of a simple material, partly because we are all familiar with it, whether, for example, in the form of bath foam, bubbles in a milkshake or the head on a glass of beer. However in practice foam is a very complex, dynamic material with its production involving physical, chemical and biological processes. Most of the common foams are an unstable, two-phase medium of gas and liquid with a particular structure consisting of gas pockets trapped in a network of thin liquid films and plateau borders. Several conditions are needed to produce foam: there must be aeration (generated for example by mechanical agitation, mixing, stirring and sparging) and surface active components (surfactants) that reduce the surface tension. There is always a natural drainage along the thin films of liquid between the bubbles. Liquid gradually drains out from top to bottom, creating a density gradient through the column of foam. The foam at the top of the column collapses as the films become too thin to support the bubbles. An equilibrium develops between this material collapse at the top and the build-up of new foam from the liquid surface below. This ongoing process limits the maximum height of the foam column. However, in some processes foam stabilising agents such as proteins reduce the drainage, resulting in much more stable foam. In these circumstances, the foam production rate can far exceed the dispersal rate and the foam can build up to a serious

There is an extremely diverse set of chemical formulations that can be effective either to prevent foam forming or to destroy it once it has formed. In practice most foam-dispersing chemicals can serve either role. Each anti-foam or de-foamer agent is specifically developed for individual applications and the world-wide market for these essential evils is worth billions of pounds per annum. Commonly used agents are insoluble oils, polydimethylsiloxanes and other silicones, certain alcohols, stearates and glycols. The most universal characteristic of any de-foamer is the fact that it is surface active. Most are insoluble but some are water-soluble adding to the complexity. (The latter have a property known as inverse solubility. An increase in the temperature of an aqueous system in which the de-foamer is present causes a decrease in its solubility. At or above the cloud point (the initial effective temperature), the de-foamer separates from solution and acts as an extremely effective de-foamer. Reduction of the system temperature below the cloud point enables the de-foamer to become solubilized again.) Insoluble de-foamers have to be formulated so that they will be dispersed as tiny droplets, i.e. as an emulsion. The surface-active nature of the material causes it to spread very rapidly onto any air-liquid interface that it encounters. This is especially the case if that interface is already covered by the types of surface-active materials that tend to stabilize foams. Anti-foamers and de-foamers operate by being absorbed into bubble surfaces in preference to the foam stabilizing agent. They are then effective in increasing the drainage rate so that the bubbles drain quickly and then collapse. An effective defoamer can disperse foam in a few seconds and the process can be dramatic to watch.

Adding up the costs

Foam generation can cause a variety of expensive and time-consuming problems. These include environmental pollution, potential product contamination, loss of product through excessive foaming, downtime and clean-up costs if foams spill over from the process. Excess foam can severely limit product throughput in a process and can result in damage to equipment including pumps, filters and valves. Add into this the ongoing cost of de-foamers and it is clear how important it is to implement effective foam control. The key problem is being able to understand the characteristics of the foam and then measure its thickness and, in some applications, where the foam-liquid interface resides. The foam can be controlled through the addition of de-foamers, but without the above key information, their addition is typically done on an empirical basis, often based on historical experience. This can then result in a cyclic or sine wave solution to the problem. De-foamers are added in quantities based on maximum demand and the foam subsides. It then develops again above acceptable levels and more de-foamer is added. This staccato, reactive rather than pro-active approach, is

PROCESS INDUSTRY INFORMER January - February 2015

mouth’ over your process?

rector Charis range for Redditch based Hycontrol Limited.

imised foam control and reduced process costs expensive and wasteful. In many cases, when the foam disappears and the problem subsides, the rate of de-foamer addition is not reduced, resulting in excess chemical usage.

Measuring problems

The effective and reliable measurement of foam thicknesses and foam-liquid interfaces presents a number of challenges. Results can be adversely affected by a range of factors including constantly varying foam density and gradual coating or fouling of the measurement probes with residual product from the process chemicals. Traditional measurement techniques have been based on a range of existing level probe technologies adapted for foam measurement. In most applications, these fall short of providing an adequate and sustainable solution.

that the liquid could be completely turned into foam if not controlled quickly enough. Typically antifoams are used to control the foam build up in fermenters but these are difficult to control and can have some unwanted side effects. Firstly, by reducing surface tension the gas bubble size increases, reducing the mass gas transfer into the broth. This can seriously limit the yield of the process. Secondly, the excess use of some anti-foamers can contaminate to the end product and be very difficult to remove.

Waste water

Bulking sludge and foam are two undesirable, complicated and unpredictable challenges for many waste water treatment plants (WWTP). In many cases, the filaments causing bulking sludge tend to float and thereby produce huge amounts of foam. The foam may vary in depth considerably and extend throughout the biological circuit, as well as to anaerobic digesters and dewatering units. The traditional approach is to dose anti-foam into the process on a continual basis. This dose rate is typically set to cope with foam during the plant’s peak demand. However on average this is far too high and in some systems there is little or no foam generation for most of the time. Alternatively the addition of chemicals is often done randomly, in far too large quantities and too late. This reactive approach results is very limited control and understanding of the entire process. In some cases, the WWTP can suffer for years without finding a sustainable solution to the problem. These chemicals themselves may also add to the foaming problem. In both cases, the excessive cost of chemicals and energy through unnecessary pumping can be substantial. Additional costs are also incurred through unnecessary equipment wear and damage.

The Solution

A highly versatile range of Foam Control systems have been specifically developed for measuring the thickness of foam in a process, detecting foam-liquid interfaces and measuring liquid levels, ignoring the presence of any foam. Hycontrol point out that the technology behind these systems originated from detailed research into foam control during pharmaceutical fermentation and that the special measuring sensors and control equipment have been designed specifically for foam control and are not modified level sensors.

Industry specific foam problems

Uncontrolled foam generation can affect productivity in a wide range of industries. It causes particular problems in the pharmaceutical, waste water and food & beverage sectors. The foam control systems are proving to be very effective in these industries, bringing significant cost savings and productivity improvements. By monitoring and measuring foam production, real time data can be used to ensure de-foamers are only added in controlled quantities when required. Accurate foam control is essential in the Pharmaceutical industry, especially during the fermentation process, which is used in the production of antibiotics, vaccines, steroids and other drugs. These products are frequently created by biotech processes which use natural organisms such as bacteria, algae or animal cells to produce the end product. (Probably the best known process of this kind is brewing in which yeast is used to create alcohol.) Natural organisms require a healthy environment for growth and optimum yields. Products such as vaccines require very high-tech fermenters for efficient production. These usually involve stirring and air or gas mixing to operate. However natural organisms also tend to create unwanted proteins as a bi-product and these act as foam stabilizers, creating the perfect environment for stable foam production on top of the broth. Stories of so-called ‘foam-overs’ abound in the pharmaceutical industry by which whole processes and equipment can be destroyed. A ruined batch can often represent hundreds of thousands of pounds in lost product before taking into account the costs of any equipment damage or clean-up costs. There is also the possibility

PROCESS INDUSTRY INFORMER January - February 2015

Food and Beverage

In the food-processing and beverage industries, foam can be generated at various points in a production process. This is caused predominantly by the presence of surface-active substances such as proteins, fatty acids and sugars. Foam is a particular problem in alcohol distillation and in the production of deep-frozen foods, deep-frying oils and gelatin, as well as in fruit conservation and vegetable washing. Invariably, the resulting foam impairs product properties in many different ways and greatly disrupts the process flow. Foam spillages are disruptive and time-consuming to clean up and dispose of.Silicone-based antifoam agents are the most common chemicals used to manage foam but product contamination is a major consideration.

Conclusion

Companies world-wide spend billions of pounds each year dealing with foam and the effects it has on their businesses. Consideration must also be given to the longterm detrimental effect that the disposal and dispersal of de-foaming chemicals has on our health and the environment. There is clear evidence that considerable savings can be made by actively controlling the addition of antifoaming chemicals and the technology is now available to achieve this. There is no need for companies to continue with out-dated control systems, which only serve the interests of the chemical suppliers.

FEATURE

Monitoring the monitors – how emissions measuring systems are checked By Steve Donnelley – Analytical Specialist- ABB Measurement & Analytics – St Neots. To control emissions to the atmosphere, you need to know what those emissions actually are. The European standard EN14181 describes the quality assurance procedures needed to ensure that continuous emission monitoring systems give sufficiently accurate readings. Plants that produce emissions to the atmosphere are regulated under strict European and national laws to protect the environment and human health. Such plants need a permit to operate, which usually requires monitoring of emissions. Permanently installed analyser systems that continuously monitor and display the volumes of substances in the flue gas are known as CEM or CEMS (continuous emissions monitoring systems) or AMS (automatic measuring systems). EN14181 is the European Committee for Standardization (CEN) standard for quality assurance of CEMS, setting performance standards and procedures for testing and approval. As well as providing the framework for legal compliance, conforming to EN14181 is required by plants participating in the EU emissions trading scheme, an aspect expected to grow in significance over the coming years. Monitoring is usually carried out by extracting a small sample of flue gas, using a pump, into the CEMS system via a sample probe. The sample is transported through a line, or umbilical, to a manifold where individual analysers extract materials. A data acquisition and handling system receives the signal output from each analyser, collecting and recording the emissions data. Alternatively, using a more modern approach, Fourier transform infrared spectroscopy (FTIR) can be used to measure all pollutants at a single point. This method analyses the spectrum from the incoming infrared light, enabling identification of the molecules as well as concentrations and temperatures of substances. The rate of flow also needs to be measured. Frequently, this is done using a pitot tube, the same technology as is used to determine the airspeed of aircraft. Other common technologies include ultrasonic, vortex shedding or optical scintillation measurement. To comply with EN14181, readings must be accurate to within a certain percentage. This only applies to the CEMS itself; the system for data acquisition, storage, handling and calculation of measurement values is not considered part of the CEMS for the purposes of the standard, but will be the subject of a different CEN standard, yet to be published.

Three quality assurance levels

Process operators have overall responsibility for complying with EN14181 but they rely heavily on the advice from their CEMS manufacturer and from test laboratories. The standard specifies three quality assurance levels (QALs) and an annual surveillance test (AST). These quality assurance levels follow a logical sequence to demonstrate the suitability of the CEMS, its proper installation, accurate calibration and correct operation. QAL1 - outlines a procedure to demonstrate that the CEMS is suitable for the intended purpose before installation. This is normally done by the system manufacturer. MCERTS product certification at an appropriate range (1.5 or 2.5 times the daily average emission limit value) is taken as evidence of compliance with the QAL1 requirements. When an operator installs a CEMS, it is essential to ensure that the sampling system is certified to national and European standards. The CEMS must be able to test for linearity, zero drift and span drift checks, as well as to check the entire system for leaks. The legislation specifies uncertainty allowances expressed as 95 percent Confidence Intervals (CIs). Once a system has been installed, conditions on the site can increase the uncertainty in the measurements. Care must be taken to ensure that the CEMS selected will meet the QAL2 requirements in the specific application. QAL2 - describes the procedure to prove that the CEMS has been installed correctly, verified and calibrated, and to check that the CEMS still meets the uncertainty requirements. Large parts of this procedure can be done by the operator, but checking calibration requires the involvement of a test laboratory. This involves inspection and functional tests, which check performance characteristics such as response time and linearity. The QAL2 test procedure is carried out when the CEMS is installed, then at specific intervals of three or five years depending on the application. It also needs to be carried out whenever there is a significant change in plant operation which alters the emissions, as well as after a repair or upgrade that requires re-calibration of the system. Functional tests are a mandatory requirement of EN14181. The operator is responsible for ensuring that these take place not more than one month before QAL2 or AST. These can be carried out either by a test laboratory, or the process operator, with or without the help of the CEMS. These checks ensure that the system is operating correctly before comparison tests are started. The system has to be calibrated against standard reference materials (gas or dust

with traceable concentrations). This is to check whether the CEMS operates correctly so that any faults can be addressed and also to calibrate the CEMS if there is a bias in the readings. The process operator has overall responsibility for ensuring that the functional checks are carried out, but they can be carried out by any party as long as the tests meet the requirements. Test laboratories are responsible for reporting the results of the functional tests, within QAL2 and AST reports. QAL3 - consists of the ongoing control of the CEMS during the operation. This is normally done by the operator, either manually or automatically with the help of the CEMS. The plant operator is required to regularly measure the drift and precision of the CEMS and use the statistical data to determine when the CEMS needs maintenance. The required frequency can be anything from weekly to several months apart. Many systems carry out QAL3 tests automatically. The data from these automatic zero and span tests is then used for the QAL3 procedure. All CEMS must have the facility to allow operators and test laboratories to perform regular zero and span tests, or to extract the data from automatic zero and span tests.

AST

EN14181 describes the annual surveillance test (AST) of the CEMS. This is a procedure to show that the CEMS continues to function correctly and that the calibration is still valid. If the AST shows that the calibration function is no longer valid, a full QAL2 test is required. With the exception of calibration tests, testing can be carried out by anyone with the required training. The AST is a reduced version of a QAL2 test. Its purpose is to check whether the calibration function determined during the QAL2 tests is still valid.

Outsourcing testing

Using a third party to help ensure your CEMS gives sufficiently accurate reading is a cost-efficient approach. For instance ABB offers a functional test as an additional service to its standard six and 12 monthly service and calibration visits. Services like these can be carried out in combination with the standard service. The tests include: • Alignment and cleanliness • Sampling systems inspection • Leak testing • Zero and span check • Linearity • Interferences • Zero and span drift (QAL3 audit) • Response time All engineers carrying out functional checks are factory certified and have indepth knowledge of the equipment, ensuring tests can be completed efficiently and accurately. Equipment failures or a test failure can be investigated and resolved quickly, ensuring there is no delay prior to the QAL2 or AST. The engineer responsible for the tests can back up all test data directly from the analyser, minimizing any error in data collection. The engineer will also review and save the QAL 3 data and write the report, ensuring that all data is accurately entered in the final report. All stages are completed by the same engineer, eliminating any delay in handing over the final report.

NETWORK & COMMUNICATIONS

Test & Measurement

ROBUST CONNECTOR HOUSING FOR EXTREME REQUIREMENTS

NEW FLUKE IR MODULE ENABLES EXISTING FLUKE TOOLS TO SHARE DATA WITH OTHER TEAM MEMBERS

The new Han® M Plus range of connectors from HARTING incorporates effective protection against extreme environmental influences through the use of an additional polyurethane coating. This new coating not only increases the connectors’ impact resistance but also protects them from extreme mechanical and chemical influences. As a result, this housing series is ideally suited to applications in transportation, the maritime environment, and the mining and petrochemical industries. These sectors all place extreme demands on the materials used in their respective industries. Connectors are subjected to impact and shocks, as well as aggressive environmental influences, and must be effectively protected against such forces. The outstanding durability of the polyurethane cover in the Han® M Plus family ensures long-lasting protection against the effects of rock chips, icing, salt mist, UV radiation, industrial exhaust gases, oils and fuels. The coating also replaces the seal where the hood and housing fit together and the flange gasket of the bulkhead-mounted housing.

Fluke has introduced a compact interlocking module which enables the wireless connection of some existing Fluke tools to the free Fluke Connect™ mobile app. By inserting the new Fluke ir3000FC Connector over the IR port of a Fluke 189, 287 or 289 Digital Multimeter (DMM), or a Fluke 789 ProcessMeter™, technicians can efficiently and safely capture realtime readings from the primary display and share data instantly with other team members in the field. Technicians can AutoRecord™ measurements safely and free to Fluke Cloud™ storage from wherever they are working, without writing anything down. Everyone on the team with a smart phone and the app can see the data. EquipmentLog™ history allows technicians to assign measurements to specific equipment, creating a cloud-based history of test measurement data for easy access during both troubleshooting and reliability maintenance. TrendIt™ enables technicians to instantly graph data, helping to identify trends and quickly make informed decisions.

For more information contact HARTING Ltd, Northampton Tel: +44 (0) 1604 827500 Fax: +44 (0) 1604 706777 Email: gb@harting.com Web: www.harting.co.uk

For more information contact Fluke (U.K.) Ltd. Norwich, Norfolk Tel: 0207 942 0700. Fax: 01603 256 606. E-mail: industrial@uk.fluke.nl Web: http://www.fluke.co.uk

PROCESS INDUSTRY INFORMER January - February 2015

FEATURE

Human error is the weakest link for process industry The process industry has one of the best safety records of all the manufacturing sectors, but when something goes wrong, there can be devastating consequences affecting not just employees, but the public too. With human error blamed for up to 80% of all accidents in the workplace, Dräger safety expert Kevin Honner, based in Blyth, Northumberland, talks about what can be done to mitigate risk. Every year, more than 200 people are killed and 180,000 injured in small-scale workplace accidents and while new technology has been invented to make our lives easier, it can in fact put lives at risk without the correct corporate

culture, knowledge or training. According to the UK Health and Safety Executive (HSE), human failures are responsible for up to 80% of all workplace accidents, therefore implementing a positive safety culture alongside technological innovations is a vital part of day-today operations. The HSE has highlighted engineering competence as vital in process safety in its ‘Human Factors’ guidance and as such is committed to driving up standards across hazardous industries through its inspections and enforcement activities. Although we can’t eliminate human error from the equation completely, more can be done to understand and control the issues that affect error. In terms of maintenance, identifying tasks most at risk from human error, need to be a part of every company’s safety management plan to avoid rising operational costs and also prevent a potential catastrophe.

A positive safety culture

The term ‘safety culture’ was first introduced after the Chernobyl disaster in 1986 after a sequence of human errors during the testing of the nuclear power plant led to the accident which claimed 31 lives. Facility operators, in violation of safety regulations, had switched off important control systems at the Ukrainian plant’s reactor, which allowed it to reach unstable conditions, according to a United Nations report. A power surge then led to a series of blasts which sent a cloud of radioactive dust billowing across Europe. Human error has also been highlighted in a number of major cases, including the 2005 Buncefield oil depot blaze in Hertfordshire which engulfed more than 20 fuel storage tanks, injured 43 people and resulted in around 2,700 compensation claims – potentially worth hundreds of millions of pounds. The Bhopal pesticide plant explosion which killed 2,000 people in 1984 is considered one of the worst industrial accidents in history. Although no one was convicted, there was evidence which suggested that workers were substantially negligent in the management of the plant.

Positive safety culture

For example, at Dräger we believe a positive safety culture is one where the importance of safety and confidence in preventative measures are experienced at all levels of an organisation. This includes leadership, a good line management system, and the involvement of all employees. Without a positive safety culture in place, it can result in corner-cutting, poor safety monitoring and poor awareness of safety issues. Following all steps in maintenance tasks is cited as a major cause of nuclear power plant incidents, therefore a technician failing to replace nuts and bolts under time pressure can have catastrophic consequences. Employers should consider training in the following areas to maximise the safety and productivity of their workforce: hazardous gases present onsite; calibration and maintenance; limitations of gas detection equipment and sensor technology; plus hands-on operation and instrument review. For example a gas detection system is only as effective as the people who are responsible for using it and routine tasks such as calibration are vitally important to ensure the accuracy of a gas detector’s reading and thus the ability of the detector to provide an alarm at the correct concentration level. Calibration can also help by determining the condition of the sensor on the as detector.

perception systems and information can be misinterpreted. Failures in decision-making and reasoning can have severe implications for complex systems such as chemical plants, and for tasks such as maintenance and planning. The focus of error management is placed on reducing the chance of these errors occurring and minimising the impact of those that do occur. We emphasise the importance of the need to provide technical training courses for workers in operation, maintenance and the proper use of equipment to ensure they know exactly how to use tools and then seek feedback from our customers to find out how our technology is being used and what can be done to make things better for the future. This not only gives the workforce greater protection, but also peace of mind and ultimately protects companies. Factors such as training and competence assurance, management of fatigue-induced errors and control of workload can eliminate some errors, but those caused by human limitations are best reduced by looking at safety culture and system design. A good system should not allow people to make mistakes easily.

Changing behaviour

Opportunities for human error are existent in every task performed by anyone working within the process industry – it is inevitable, but also manageable. Identifying the root cause of the error is vital in order to reduce accidents an minimise the consequences of those that occur. It is best achieved by learning from errors, rather than by attributing blame. In order to fully maximise the use of gas detection systems and the safety they provide, it is necessary for businesses to ensure that they are used by a team which has received the necessary training and education. At Dräger, we have a holistic approach to safety. It’s important to us that a customer has innovative solutions to protect their workforce and the public, but we’re not just product-focussed. We believe in feeding information from our customers that have been involved in human error incidents back into our design solutions. That way, we not only reduce the chance of future accidents, but by studying human error, it gives us a very important tool for preventing disaster.

Top tips for employers

It’s important to identify all hazards and risks in the workplace: Training – train people so that they understand the risks and what to do about them. A lack of training can cause an essential element of control to be lost. Competence – ensure staff involved with risk control tasks have the appropriate competence for those tasks. Failure to do these things leads to mistakes. Priorities, attention and conflict resolution – get workers involved and communicate with them about their job and equipment design so that demand-capacity mismatches can be fixed. Assurance – ensure standards and procedures get used. Sometimes, the organisation fails to update its own knowledge base.

Importance of training

As it is inevitable that errors will be made, improving management systems, providing extra training, changing working conditions and adapting the organisational culture all need to be looked at to slash the risk of such devastating incidents in the future. At Dräger Safety UK, we are committed to working alongside our industry partners to pioneer safety solutions for the future. We don’t just provide a range of new technologies, as once they are installed in work environments it can challenge human

PROCESS INDUSTRY INFORMER January - February 2015

HEALTH & SAFETY CASTELL LAUNCHES NEW HEAVY-DUTY ACCESS INTERLOCKS TO PROTECT WORKERS IN HEAVY INDUSTRIES AI-HD and AIE-HD withstand high potential loads and high frequency of use Industrial safety specialist Castell has launched heavy-duty access interlocks for use in industries such as waste and recycling, aggregates, steel and chemical processing. The AI-HD and AIEHD have been designed to deliver robust performance where there are high potential loads and a high frequency of use. The risks to personnel safety in harsh environments can be increased due to the heavy wear placed on safety components. The UK’s HSE recently reported that the construction industry in particular, while accounting for only around five per cent of Britain’s employees, still accounted for 31 per cent of fatal injuries to employees and 10 per cent of reported major or specified injuries. Recognising these issues, Castell examined how it could develop its durable AI and AIE access interlocks to deliver enhanced products that would meet the day-to-day operational cycles encountered in heavy industry. The AI-HD and AIE-HD will deliver years of performance in the harshest environments. The products use a heavy-duty stainless steel support mechanism, designed to take up to 1.5 times the load of current access interlocks, which reinforces the locking action. The design also provides additional protection for applications with high levels of vibration, such as mixers and shredders. Elisa Hunt, Castell’s marketing manager, commented: “Castell has always been synonymous with high-performing products in harsh environments and the new HD access range takes this to a new level. Taking feedback from our customers in the cement mixing, tanker loading and waste and recycling industries has enabled us to develop a product that offers new levels of safety performance.” Castell Safety International protects personnel, assets and the environment worldwide across the energy, industry, manufacturing and transport sectors. Castell products are designed to work in the harshest environments, delivering safe and efficient solutions.

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

HARD GRAFT MADE EASY: PARKER MERCHANTING EXTENDS ITS ‘GRAFT GEAR’ RANGE Parker Merchanting, the UK’s leading PPE supplier, has extended its popular ‘Graft Gear’ range to provide workers in industry with safe and reliable top-to-toe workwear solutions at the same competitive prices. Showcased in the new Parker Merchanting catalogue, the new-look ‘Graft Gear’ range offers workers guaranteed safe, high-quality and affordable workwear solutions; from headgear and eyewear right down to disposable respirators, safety gloves, work trousers and safe footwear. The extension of the range couldn’t have come at a better time for workers and employers alike, following the government’s ongoing crack-down on sites which fail to comply with health and safety regulations. All products in the range are designed with safety in mind and are fully certified with the relevant EN safety standards, ensuring that contractors are kept safe on the job and taking the stress out of adhering to workplace safety standards. Alongside the range’s dedication to safety, all ‘Graft Gear’ products have been ethically sourced from factories audited by Parker Merchanting team, ensuring providing contractors with safe, affordable products which are ethically sourced.

The brand new ‘Graft Gear’ range is now available in the latest Parker Merchanting catalogue, in Parker Merchanting stores, and online via their website: www.parker-direct.com.

PROCESS INDUSTRY INFORMER January - February 2015

INTERLOCKING IN HARSH ENVIRONMENTS IS EASY WITH SMITH FLOW CONTROL’S NEW ELLIS KEY Smith Flow Control (SFC), specialist in mechanical valve interlocking equipment, has redesigned the key for its wellknown Ellis interlocking range. Recognised worldwide, Ellis interlocks are used for critical process applications in oil and gas, petrochemical and water industries. The new Ellis key is suited to the most aggressive industrial environments. Featuring a spring-loaded rubber seal, which helps prevent ingress of sand, dust and water or any other foreign matter, its robust body has an ergonomically designed grip, ensuring improved handling. The re-design allows markings to be displayed on both the top and side of each key flag, making tags much easier to see. If a key tag is damaged during operation, the tag plate can be easily removed without needing to replace the complete key. The key is also compatible with existing plant key cabinets – all that needs replacing are the individual base plates, which clip in effortlessly. There is no change to the coded section of the key.

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

DETECTION SYSTEMS BONA FIDE DETECTION SYSTEMS FROM ANRITSU OFFER THE SAFEST SOLUTIONS FOR MEAT & POULTRY PROCESSORS Anritsu Industrial Solutions Ltd, an award-winning supplier of food safety solutions, boasts a range of cutting-edge X-ray inspection systems to help meat and poultry processors detect foreign bodies and contaminants in their products, including the very latest technology for improved bone detection, the KD Series with DUAL X technology. Protecting consumers from contaminants in the food chain is paramount to protect both the retailer and supplier alike. Conventional bone detection methods by lowering X-Ray tube voltage to increase image contrast does not help if there is no difference of effect between a contaminant and a product, such as poultry bone in poultry meat or foreign bodies in a product with uneven thickness. The KD Series of X-Ray Inspection Systems from Anritsu is highly sensitive for detecting the smallest bone fragments in a huge variety of food raw materials and finished poultry, beef and pork products, including fan, wish and rib bones in chicken breast meat. KD-7 with DUAL X is the latest ultra-high sensitive addition to the range, which has a newly developed sensor. This dual sensor technology and the unique image processing algorithms using high energy and low energy simultaneously enhance detection sensitivity to previously unattainable levels. It performs reliable and accurate inspection of overlapping and randomly oriented meat products without negative effects.

For more information contact Anritsu Industrial Solutions Europe Ltd, Tel: 0845 5399729 Email: glen.oxborough@anritsu.com Web: www.anritsu-industry.com

PROCESS MEASUREMENT & INSTRUMENTATION Data logger specifically for compressed-air plants With a data logger which was specifically developed for the employment in compressed-air plants BEKO Technologies extends its METPOINT® measurement equipment family. The new device boasts a multitude of application-specific capabilities, stretching from the number of connectable transducers to software specifically for the analysis of compressed-air processing. The METPOINT® BDL data logger allows for the connection of up to eight or even 12 transducers or sensors, depending on the model. With this capacity the new device distances itself from standard data loggers which, in most cases, do not allow for such an option. Sensors combined in a user-defined manner can be assigned to the numerous connections of the METPOINT® BDL. With pressure transducers, for example, or with pressure dew point transmitters, volume-flow sensors, temperature sensors, clip-on ammeters, etc. 32 limit values on the whole can be freely defined and assigned to four different alarm relays. An automatic early warning guarantees the utmost precision and process safety. At the device, the measured values are indicated on a 7” colour display with a zoomable touch panel. It allows for tabular, graphic, and combined presentations. Saving potentials become transparent via daily, weekly, and monthly reports. Any exceeded limits are highlighted in red. The number and moments of alarm messages are also indicated. The breakdown into minimum and maximum values completes the extensive reporting. Although the METPOINT® BDL already guarantees a considerable volume of information as a stand-alone unit, it really shows its entire functionality through networking with the other systems of the company. Equipped with all the common types of connections and a web server, the device ensures the utmost flexibility regarding the data transmission to a PC and the World Wide Web. Measured data can be read via the Internet, directly evaluated on the PC and further processed in the user’s own systems, for example in a MySQL data base. For this diversity of functions, BEKO Technologies provides two software variants that are specifically tailored to the METPOINT® BDL. The METPOINT® READER SW201 program addresses the comprehensive graphic and tabular data evaluation and analysis at the stationary PC workplace. The readout of the measured data from the data logger is implemented via USB or Ethernet. The METPOINT® Connect software acts globally. With it, any number of METPOINT® BDL data loggers can be evaluated from any location. For this purpose, the measured data are stored and procured on a server in predefined cycles. Upon request, an alarm is automatically sent via SMS or e-mail in the event of exceeded limit values. The evaluation of the measured data of all the METPOINT® data loggers that are integrated into the system can be realised from any workplace worldwide. For clear task assignment, however, the access of individual employees can also be restricted to certain devices. The compact METPOINT® BDL with a weight of slightly less than seven kilos and a housing made of powder-coated aluminium can be integrated without great efforts into existing and new compressed-air systems. Due to the employment temperature of up to 50°C, installation points close to the production do not pose an obstacle to the BEKO data logger.

For more information contact BEKO Technologies Limited Tel: 01527 575778. Fax: 01527 575779. E-mail: info@beko-technologies.co.uk Website: www.beko-technologies.co.uk

AQUAFLOW, A DIVISION OF T-T PUMPS LTD, INTRODUCES THEIR RANGE OF NEW LIQUID TURBINE FLOW METERS. Acuflux is designed with reliability, durability and practicality in mind to incorporate the required features of a flow meter with manufacturing expertise to produce a flow meter that operates efficiently in demanding media conditions. The Acuflux’s durability is demonstrated in its diverse temperate range, allowing a flow of liquid from -40°C to +85°C and a 40 bar maximum working pressure. Not only is the Acuflux reliable in terms of its robust design of corrosion resistant stainless steel, it is also reliable in terms of its data capture with the readings guaranteed to achieve accuracy within one per cent. Aquaflow, recognising the importance in customer satisfaction, have produced a product with usability in mind. The simple-to-use flow meter incorporates a two line LCD display indicating flow rate, volume and cumulative totals for clear data recording. The Acuflux also comes with preferential display units, including litres, US gallons and imperial gallons. Alongside these necessary features the Acuflux includes a low battery indication and display capacity up to 999,999 units, ensuring the user has maximum usage of the product. Options include remote display, stainless steel bearing supports and predetermined electrical output pulse. Aquaflow is an established manufacturer of waterworks valves, and related products and services, to the water, process and allied industries.

If you wish to know more about the Acuflux or any more of Aquaflow’s range please visit www.aquaflowvalves.com or call 01630 647111.

HANDHELD INFRARED THERMOMETER RAYNGER® 3i PLUS FOR HIGH-TEMPERATURE APPLICATIONS Raytek® presents a new handheld thermometer series for flexible temperature monitoring in hightemperature industrial applications from 400 to 3,000 °C, such as steel production and processing, chemical and petro-chemical industry, as well as heat treatment and power plants. The Raynger 3i Plus 1M and 2M models measure infrared radiation Raynger 3i Plus handheld thermometer in the shortwave spectrum (1 µm and for flexible monitoring of critical 1.6 µm) and provide high precision processes and quick verification of ( +/- 0.5%, 1 °C). Thanks to the fixed sensors superior resolution of 250:1, critical plant parts and products can be reliably monitored from longer distances. For exact aiming, the measurement spot is highlighted with two laser beams. Moreover, even red hot objects can now be easily targeted by means of a new “Red Dot” scope sighting function (patent pending). Additionally, the use of a “Red Nose” heat-resistant warning detector and alarm reduces the risk of the sensor overheating — minimizing repair costs — while averting costly accidents and ensuring operator safety. The robust handheld devices withstand drops of 1 m. A powerful firmware supports display, analysis, and trending within the device. Up to 4,900 data points can be recorded. The scope of delivery furthermore includes the Raytek DataTemp® Windows PC software which supports real-time communication and further data processing. In addition to on-board USB and Bluetooth interfaces, a mobile app allows for comfortable data storage and sharing. The display can be set to degrees Celsius or Fahrenheit. The devices are equipped with a Lithium-ion battery that can be easily recharged and allow an operational cycle of 24 hours.

For more information contact Raytek GmbH, Blankenburger Str. 135 13127 Berlin, Germany Tel.: +49 30 / 47 80 08 – 411 Fax: +49 30 / 47 10 251 Email: jschwelm@raytek.de Web: www.raytek.de

PROCESS INDUSTRY INFORMER January - February 2015

FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves WANNER OIL COOLER RANGE EXTENDED Wanner International has extended its range of oil coolers with the introduction of two new models, designed for use in potentially harsh and corrosive environments, including marine applications. Oil coolers complement Hydra-Cell pumps by extending their upper temperature operating range. Hydra-Cell pumps have an excellent reputation for pumping hot liquids as they have no tight tolerances or dynamic seals that could be adversely affected by differential thermal expansion problems. The Wanner Oil Coolers are ‘air blast’ coolers with a circulating pump and an oil filter; designed to give excellent cooling efficiency and maintain oil condition, viscosity and performance. The two new models, (one three phase and the other single phase) are fully ‘marinised’ to meet the requirements of IP56. They are produced with special coatings to resist the aggressive environmental conditions and pass the accelerated saltwater test. Hose kits are available to connect the oil coolers to either 1 or 2G10, G15, G25 or G35 Hydra-Cell pumps.

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

The Ecademy clicks with installers

VALVE RANGES COMPLEMENT HYDRA-CELL PUMPS

The new Grundfos Ecademy re-launched recently and is now bigger and better than ever. This UK branch is already proving to be very popular with a wide range of installers, heating engineers and merchant counter staff. Today this internet based training and information platform now offers the opportunity for interested parties to learn more about a wide range of topics including pump theory as well as different pump designs and technologies. Or perhaps you are interested in finding out more about energy friendly and cost saving pump solutions. Whatever is selected, each topic is divided in bite sized sessions and on the completion of 4 modules participants will have the opportunity to choose a reward. With the benefit and flexibility that comes with 24/7 access, plus the fact that this new platform is also accessible from your smartphone or tablet, this makes it easier for you to reference it on the move. In addition there are videos to watch as well as downloadable articles and presentations.

Wanner International offers a wide selection of Back Pressure Valves and Pressure Relief Valves that it claims are ideal for use in chemical dosing systems and complement its Hydra-Cell diaphragm pumps. Wanner Back Pressure Valves help ensure that Hydra-Cell pumps provide accurate predictable flow, while the Pressure Relief Valves protect pumps and systems from over pressure situations. Like the Hydra-Cell pumps, the robust low maintenance diaphragm valves have no dynamic seals, guaranteeing complete 100% containment of the pumped liquid. Both ranges are available in a wide range of materials including 316 Stainless Steel, Hastelloy C, PVDF and Polypropylene making them the ideal choice when pumping corrosive or hazardous chemicals. With flanged, union, threaded and socket connection options, they offer high reliability in rigorous service and require minimal maintenance that can invariably be carried out in-situ without removing the valve from the pipe work.

Find out more and register today by visiting www.grundfos.co.uk/ecademy after all it’s only a click away.

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

mini CORI-FLOW Coriolis Flowmeters

/hr 1000 kg r 100 kg/h

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Low Installation Costs Increased Productivity Improved ROI Space Saving Decreased Inventory or Spares

Innovation - Experience - Responsibility

Bronkhorst (UK) Ltd - T 01223 833222 - I www.bronkhorst.co.uk - E sales@bronkhorst.co.uk PROCESS INDUSTRY INFORMER January - February 2015

FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves NEW SIPOS SEVEN ELECTRIC ACTUATOR SERIES IS LAUNCHED A new electric valve actuator range has been launched by SIPOS Aktorik. The SIPOS SEVEN series features a number of breakthrough innovations to enhance the flexibility and functionality of actuation technology. Pioneering advancements include large color display, simple ‘joystick’ control and USB interface. SIPOS SEVEN products include the Ecotron, Profitron and high precision, HiMod. Full Color Display: SIPOS SEVEN’s large, full color display is a first for an electric actuator. Designed to be easy to read, all essential information is visible and is configurable by the user in a variety of different languages. Simple animations provide step-by-step instructions for actuator set-up and operation, reducing the need for instruction manuals on-site. Complete Control: A Drive Controller is also a pioneering feature enabling easy, intuitive actuator operation: controls are managed with a single, multi-functional ‘joystick’ which has no through-housing connections ensuring leak-tight operation. The Drive Controller simplifies use of the actuator in any orientation and multi-level access passwords ensure tamper free operation. USB Interface: Another design breakthrough - process control set-up can be carried out without connection to a mains power supply using a laptop or USB battery. Setup and spare parts management is also simplified using the USB port for cloning. SIPOS Aktorik – the manufacturer and global supplier of standard and specialist electric actuators.

For more information contact SIPOS Aktorik GmbH, Aldorf Germany Tel: +49 (0)9187 9227-0 E-mail: info@sipos.de Web: www.siposseven.com / www.sipos.de

AQUAFLOW ARE PLEASED TO ANNOUNCE THE INTRODUCTION OF A RANGE OF STAINLESS STEEL PRESSURE REDUCING VALVES (PRV). The valve will automatically reduce and stabilise downstream pressures regardless of upstream pressure and flow rate fluctuations, due to its responsive directly-acting spring. The downstream and upstream pressure balance, obtained by the intermediate chamber and guided piston, guarantees a high accuracy and long lasting performance. By means of the innovative self-cleaning piston technology, the pressure regulator stands out for its higher reliability when compared to pilot operated control valves that are vulnerable to fine particles. The hydrodynamic profile of the valve body, with its large downstream chamber, ensures high resistance against cavitation effects and vibrations in the event of high pressure ratio conditions. These robust pressure reducing valves are precision machined from a solid piece of stainless steel material, upstream (inlet) rated to 64 Bar, downstream (outlet) adjustable down to as low as 1½ Bar and having female threaded connections. Additionally, various seat materials are available to suitable the media and temperature. The absence of pilots and hydraulic circuitry avoids rapid variations and consequently the risk of pressure surges, as well as possible pulsations and potential dynamic instability. Even in terms of reaction time this pressure reducing valve stands out to be the safer solution; always ensuring the correct functioning in maintaining the downstream pressure value to a constant level also in the case of rapid variation in demanding and static conditions, for example when used before valves in charge of tank regulation and control. Aquaflow is an established manufacturer of waterworks valves and related products and services, to the water, process and allied industries. If you would like to know more the pressure reducing valve range, or any of our products please visit www.aquaflowvalves.com or call 01630 647111.

CONTROL VALVES FOR HIGH PRESSURE INJECTION APPLICATIONS Badger Meter HP-60 ultra-high pressure control valves are ideal for offshore, oil and gas control applications with up-stream pressures of up to 60,000 psi. Available in the UK through liquids handling specialists PUMP ENGINEERING, the Type HP-60 control valve utilises a 17-4 PH body along with a solid Stellite® inner valve assembly. The HP-60 valve is also ideal for use in industrial research and process pilot plants on liquids and gases, with typical applications being chemical injection, for example in the production of high pressure, low density polyethylene (HPLDPE). Standard features include, pressure rating to 60,000 psi (4135 Bar) @ 100o F, a wide range of interchangeable trims, choice of linear or quick opening trims, ANSI Class lll shutoff (size P-1 through P-9) and ANSI Class lV shutoff (size K through O). The inner valve (plug and seat) is constructed from solid Stellite® while Titanium Nitride coated Stellite is available as an option. Standard packing is Torlon®/PFA CV rings. For lower pressures up to 350 bar, the standard RC200 valve in 316 stainless steel is available with a larger range of trims. All the valves can be supplied with standard (air-to-open, air-failclose, air-to-close, air-fail open) actuators. However, actuators in Stainless Steel with integral top mounted positioner or side mounted positioner, are also available. A wide range of accessories, such as filter regulators, gauges, I/P converter, limit switches and solenoids, are also offered.

CSF centrifugal pumps are quick-strip, easy-clean and reliable…perfect for food, brewing, pharmaceutical and other ‘sensitive’ applications. ● Can handle capacities from 1 to 550 m3/hour at heads up to 155 metres ● AISI 316L stainless steel for all wetted parts ● Quick strip, easy-to-clean and designed for CIP(clean-in-place)

Pick the perfect pump – from Pump Engineering

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For further details are available from Pump Engineering Ltd, Littlehampton, West Sussex. Tel: +44 (0) 1903 730900 E-mail: sales@pumpeng.co.uk Web: www.pumpeng.co.uk

PROCESS INDUSTRY INFORMER January - February 2015

It’s your BPMA News.. As readers of “the News” it is important that we bring you informative and interesting articles and information from the association and its members. But do we do enough? Probably not!! We can do much betterbut we need your help. Tell us what you like and dislike about the content, do you want more articles, special sections, a people page, comments and so on - and please don’t pull your punches… Email your thoughts and comments to the editor at peterullmann@piimag.com This also applies to our members – your comments too please– it is after all your “soap box”.

NEWS

JAN / FEB 2015

Meet the family the fast way. All our Eta pumps at a glance.

On show…. It’s been a while since we publicly “showed off” – but this year we will be, for the first time “on show” at the MAINTEC 2015 Exhibition at the NEC 24th – 26th March. There is possibly much that readers don’t know about the association, excepting members of course, so if you & your company feel that learning more about the BPMA could be beneficial, here’s the opportunity to go ‘face to face’. A night out and a stroll in the park… March 19th sees this year’s Pump Industry Awards Gala Event and May 15th our annual Golf Day – to book your seat or pull on your “plus fours” see page 2.

Eta keeps the world on the move Our Eta pump family keeps the world on the move. And there are plenty of big reasons: the highly efficient top-class hydraulic system. Dozens of sizes, materials and drives in almost any combination. And service that puts rivals in the shade. After millions of great pumps, the new generation is here. So discover what Eta can now do for you. www.ksb.com/eta-en • KSB Limited • 2 Cotton Way • Loughborough • Leicestershire • LE11 5TF • 01509 231872 • www.ksb.co.uk

Etanorm

Etaline

Etabloc

Etanorm SYT

Our technology. Your success. Pumps Valves Service n

The bottom line for business: save energy, save money By reducing energy consumption by 1 per cent, big businesses could save over £250 million on their energy bills annually. Big businesses are paying for five power stations worth of electricity each year they don’t need. However even reducing their energy consumption by 1 per cent could save over £250 million on their energy bills annually. The new Energy Saving Opportunity Scheme (ESOS), launching in December, will help large organisations cut their electricity use with a detailed energy audit. Over a hundred representatives from businesses, charities and universities met with Energy and Climate Change Secretary Ed Davey in January to explore how to use energy more efficiently and lower their energy bills. Addressing the event, Ed Davey said: “Britain’s big firms are spending around £2.8 billion extra each year on inefficient energy technologies – the equivalent output of nearly five power stations. Now is the time to seize the opportunity with ESOS – and organisations up and down the country are already gearing up to make changes to save energy, save money and save the environment. If you act and invest, you will save – and that’s the bottom line” Through ESOS all large organisations that employ at least 250 people, or have an annual turnover of above around £40 million and a balance sheet above around £34 million, must carry out energy audits every 4 years. Hugh Jones, Managing Director, Advisory at the Carbon Trust commented: “At the Carbon Trust we have already engaged with hundreds of businesses on ESOS, helping to explain how they can achieve compliance while also making significant energy savings and cutting carbon. From the interest we have seen so far we expect ESOS to benefit British business by helping companies to reduce overheads and increase competitiveness. Businesses often aren’t aware of opportunities in energy efficiency, or they don’t realise how attractive the paybacks can be. By requiring companies to understand exactly how they can make cost-effective investment in energy efficiency, they are far more likely to take action”. The event was held at the Institute of Directors and included a panel discussion with Ed Davey, Rhian Kelly (Director of Business Environment at CBI), and Paul Ekins (Director UCL Institute for Sustainable Resources & Deputy Director of the UK Energy Research Centre). Attendees explored how to encourage take up of energy efficiency opportunities to make the most of the scheme. Notes • The Energy Savings Opportunity Scheme (ESOS) is a mandatory energy assessment scheme for all large organisations - including businesses, charities and universities - in the UK. We estimate this includes around 9,400 organisations. • Qualifying organisations must carry out energy audits every 4 years, with the first assessment due by 5 December 2015. The audits will provide them with high-quality information about how they can improve their energy efficiency and ultimately save money on their energy bills. • Government established ESOS to implement Article 8 (4-6) of the EU Energy Efficiency Directive. In line with the Directive, the scheme does not apply to the public sector. • Find out more details about ESOS go to: www.gov.uk/energy-savings-opportunity-scheme-esos The Department of Energy and Climate Change will review the ESOS policy in 2016.

And do not forget Guidance has also been published to help potential participants in the scheme understand their obligations and on page 43 of the full ESOS guidance document you will see that the ISO/14414-Pump System Energy Assessment standard is referenced as an auditing methodology that can be accepted by “Lead Assessors” approved by the Environment Agency. Accordingly it is hoped BPMA CPSA accredited persons (who are trained according to the IS0 14414 standard) will be recommended by Lead Assessors to undertake the pumping system elements of company energy audits. And bear in mind:• Pumps are the largest consumers of global motive power • Pumping System improvements can deliver up to 40% reduction in energy costs – and therefore improve user bottom line P&L account performance • The fact that BPMA’s CPSA scheme has been designed to help by equipping people with the skills to conduct a Pumping System Audit in accordance with ISO/14414 So when considering auditing your pumping systems, remember the BPMA Certified Pump System Auditor Scheme (http://www.bpmacpsa.co.uk) has established BPMA as THE body to train and certify personnel who undertake “Pumping System Assessments” as referenced in UK Government Energy Strategy documents.

BPMA

COMING EVENTS March 19th – Pump Industry Awards - Held at the Chesford Grange Hotel – Kenilworth The Pump Industry Awards held in association with the BPMA, has been recognising the best performing companies and people for their achievements and positive contributions since 2000. In 2015, we are proud to be leading the call again in championing those responsible for pioneering new frontiers, inspiring others and achieving growth in challenging markets. We hope you’ll join us in this unique opportunity to network, exchange ideas and celebrate with the industry’s best and brightest. For more information please turn to page 4. March 24th – 26th – Maintec 2015 The BPMA has taken a stand at the show for the first time at this year’s event. Positioned in the dedicated ‘pump sector’ where you can find us at Stand M30L - so if you are attending make a point of coming to see us and find more about our services and facilities –you will be surprised of what we do and offer… May 14th - Our Annual GOLF DAY + Breakfast on the 15th – no not the hole – the day… This year it is being played at ‘Glorious Goodwood’ – not in the midst of the race course, but at Goodwood Park, one of the UK’s premier sporting venues and it’s a great place to entertain your clients or employees alike. For what is always a great day+ it’s amazing value at just £220 per player + vat and with “special room rates for the 13th & 16th, how can you refuse to make your reservations…. For more information log on to www.bpma.org.com and go to “Events” or call Jeanne Page on 0121 601 6691

BPMA Pumping Fundamentals courses Venue: National Metalforming Centre 1 minute from J1, M5) Cost: £300.00 + VAT per delegate per course (BPMA member discounts available) Scheduled course dates for 2015: 23/24 February 1/2 June 24/25 August 23/24 November

When safety matters Rely on us

Module 001 Part 1 – Pumping Fundamentals • Introduction • Pumps as machines, liquid properties & definitions • Terminology – definitions • Fluid flow – basic concepts, cavitation & NPSH • Systems performance, pump • Performance, matching pump & system

We are the most experienced and respected specialists in the business. Rely on us to help manage your health & safety responsibilities more efficiently and effectively.

Module 001 Part 2 – Pump Selection • Introduction • Recap on part one • General Approach to Selecting A Pump • Defining The Need • Collecting Information From Customer • Grouping The Desired Features

Whether it’s preparing your health & safety policy, carrying out a risk assessment or help with a strategic initiative such as improving health & safety standards across multiple sites, you choose what you need from our comprehensive mix of services centred on our consultants, practical online tools, health & safety management systems, audits and advice lines. Members of BPMA qualify for a special membership discount. Quote 81957DL when you contact us.

We are able to offer all of our lecture-based courses “inhouse”. Contact j.page@bpma.org.uk for further details. Other modules available visit www.bpma.org.uk

To see how we can help you manage the health & safety risks in your workplace, visit

www.cronersolutions.co.uk/bpma ®

denise.leigh@wolterskluwer.co.uk

BPMA E-learning Courses BPMA also offer a choice of two on-line courses: Technology Level Two (QCF) Introduction to Pumping This provides standardised terminology and a very basic approach to the various pump types. It is targetted at all employees who need to know the language of the pump industry. Essentials of Pumping Technology Level Four (QCF) For those students who have day-to-day involvement with pumps and pumping systems, this course aims to provide the knowledge needed to cover normal situations. Likely candidates are all personnel who manage or are involved in designing, specifying, sourcing, installing, servicing and maintaining pumping equipment. Both courses are accredited by the Open College Network and certificated by BPMA. Visit www.bpma-elearning.co.uk for more information and costs.

BPMA held yet another successful 4-day residential CPSA (Certified Pump System Auditor) course held at their West Bromwich offices in December 2014. The course culminating in certification and eventual personal ID “Certified Pump System Auditor” status following approved audits. 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

SPP Pumps receives regional growth fund of £1.12m for R&D facility SPP Pumps, leading manufacturer of centrifugal pumps and systems, has won Regional Growth Funding to build a new R&D facility within its Pump Manufacturing Centre in Coleford, UK. Site Director Ken Winn expressed his delight at the funding news saying: “We are thrilled to have received the allocation of funding. Of course we need to work through Due Diligence and other approvals, but this allows us to build a fantastic major pump R&D facility right here in Coleford. This will guarantee high skilled jobs in the area for years to come, ensure local employment growth and help position the UK economy for further export success. This funding will also help our business fulfil our objectives to be the Manufacturer of Pumps - for where it really matters.” The state-of-the-art facility will offer SPP a higher rated power supply, eliminating the need for generator hire. A new packing and despatch area with 2 x 25ft cranes will free up a further 60% of existing floor space to build more centrifugal pump solutions. A new paint spray booth is planned into the facility, and a higher capacity test well will offer improved capability, health and safety and efficiency for the company. SPP Pumps is well respected within industry having recently won ‘Pump Manufacturer of the Year’ for two successive years at the British Pump Manufacturers Association (BPMA) awards in April 2013. Ken continued by saying “The funding will help us to realise our vision for the new facility, giving us much more capacity, improving efficiency and reducing lead times - but most importantly will allow us to manufacture solutions that meet our customer specifications far more effectively.”

For more information contact SPP Pumps, Reading, Berkshire. Tel: 0118932 3123 Fax: 0118932 3302. E-mail: enquiries@spppumps.com Web: www.spppumps.com

You are invited to cast your vote! The Pump Industry Awards saw a record number of nominations this year, demonstrating the scope of success and innovation in 2014. The judging panel is now ready to announce the ﬁnalists... to submit your vote visit -

www.pumpindustryawards.com

BOOK YOUR PLACE TODAY!

Gala Aw ards Cerem ony hosted

Babita by Sharm a

www.pumpindustryawards.com hannah@touchwavemedia.co.uk ORGANISED BY:

British-based pump manufacturer enjoys international success The pioneering spirit that characterises specialist pump manufacturer Flotronic Pumps Limited’s approach to innovation and design has also been driving the company’s recent success in developing new markets overseas. Flotronic, the only British-owned specialist manufacturer of airoperated doublediaphragm pumps in the UK, has seen exports as a percentage of total sales rise from just 15% in 2003 to 40% in 2013. 25% of exports go to Europe - but pumps are being sold in increasing numbers across the world including the US and Canada (5%) and the Far East (2%) - with the remaining 8% distributed to the Middle East, India, South America, South Africa and Australasia. The company is seeing particularly high overseas growth in pump sales into its target Pharmaceutical, Food & Beverage, Chemical manufacture and Cosmetics markets, with the two most recently developed products, the ‘Minichem’ - machined from a solid block of PTFE - and the 3-A accredited ‘H’ series hygienic applications pump generating particular interest. Jane Waite, the company’s Managing Director, puts Flotronic’s international success down to three essential factors. “First and foremost,” she says, “you need to be confident that the features and benefits offered by your products are compelling for potential customers. Domestic customers’ feedback that our pumps’ versatility, levels of compliance, unique ‘ONE-NUT’ design ease of maintenance and capability in almost any application gave us the confidence that overseas customers would find our pumps just as desirable.” Infrastructure is the second most important factor on Jane’s reasons for success list. “Flotronic has invested heavily in establishing and supporting local dealer networks. The recruitment process includes an assessment of whether the dealer can deliver on key Flotronic brand values like our commitment to quality and the highest standards of customer care. Support includes literature and other marketing collateral, local PR, high visibility at trade exhibitions and funding help in establishing a credible online presence.” “The third factor,” says Jane, “is to recognise local differences. For example, while not yet particularly important to customers in the UK, we recognised that 3-A Sanitary Standards Inc accreditation for Flotronic’s ‘H’ series hygiene pump would be a requirement of many if not all of our US food industry customers. The ‘H’ series has had to meet the high standards demanded by 3-A, including stringent criteria controlling those design features which affect the cleanliness of the pumps.” Flotronic Pumps Ltd is determined to build on its burgeoning international sales success, with exports as percentage of total sales expected to rise to 50% by 2015, representing some 750 Pumps. “I would encourage all manufacturing companies in the UK to consider exports in their strategic plans,” says Jane. “Building domestic market share, not always easy in highly competitive industries, doesn’t then become the be all and end all of a company’s future success. And there’s also the kudos attached to making a contribution to the UK’s balance of payments.”

For more information contact Flotronic Pumps Ltd, Bolney, West Sussex. Tel: 01444 881 871 Fax: 01444 881 860 E-mail: sales@flotronicpumps.co.uk Web: www.flotronicpumps.co.uk

The Extended Range of Magneta ErP Compliant Circulators from

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

• Future-proofed optimised efficiencies, exceeding future energy efficiency regulations. • Magneta models are single phase IP44 Advanced Technology – Simple to use with no gimmicks • Commissioning is straightforward with the press & turn dial. • Integrated display and symbols indicating the operating mode. • Dual pump operation with auto changeover (integrated interface). • Integrated protective and manual functions.

Cost-Efficient

• High-efficiency technology combined with speed control • Advanced Eco Mode offer maximum savings. • Fully integrated communication interfaces that save on both investment and commissioning costs.

Versatile

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

New waterworks facility is truly innovative

Goulds Pumps ISO Process Pumps now come with a 5 YEAR WARRANTY

As the 2nd biggest city in Denmark, Aarhus faces many of the same challenges that are seen in places with a high population density. This includes delivering clean water as effectively as possible and recently they have developed a groundbreaking solution to achieve this. At Truelsjerg Waterworks a new system, supported by Grundfos Pumps, has been installed that is a closed water treatment system that has changed traditional waterwork designs by pioneering a method that will deliver the highest possible water quality. This approach means that now there is an entire, enclosed above ground water treatment system. Which results in an end to open cascade aerators that are vulnerable to contaminates. This visionary solution utilises a wide range of Grundfos Pumps that supports all the processes needed for a pressurised closed water systems at every point from source right through to delivery at the tap. Grundfos were chosen as the ideal partner as they had the perfect range of stainless steel pumps, motors with built-in frequency control and a wide range of sensors that work to support the system. In addition, Grundfos also supplied a range of pumps to support the centres full-scale test facility that will be used by staff and research workers.

What would give to spot a pump failure sooner? With the Goulds iFrame you could.

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

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 Email: www.gouldspumps.com/Contact-Us Web: www.gouldspumps.com

New HMD Kontro Sealless Range Brochure All Latest Products & Parameters Now FeaturedSundyne HMD Kontro has announced a comprehensive update to their main product range brochure. This now includes all of their comprehensive range of sealless pumps including recent product introductions Many of the operating parameters for the existing pumps have also been updated. These details are now being integrated into their website and all other literature is being updated. In addition the recently introduced pumps are all featured including: - GSPX: Multi stage - GSPLF: Low flow - LMV 801S: Vertical low flow The opportunity has been taken to give the publication an updated cover design, in yellow, to differentiate with the previous version. You can obtain an electronic copy of the brochure in the downloads section of their website. Please visit www.sundyne.com/hmdkontro. Alternatively for a printed copy or further information, please do not hesitate to contact Vince Lee, on +44 1323 452141 or by email to vince.lee@sundyne.com.

The choice is clear with the Grundfos Product Center Having a single source of reference to allow you to make the best pump choice is something Grundfos are very aware of the necessity for. So for many years their product portfolio was supported by industry leading on-line and offline pump selection tools WebCAPS and WinCAPS. After many years of faithful service it became clear that with all the new technology available, we should invest in improving this support system. Following extensive development the new launched Grundfos Product Center has built on the positive elements from its predecessors as well as incorporating new aspects that will make this pump selector, the tool of choice. In fact you can think of the Grundfos Product Center as your own personal assistant for all things Grundfos. It can remember who you are, how you prefer to work and record your recent searches. Simply log in and the Product Center will display any recent and saved items â&#x20AC;&#x201C; including complete projects â&#x20AC;&#x201C; right on the main page. Another plus is that the entire Product Center system is now optimised for viewing on mobile devices, so you can access it anywhere, from your smartphone or tablet device. A clear choice for pump selection.

For more information contact Grundfos Pumps Ltd, Leighton Buzzard, Bedfordshire. Tel: 01525 850000 Fax: 01525 850011 E-mail: grundfosuk.com Web: www.grundfosuk.co.uk Motors | Automation | Energy | Transmission & Distribution | Coatings

New 2015 EuP legislation. Relax, we have it covered. The new EuP Directive for efficiency of electric motors came into force on 1st January 2015. The W22 range of electric motors from WEG meets or exceeds the requirements. Our CFW range of drives also help to meet the legislation, meaning we can all sleep soundly in the knowledge of reducing our carbon footrpint and saving money. Transforming energy into solutions. www.weg.net

CENTRIFUGAL PUMPS OFFER GREAT POTENTIAL SAVINGS By Dipl.-Ing. Christoph P. Pauly (KSB Aktiengesellschaft, Frankenthal, Germany) Pump systems are a key technology for numerous applications in diverse industries. They account for a major share of all electricity consumed for industrial purposes. That is why users are now much more concerned about their equipment’s power consumption than they were only a few years ago. Pump systems are a key technology for numerous applications in diverse industries. They account for a major share of all electricity consumed for industrial purposes. That is why users are now much more concerned about their equipment’s power consumption than they were only a few years ago. Depending on the scope of analysis, the potential savings on energy in current industrial systems range between 30 percent and 40 percent. In concrete terms, the German Energy Agency (dena) has calculated that pump system operators in Germany could save as much as 14 billion kWh per year. That would translate into annual savings of 1.12 billion Euros for the operators themselves and a drop of 7.7 million tonnes in CO2 emissions. There are many reasons why much too much energy is still being wasted in connection with pump operation. In processing facilities and refineries, for example, maximum priority is attached to productivity and getting back on stream following repairs. Often, this is achieved at the expense of a hydraulically optimised system. Frequently, when piping systems have been rearranged for production-related reasons, the installed pump sizes are not subsequently adjusted to match. Oversized and undersized valves, inadequate pipe radii and incrusted pipe cross-sections throttle the flow and contribute extensively to the waste of energy. Also, many large chemical facilities have their own power plants and therefore enjoy access to lower cost electricity.

and electrical data such as momentary motor outputs. Pump bearing housing vibrations can also be measured. This data provides information on the wear state or condition of each pump, hence enabling identification of misalignment, shaft deflection, unbalance and imposed vibrations from the periphery. All these factors have major effects on pump availability and service life. Service specialists use the recorded data yielded to carry out a detailed Figure 3: Data loggers record analysis. They make suggestions on various cost- all of a pump’s relevant data cutting measures and calculate the anticipated payback periods. Then, if an operator decides for weeks at a time. to implement one of the proposed measures, the service specialists will perform a second set of measurements on conclusion of the project in order to demonstrate and validate the measure’s success. In practice, a detailed analysis of a pump’s operating behaviour often reveals that it is not running at its optimal, energy-efficient operating point. A common cause for operating outside the design conditions is due either to system oversizing or to normal temporary variations in flow rate arising from system processes. If power input is not adjusted to demand via some form of system control, valuable energy is wasted. The pump’s power input can be matched to the precise requirements of the system by altering its speed. In the case of closed-circuit systems, energy savings of up to 60 percent can be achieved depending on the load profile. The industry offers a variety of technical options which allow energy consumption to be influenced via speed control. These potential savings can be demonstrated using a practical example. An industrial pump transports water with Antifrogen for cooling purposes. The required head is 38 metres. The required cooling water flow rate depends on the process involved and ranges between 200 and 300 cubic metres per hour. During fixed speed operation, the pump consumes 215,467 kWh a year. Assuming a cost of 8 pence per kWh, this adds up to £17,785.56 per annum. However, if the same pump is equipped with a speed control unit with a simple differential pressure control setup keeping the discharge pressure constant, a saving of some £1,568.59 annually can be realised. These potential savings can be exploited with almost any standard frequency inverter.

Potential savings are dependent on the system’s load profile…

Figure 1: Selection chart of the standardised chemical pump series MegaCPK for 2-pole motors running at 50 Hz / 2,900 rpm For new installations, it is relatively easy to select a hydraulically optimal pump. As long as the requirements to be met by the pump are known, a very energy-efficient pump set can be chosen with great accuracy by way of pump selection programs which most manufacturers have on hand for their customers. It is, of course, essential that a large number of closely spaced pump sizes be available to the user (Figure 1), and that the impeller diameters (Figure 2) be trimmed to match the required operating point. It is also of elementary importance that no safety margins be added: even efficient pumps cannot run economically if they are used in the wrong operating mode.

An ageing system needs more consideration…

Figure 2: Trimming an impeller to the exact operating point

If a system has been in service for a number of years, it is not quite so easy to determine its actual saving potential. The first step is to ascertain the pump’s present operating point and mode of operation since all other costcutting measures depend on them. Professional assistance can be quite useful in this connection. Some service specialists are able to utilise special data loggers (Figure 3) to record relevant data over a representative period of time. These instruments measure the flow rates, pump suction and discharge pressures

The most significant cost reductions are achievable if the pump in question frequently operates under low flow conditions. Speed control will not deliver cost savings on pumps where the total volume flow rate is required continuously. In addition, the available range of off-the-shelf variable speed systems for use in potentially explosive atmospheres is still rather small. Indeed, the operators’ myriad different work standards make it nearly impossible for pump manufacturers to economically adapt their “motor-mounted” variable speed systems to the respective set of requirements and then get them certified. The same applies to the new highefficiency drive motors. While they do generate less heat and would therefore be ideal for such applications, their working principle often makes them dependent on an accessory frequency inverter (FI). Of course, one option would be to install the FI outside of the potentially explosive atmosphere. That, however, is a rather unpopular choice, because it would involve extra cabling runs to bridge the longer distances between motor and frequency inverter. The additional cost of sine filters and expensive shielded cables would reduce the achievable savings and extend t h e payback period. Consequently, the job of tapping into the savings potentials that speed control has to offer for pumps in potentially explosive atmospheres is reserved for the operators’ own instrumentation & control departments. Modern centrifugal pumps (Figure 4) have already achieved a level of efficiency that can hardly be further improved. When they appear to be consuming more energy than necessary, Figure4: Standardised chemical it is very probably due to the fact that too little pumps like this MegaCPK have attention has been paid when the pump duty was specified. No pump can operate more already achieved a level of economically than its surrounding system efficiency that could hardly be allows. further improved.

FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves Get FIT with Wilden AxFlow has introduced the new Wilden Advanced FIT line of air operated double diaphragm (AODD) pumps. Delivering enhanced flow rates, Advanced FIT pumps have the competitive advantage over other makes in that they are easier to install. With Wilden’s Advanced FIT pumps ‘fit’ boltto-bolt and pipe-to-pipe into existing fluid handling piping systems, thereby increasing performance without the need for new piping. The pumps have been engineered to be an easy, cost-effective way of enhancing and upgrading existing pump performance with superior bolted product containment.

systems for reduced air consumption. · Fits competitors’ pumps footprint. Advanced FIT pumps are available in 51mm and 76mm sizes with aluminium housings and in 38mm, 51mm and 76mm sizes with stainless steel housings.

For further product details contact Axflow Ltd, Ealing, London. Tel: 202 8579 2111 Email: info@axflow.co.uk / Web: www.axflow.co.uk

“Advanced FIT pumps represent a major breakthrough in reducing installations costs when upgrading your AODD pump as they have been designed to drop into the existing plumbing footprint without any rebuilds being necessary,” reports Peter Carfrae, AxFlow’s Wilden Product Manager. “FIT pumps also offer an enhanced level of performance and higher flow rates, resulting in potential energy savings and reduced air consumption.” Key features include:

· Re-engineered fluid path increases flow rates up to 54%.· . Exact FIT from bolt-down footprint to inlet and discharge connection heights. · Fewer fasteners and easy accessibility for faster assembly/disassembly and shorter downtime. · Labour-saving manifold flexibility to assists in tight fitting installations. · Fast ROI, reduced installation costs without repiping. · Bolted configurations for superior product containment with NPT or BSP threads or ANSI or DIN flanges. · Exception performance for abrasive applications. · Higher flow rates translate into increased productivity and profitability. · Longest MTBR for lower maintenance. · Available with the Wilden Pro-Flo X of Pro-Flo SHIFT air distribution

PROCESS INDUSTRY INFORMER January - February 2015

ANALYSERS MIRA – NEW HANDHELD RAMAN SPECTROMETERS WITH REVOLUTIONARY ORS TECHNOLOGY Metrohm is pleased to introduce the Metrohm Instant Raman Analysers (Mira). The Mira spectrometers are the only handheld Raman analysers available with Orbital-Raster-Scan (ORS) technology. This highly reproducible averaging technique extends the scope of possible samples to any kind of heterogeneous and sensitive materials. The Mira analysers are handheld, high-performance spectrometers for rapid, non-destructive analysis of chemical and pharmaceutical samples, be they liquid or solid. Barely larger than a smartphone, the Mira analysers may be used anywhere: in the warehouse, in the process, in the field, and – of course – in the laboratory. The user benefits of Mira in a nutshell: • Light, compact, and handy – single-handed operation • Instantly ready to use in any place • Fast and reliable real-time results – no sample preparation required • Point-and-shoot identification – close-range measurements through packaging of different thicknesses (including plastic and amber glass) • Orbital-Raster-Scan technology – reproducible measurements, even of temperature sensitive and heterogeneous samples • Safe – the Basic Package can be used without any additional safety measures required(laser protection class 1) • Maximum flexibility – comprehensive spectral libraries • Robust and maintenance-free • Wide Range of applications – from temperature sensitive samples to any kind fluorescent samples • Automatic calibration in critical applications

For more information contact Metrohm U.K. Ltd, Runcorn, Cheshire Tel: 01928 579600 E-mail: info@metrohm.co.uk Information about Metrohm’s strategic alliance with SnRI or technical information about the MIRA visit : www.metrohm.co.uk

LPW TECHNOLOGY INVESTS IN MALVERN SYSTEMS TO MEASURE PERFORMANCEDEFINING PROPERTIES OF AM POWDERS Particle characterization systems from Malvern Instruments are helping LPW Technology, a UK-based global supplier of metal powders, to provide certified powders for additive manufacturing (AM) applications in the aerospace, automotive and biomedical sectors. Malvern’s Mastersizer 3000 laser diffraction particle size analyzer delivers rapid, routine particle size measurement for all the powders that LPW supplies. Morphologi G3, a microscopy-based automated image analysis system, enables quick measurement of particle size and shape parameters. “Malvern’s reputation and local presence in the UK were key factors when it came to buying the Mastersizer 3000,” said Dr. Robert Deffley, Research and Development Manager at LPW Technology Ltd. “We use software capabilities to apply and demonstrate the analytical rigor required for certification of our powders. The performance of the dry dispersion system allows us to measure powders in the dry state. This makes measurement and analysis fast, easy and efficient so we achieve excellent analytical productivity.”

For more information contact Malvern Instruments Ltd, Tel: +44 (0) 1684 892456; Fax: +44 (0) 1684 892789 E-mail: salesinfo@malvern.com Web: www.malvern.com

METTLER TOLEDO Launches the M100 2-Wire, Head Mount Transmitter for Hazardous Area Applications in Process Analytics METTLER TOLEDO Process Analytics has launched the M100, a 2-wire transmitter for liquid analytics in the pharmaceutical and chemical industries. The M100 is a unique transmitter for analytical measurement based on a compact head mount design without a local interface. It offers global approvals for hazardous area use and combines multi-parameter measurement with remote access to predictive sensor diagnostic tools over the HART communication protocol. The transmitter covers pH/ORP, dissolved oxygen and conductivity measurements. The possibility of remote access to sensor diagnostics over HART or the transmitter’s second analogue output, increases the communication capability and helps to avoid unplanned shutdowns. This leads to improved productivity and a reduction in operating costs. In addition, the M100 2-wire series includes the connection of METTLER TOLEDO’s digital ISM sensors. Intelligent Sensor Management (ISM®) is the key: This leap forward in field instrumentation is possible because ISM enables sensors to be calibrated away from the process in a convenient location such as a workshop, and quickly swapped in the field. This feature, called Plug and Measure, means measurement point start up is fast and error-free and does not require a local interface. The support of all major asset management tools such as AMS (Emerson), PDM (Siemens) and the open standard FDT/DTM ensures the widest compatibility and remote access to sensor diagnostics. Installation in hazardous area: The new 2-wire transmitter series is designed for use throughout the chemical industries and therefore has approvals based on explosion proof/flameproof and intrinsically safe protection for installation in hazardous areas.

For more information contact Mettler Toledo Ltd, Beaumont Leys, Leicester More information is available at: http://www.mt.com/m100 Watch an online webinar: www.mt.com/uk-M100-webinar Call: 0116 234 5095 Email: enquire.mtuk@mt.com

NEW MASTERSIZER 3000 HYDRO SV REDUCES SAMPLE VOLUME FOR PARTICLE SIZE ANALYSIS TO JUST A FEW MILLILITERS The new Mastersizer 3000 Hydro SV small volume liquid dispersion unit delivers reliable particle size measurement using just a few milligrams of sample. Particle size is a performance-defining parameter for many industrial products. The ability to measure small samples sizes becomes crucial when sample availability prevents the use of larger amounts of material. This is especially true during early stage product development, for example. By minimizing sample and dispersant use the Hydro SV also reduces the development, purchase and disposal costs associated with routine analysis. Efficient sample dispersion ensures that the particle size data measured by a laser diffraction analyzer are both representative and relevant. Launching on the third anniversary of the Mastersizer 3000, the Hydro SV is a simple, easy to use wet dispersion accessory. Hydro SV has been developed with the same intense focus on ease of use that underpins every element of the Mastersizer 3000 and enables all users, even those primarily familiar with dry measurement, to access the benefits that wet dispersion offers. These include the ability to recover the sample following analysis.

For more information on Hydro SV contact Malvern Instruments Ltd, Malvern, Worcs. Tel: +44 (0) 1684 892456 Fax: +44 (0) 1684 892789, E-mail: salesinfo@malvern.com, register to view Malvern’s launch web event at http://www.malvern.com/msevent or visitwww. malvern.com.

PROCESS INDUSTRY INFORMER January - February 2015

FEATURE

Manufacturers use asset optimisation to extract value For manufacturers working in a competitive global market environment, product price point is an imperative. And yet, the intelligent optimisation of assets, which can have a major impact on reducing production costs, is an area often overlooked. Aureconâ&#x20AC;&#x2122;s Head of Asset Management, Clive Ross, says manufacturers can enhance their success by creating a proactive asset management culture and taking a more sophisticated approach to maintenance that optimises asset performance and value. Hardwired in the psyche of manufacturers is the constant vigilance on total production cost. Sometimes, deferring or minimising maintenance results in cost savings. However, these incremental savings are typically false economy. A strategic asset management approach can create far greater value for the business. Focusing on asset uptime availability and equipment peak operating efficiencies yields substantially more value than driving maintenance costs down. This value is at times less visible and tangible without a detailed knowledge of asset value creation. Over the past two decades, the world has experienced an unprecedented demand for raw materials products and processed goods. As a result, manufacturing plant, production facilities and many ancillary infrastructure assets have been pushed to limits well beyond their initial design specifications. Our urgency to get more from less has brought many facilities to breaking point. Maintenance of the asset, a cost not directly linked to productivity or revenue generation, is often deferred or worse, ignored. Organisations will take a range of approaches to asset management with varying results: 1. Measured and controlled asset debottlenecking exercises and asset efficiency design upgrades through sustainable work capital programmes. These programmes generally result in engineering standard and legislative compliant designs and production optimised assets that will continue to deliver enhanced production throughputs in future years. 2. Fast track projects that deliver immediate returns and enable the asset owners to capitalise on the demand experienced during these years. While these programmes generally comply with the engineering design and legislative requirements, many are not optimised, and deliver suboptimal performance and efficiency. 3. Increased production throughputs via existing assets, reducing access to plant for planned preventive maintenance and managing the higher rate of asset degradation through increasing breakdown maintenance. This short term action solution results in overloading, higher wear out rates and component stresses, and increased breakdowns, which ultimately leads to an increased forward maintenance log. While the development of comprehensive asset life cycle management plans and strategies may have been considered in tactic 1 above, it is unlikely they were in tactics 2 and 3. The primary consideration at the time would have been to produce as many tonnes of product as soon as physically possible. As a result, the performance of these assets is likely to be suboptimal. This operating environment created a culture resulting in an outsourced maintenance cycle. Where maintenance is an activity focussed on only restoring or maintaining functional capability in plant that has been lost through errors in the engineering, project delivery and operations cycle. Figure 1 explains this.

on critical assets to perform an optimum level of maintenance work has proved to reduce production costs.

Figure 2: Balancing costs of maintenance and asset unreliability As manufacturers move to a strategy of higher levels of automation to further reduce dependency on labour costs, this focus on intelligently optimising the asset becomes even more important. The solution, as illustrated by Figure 3, lies in working to create a proactive culture, which drives asset management improvement plans that guide the engineering, project delivery and operations activities in the plant, process, product and people, to eliminate, prevent and control functional failures and extract greater value from existing investments.

Figure 3: Implementing cultural improvement to drive value The solution also lies in looking at the facility, its processes and its equipment with a forensic engineering lens, identifying equipment with the highest run time hours or lowest availability rating, to find the weak point in the production chain. This type of analysis roots out the highest likely causes for breakdowns and production interruptions and eliminates them by implementing improvement plans and actions for execution by their maintenance practitioners. This entire process is even further enhanced if strategic asset management is embedded at the start of a project. If followed from the design stage, this approach incorporates asset reliability and maintainability to eliminate these as a source of breakdowns and production interruptions prior to commissioning future assets. It ensures equipment and processes are designed and selected with their long term operability and value adding potential in mind. Figure 1: Product loss cycle â&#x20AC;&#x201C; The contribution of maintenance to losses Product price point is vital for manufacturers working in a competitive global market. Strategic asset management enables an organisation to find the optimum level of asset management and maintenance activity to meet their organisational plans as depicted in figure 2. Focussing the appropriate resources

PROCESS INDUSTRY INFORMER January - February 2015

About Clive Ross

Clive Ross is Aureconâ&#x20AC;&#x2122;s Head of Asset Management. He has over 30 years of asset management experience, with an expert understanding of best practice asset management, operations and maintenance, and engineering, procurement and construction services. You can contact Clive at clive.ross@aurecongroup.com.

FEATURE

LOOK TO THE SEAS FOR EFFECTIVE STORM TANK CLEANING Ivan Zytynski - Director of Lewes based BETE Ltd considers the options and springs a surprise…

As climate change drives more extreme weather the occurrences of waste water and sewage systems being unable to cope with excess water is increasing. As a result, storm overfill tanks are being used more and more frequently as is the need to fill and empty them more regularly. It’s not surprising then that more storm tanks are being commissioned into the UK’s water system and the situation is acknowledged as a current “hot topic” of focus for the environment agency with attention being directed at reducing odour pollution. This means that storm tanks are being used more heavily at exactly the same time as the environment agency is insisting that any foul smelling residues need to be cleaned more thoroughly.

What are the current methods of cleaning?

Tipping buckets Large buckets of water are emptied into the tank from one end creating a wave that will remove debris from the bottom of the tank. Eductor / swirl systems These systems use a large educator nozzle to create a whirlpool as the tanks empty in an attempt to dislodged debris. Manual cleaning Operators enter the tank with a pressure washer. Impingement cleaners A rotating nozzle head operates through an automated cleaning cycle where powerful cleaning jets target each part of the tank.

The case for impingement cleaning

Impingement cleaning is by far the most water efficient method of cleaning a tank. Although not new this technology has been deployed for cleaning all types of tanks and process vessels for decades. Most large chemical, petrochemical and food processing plants will have impingement tank cleaners as part of their vessel cleaning systems. This technology has been used with mixed results for cleaning storm tanks but often runs into problems for the following three reasons: Scale The size of tanks in the chemical and food industries are generally far smaller than storm tanks. A large process vessel may be 7 or 8 meters in diameter but that is very small for a storm tank. Whilst some of the larger petrochemical storage tanks are comparable to the scale of storm tanks the cleaning systems generally deployed in in the process industry are for cleaning much smaller areas. Environment Unlike the impingement cleaners deployed in the process industries, storm tank cleaning systems are not situated in a clean factory or maintained by a team of process engineers. Instead they are left in a cold, dirty environments exposed to the elements which are largely unmanned most of the year. Cleaning fluid quality When cleaning chemical and food tanks, a reliable supply of clean filtered water is normally assured whereas storm tank cleaning systems will often operate on final effluent with variable particulate content. This puts a significant strain on a cleaning system that is not designed to handle such poor quality cleaning fluids.

What this means

Simply taking a process tank cleaner out of its ‘normal’ environment and deploying it in a storm tank will not work. Some models on the market will have sufficient reach and power to clean large storm tanks but the tough environment and poor quality cleaning fluid quickly results in the machines clogging and failing. Typically these machines have an exposed gear system that can become gummed up with algae, slit or smaller debris which can find its way into the supply water. On the one hand we have a technology that can deliver more effective cleaning for less water and less cost, but conversely there are reliability issues when it is deployed.

So what is the solution?

A solution comes from a seemingly unlikely source but it is one that after a little reflection is entirely logical. In the shipping industry and in particular cleaning oil tankers, it is an essential requirement. Crude oil tends to form thick sticky layers of waxy residue over time and this impedes the carrying capacity of the tanker. The problem is that oil residue is very difficult to clean and using water to clean these tankers creates a massive amount of oil

/ water mix which needs to be filtered and disposed of. Furthermore, water does not actually clean oil residue off very well (water and oil classically don’t mix!). The solution to this problem is to actually use crude oil as the cleaning fluid. Raw oil is put through high powered rotary jet cleaning systems to dislodge residue in the tanker to give it a thorough clean. The tank is mostly emptied and then the remaining oil sludge / mud is circulated through the tank cleaning system. The very large solids removed are then filtered out but the rest of the sludge is passed through the impingement tank cleaner. Clearly these tank cleaners need to be far more powerful than their counterparts deployed for example, in the food industry. Also, these tank cleaning systems need to remain in place unused for months at a time often submerged in the crude oil in the tank. When not covered with crude oil they are exposed to the salty, corrosive marine environment. Cold, wet and exposed to the elements and very rarely even seen by anyone, let alone maintained, this environment may be starting to sound familiar. This type of tank cleaning technology has been deployed by many of the world’s leading shipping and oil companies for over 40 years and is acknowledged as tried and tested and therefore could be applied to the challenges of cleaning storm tanks.

How does it work?

The principles of impingement jet cleaning are exactly the same as those in the food, pharmaceutical and chemical industries. Rotary jets spin through a set cleaning cycle directed to each part of the tank, blasting away residue as the jet “explodes” outwards on impact. However, there are key differences in the design of oil tanker cleaners compared to process tank cleaners. Sealed gear box One of the most important design features is the presence of a sealed greased gearbox within the machine. Process industry tank cleaners are normally lubricated by the cleaning fluid with an exposed gear system. This is sensible in hygienic applications where contamination from lubricants is a considerable concern. In the oil tanker cleaning applications such contamination concerns are less important so a sealed lubricated gear box can be used. This then allows far more particulate to be passed through the tank cleaner with little or no risk of clogging the cleaner. Tough design When designing rotary tank cleaners used in process vessels the focus is on creating a hygienic and self-cleaning machine. It needs to be polished and free from any traps and crevices where contaminants or bacteria occur. This inevitably means some sacrifices need to be made in ruggedness. In contrast ship tank cleaners have none of these concerns and so have been designed to be extraordinarily tough and this rugged design is perfect for use in cleaning storm tanks Large nozzles The big tanker cleaners will have 14, 16 or even 20 mm nozzles which can throw a cleaning jet over 25 meters and this means a cleaning radius of 25 meters, so a 50 meter diameter tank could be cleaned with a single machine. Rough clean and opposed to precision When cleaning a crude oil tanker it does not need to be spotless, as long as the vast majority of the residue is removed, this is sufficient. In contrast chemical and food tanks need to be completely cleaned so the cleaning patterns of process tank cleaners tend to be tighter with more rotations and more water. This would be wasteful in storm tanks because they simply do not need to be that clean. The level of cleaning required is very similar to that of oil tankers because storm tanks don’t need to be spotless they just need to have enough residue removed to ensure odour problems don’t occur.

Conclusions

The redeployment of tanker cleaning technology to solve the problems of cleaning storm tanks is entirely logical. The environments that the ship cleaners need to operate in are probably tougher than anything they will be exposed to in storm tanks. They can handle dirty, particle contaminated cleaning fluids easily, they are relatively cheap to install and give by far the best cleaning of any method (with the possible exception of manned entry cleaning). In short, tanker cleaning technology represents a potential solution to storm tank cleaning problems.

PROCESS INDUSTRY INFORMER January - February 2015

MAINTENANCE ELIMINATING COSTLY PROCESS DOWNTIME DURING MAINTENANCE SCHEDULES Test-Tel™ is a non-invasive tool to check the status of a rupture disc device in situ

To ensure all plant processes remain safe and continue to be efficient, a regular maintenance schedule is a key part of every site’s operation. While rupture disc devices are essentially low maintenance, they still form part of this schedule. A traditional maintenance check for a rupture disc device requires the plant to be fully de-pressurised and for processes to be completely stopped, while each disc is removed from its holder and inspected. This system downtime is costing companies thousands in lost production during every maintenance check, particularly in lucrative industries like the Oil and Gas sector. Significant time and cost savings are now being realised by Elfab customers through the use it’s low-cost, portable, ATEX-approved Test-Tel™ tool. Offering a simple and cost-effective means of checking the status of both the rupture disc and the associated burst detection system, this part of the maintenance schedule can be completed without having to shut down the entire process. The Test-Tel™ tool can also be used to confirm correct installation of the rupture disc device and its associated detection system.

For more information contact Elfab Ltd, North Shields, Tyne & Wear Tel: +44 (0)191 293 1234 Fax: +44 (0)191 293 1200 E-mail: pr@elfab.com Web: www.elfab.com

AIR COMPRESSORS

Separator LinesF

Processing Algae

NEW SEPARATOR LINES FOR PROCESSING ALGAE – PRIME AND PRO GEA Westfalia Separator has launched a new separator generation for the concentration of algae: algaeprime and algaepro. The prime series with its capacity range from 100 to 23,000 l/h is ideal for research and development but also for start-up companies. It offers high flexibility for processing all kinds of algae with all possible recipes and features and easy and simple operation, high capacities and separation efficiency along with maximum scale-up safety. The algaepro series is the best solution for processing algae on full industrial scale, for capacity ranges of 20,000 to 80,000 l/h. The separator can be customized right down to the smallest detail to optimally fit process and demands. Highlights are the new 2-in1 ejection system for a fast and easy change of algae types as well as the integrated directdrive which you can choose for maximum energy efficiency. Space saving, low noise design. Available in foodgrade design. The algaeprime series are automatic discharge and cleaning; no manual intervention anymore so processes stay closed, clean and safe.

For more information contact GEA Mechanical Equipment UK Ltd, Tel: 01908 576512 Fax: 08708 305515 Email: Darren.Lenton@gea.com Website: www.gea.com

WATER TREATMENT NEW PRESSURISED DEAERATOR SYSTEM CUTS BOILERHOUSE ENERGY AND OPERATING COSTS

The absolutely oil-free, piston compressor series from BOGE provides maximum air delivery with minimum power consumption and footprint Piston compressors have been given a fresh face with the new oil-free PO series from BOGE. Compact, energy efficient, durable, low maintenance and highly economical to use, the complete absence of oil in the series guarantees uncontaminated compressed air. The modular format of the compressor range is designed for flexibility. With an impressive 28 variants in series, including the option of a twin compressor units, dryers and air receivers, customers can add the appropriate component to suit their application. The guarantee of oil-free compressed air is essential for a number of sectors and applications, where the provision of compressed air with high purity is a critical factor. Widely used in medical environments this latest technology will now benefit a multitude of other sectors and industries, including paint, food processing and water treatment. The PO Series is available as both single-stage (10 bar) and two-stage (15 bar). With a slim-line design, the series also provides a smaller footprint saving on space, but without any compromise on functionality or features.

Spirax Sarco has launched a pressurised deaerator system that reduces the dissolved oxygen content of boiler feedwater to virtually nil without chemical treatment. This enables steam plant operators to reduce energy consumption, save water treatment costs, increase productivity and meet BG01 “Guidance on Safe Operation of Boilers”. With a pressurised deaerator system, feedwater can be heated to greater than 100°C without boiling off to steam, removing virtually all of the dissolved gases without the need for water treatment chemicals. Oxygen levels in the feedwater are reduced to 0.02 mg/litre of water (20 parts per billion) – 1,000 times less than can be achieved with a conventional atmospheric deaerator system. Removal of oxygen is important because untreated boiler water would corrode the boiler and pipework, increasing maintenance and repair costs and reducing productivity. Spirax Sarco can provide all the ancillaries required for the control and instrumentation of the pressurised deaerator, as well as full training and ongoing support.

For further information contact BOGE Compressors Ltd. Tel: +44 14 84-719921 Fax: +44 (0) 1484 712516 E-mail: m.heeley@boge.com Web: www.boge.co.uk

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

BOGE BREATHES NEW LIFE INTO OIL-FREE PISTON AIR COMPRESSORS

PROCESS INDUSTRY INFORMER January - February 2015

FEATURE

Heating & cooling systems – the little things that count

Those within the processing industries can often overlook the impact that heat transfer fluids used within heating and cooling systems can have upon their systems. System corrosion can cause issues for both installers and end users. Due to the buildup of bacteria and scaling and resulting issues such as system leaks and failures, poor quality heat transfer fluids can have a negative impact on the longevity and reliability of systems. Andrew Murray, head of sales and marketing at Kilfrost’s Speciality Fluids Division, reviews things to consider when purchasing cooling and heating systems, the growing importance of environmental considerations and the need for improved industry standards. Impact of heat transfer fluids on the processing industries

Corrosion, bacteria and scaling have the potential to impact the life span and reliability of systems considerably. Corrosion can result in a greater need for maintenance and repairs, leading to downtime and reductions in productivity. Glycol itself is not particularly corrosive, however when mixed with water to achieve frost protection, corrosion can become an issue. As a result, it is important to choose a heat transfer fluid that has advanced glycol inhibitors. Inhibited glycol-based heat transfer fluids mixed with water of a sufficient quality can limit corrosion within a system. Despite the relatively low initial cost to the customer, a heat transfer fluid can quickly become the most expensive part of a cooling or heating system. Using a high quality fluid maximises a customer’s upfront investment in systems and can also reduce energy waste and extend the life of capital equipment. Downtime, outages and the failure of heating or cooling systems can be extremely damaging within the processing industries. In these industries, time is money so system reliability is a key priority. Downtime needs to be kept to a minimum to avoid damage to productivity, loss of profits and resulting risks to a company’s reputation. To ensure the safety and longevity of products at breweries, for example, they must be stored and processed at the correct temperature, so that product quality is maintained. This is relevant across all food and beverage industries, where the safety of the end user cannot be compromised, meaning there is a vital requirement for effective and reliable cooling and refrigeration systems. In the pharmaceutical and chemical industries, processes need to be carefully temperature controlled to meet stringent regulatory requirements.

Industry standards

When system manufacturers and installers are tasked with specifying fluids, they will look at the thermal capacity, viscosity and density of a fluid. Ultimately, they are looking for the most efficient fluid. The thicker a fluid is, the harder it is to pump round a system and therefore a larger pump is needed. This leads to a more expensive pump, higher running costs and greater energy use. As we move forward, thinner fluids will help improve pump efficiency, requiring less energy and smaller, more cost effective pumps. As well as considering which heat transfer fluids are used, it is important that end users abide by an effective maintenance regime, checking heat transfer fluids regularly in heating and cooling systems. Within the processing industries, there is a lack of formal guidance on the maintenance needed within systems. Fluids need to be checked for pressure and the presence of any foreign bodies which may indicate the breaking down of the fluid. The conditions under which fluids are transferred, stored, heated and applied can all have an impact on the fluid’s performance. An international standard known as the ASTM D 1384 corrosion is playing an increasingly important role within the industry. All Kilfrost’s fluids adhere to this standard, but the standard has not been embraced by everyone in the industry and currently remains voluntary. Greater adoption of the standard is needed, as any fluid can claim to contain corrosion inhibitors but without the presence of a mandatory test standard, it is difficult to gauge the extent of the protection. The test works by assessing the impact of heat transfer fluids on a system. This involves analysing metals used in heat transfer systems, such as aluminium, iron, steel, brass, solder and copper after they have been immersed in an inhibited glycol/water mixture. These tests are carried out over a period of

four weeks under stringent conditions, at the end of that time the extent of any corrosion is determined by the weight of each metal. This gives system installers greater confidence by demonstrating how the fluid minimises the on-set of corrosion.

Environmental considerations

Many companies in the processing industries are looking to lead the way in their sector, by managing their impact on the environment and choosing products that will reduce their carbon footprint. Using a sustainable glycol in the manufacture of heat transfer fluids is set to have a dramatic impacton the carbon footprint and greenhouse gas emissions resulting from the processing industries. It is possible to develop heat transfer fluids using corn-derived inhibited glycol, which is sustainable and biodegradable with low toxicity levels. This sees a significant reduction in carbon footprint, consuming 40 per cent less energy, from “cradle-to-gate” during the production of the base fluid. Greenhouse gas emissions are also reduced by more than 40 per cent versus petroleum based propylene glycol fluids. Using non-toxic fluids is imperative in industries such as food and drink processing in order to safeguard the health of the end consumers, as well as staff working on the production and processing line. It is also possible to use a bio-derived PDO based concentrate fluid which provides an alternative to monopropylene glycol based fluids. The use of this type of bio-PDO based fluid helps to minimise the risk to the environment, as well as those that may be exposed to the fluid. It also improves the longevity of the heating system thanks to its higher resistance to degradation.

Moving forwards

As we move forward, companies will continue to look for solutions that offer improved heating and cooling efficiency and enhance their low carbon footprint credentials. Manufacturers and system installers will be striving to provide solutions that are reliable and that offer high performance levels. C o n s e q u e n t l y, the focus of heat transfer fluid providers will be to deliver innovative, more efficient, greener fluids that enable the heating and cooling industry to achieve optimum results, reducing corrosion, energy waste and improving the life span of systems.

PROCESS INDUSTRY INFORMER January - February 2015

SHA PA N

Solids Handling & Processing Supplement

January - February 2015

PRUDENT PROCUREMENT By Gus Bishop – Solids Handling & Processing Association

In it together... We are all customers at times, whether as mere consumers or maybe as professional industrial buyers with challenging technical aspirations and even more challenging budgets. We all have increasingly ambitious expectations of the “shopping experience”. Gone are the days of the surly shopkeeper for whom the customer was an intrusive irritation. The sheer range of goods in all fields is so vast that we cannot be universal experts; we expect to be led honestly and economically as we narrow down both needs and available options. We expect patience, the opportunity to modify our desires (change our minds...) and the timescale and budget for intended purchases.

A step further

What more, therefore, should a professional industrial buyer demand when on business? For a start, all of the above. However, unlike the typical personal shopper, he or she will probably be using someone else’s money to procure goods and services that must satisfy the employer’s need – for a long time. The purchaser needs total confidence in the chosen vendor or supplier, who must commit to long term support. The procurement officer is a shopper with an agenda upon which his or her livelihood may well depend. So, suppliers shoulder a great burden of responsibility and must enter into a high quality reliable partnership with the buyer. But what about the process machinery supplied? In its own way it is both customer and supplier. To operate effectively it must receive properly prepared material in the correct quantity and condition. Whether the equipment in question is used to convey or grade or mix the material, its working parameters must be met. The equipment then supplies its finished material to the next stage. The receiving machinery will expect it delivered in the right quantity and condition – and so on to the very end, perhaps to bagging, palletising and outloading. Good suppliers will see their offer from the customer’s viewpoint. The purchaser really wants to feel that the best choice has been made; no nagging doubts, sleepless nights or awkward edgy meetings with the boss or indeed, colleagues. “Where on earth did you buy this ****?” is not a question the purchasing professional will want to be asked.

The easy way is never easy

The economy is recovering, but the path is neither broad nor straight. This last year has seen many pitfalls, with stalling export markets, slackening pace of development in major prospective markets such as China, abrupt stock exchange fluctuations, political jitters on many fronts, all hitting confidence amongst investors: the list goes on. Recently there have been further rumblings within the Eurozone, with visions of deflation, stagnation and generally difficult trading conditions. The wildly fluctuating oil prices, down in January by more than 50% have been seen as both good and bad news depending upon the viewpoint. However, business continues, indeed impressively buoyantly in some sectors and purchasers continue to purchase, albeit with added WESTINGHOUSE vigilance and care.

the Association’s inception in 1981. The SHAPA mission statement includes such aims as reducing capital expenditure, cutting operating costs and increasing product reliability. Technical papers published and cogent seminars held as and when the need arises arm members with up to date, high quality tools to assist their customers to achieve these aims. Again, members benefit from assistance with export markets, with trade missions and oversees contacts. Because of the huge range of equipment and services that are required within our industries, many members find themselves suppliers to or customers of other members, sometimes both concurrently. Quarterly General Meetings have become an ideal forum for exchange of ideas and commercial networking as well as sources of good intelligence from the regular high profile invited speakers. For example, at the recent January meeting a number of members delivered presentations on various aspects of ATEX compliance.

Very useful information

The seventh annual Digital Marketing Workshop is scheduled for 11th March. Originating as a “one-off” event, it has returned year after year by popular demand – its relevance and importance increasing steadily. Subjects professionally explored include what’s new in Google, selling on LinkedIn, a web clinic and an email masterclass, all to offer the best opportunities in digital marketing. Whilst this is a members only event, a browse through the recently updated website at www.shapa. co.uk will reveal a plethora of useful technical, commercial and legislative information, open to all. There are now twenty Technical Papers on subjects ranging from sources of useful information, ATEX legislation, powder characterisation, various processes and equipment to directives old and new. In addition there are now six Application Sheets also freely available, as well as technical advice at the click of a mouse upon request. For suppliers of solids handling machinery and services, the benefits of SHAPA membership are compelling at any price – our persistently low annual fee puts this beyond doubt! For project managers, process engineers and procurement professionals with quality processing projects to develop, install or simply to maintain, then the SHAPA website Equipment Finder at www.shapa.co.uk will offer a secure starting point, with all companies displayed there able to benefit from decades of SHAPA accumulated knowledge, experience and insight.

Enjoy the following pages.

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

SHAPA commitment

Nobody takes the supply of engineering products more seriously than the 100+ strong member companies. For well over 30 years the Association has been developing a knowledge and skill base to assist the members – key manufacturers and suppliers of burden they have been eager to lighten on a continuous basis. As you scan the pages of this SHAPA supplement it will become clear that SHAPA member companies number amongst the most knowledgeable and technically capable in all aspects of solids material handling and processing. Furthermore, the membership also includes advisory and research bodies involved in continuously refining experimental data on material flow and characterisation. Many companies have been part of the SHAPA family for many years, with some founder member companies involved since

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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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

We expect the seller to “know their stuff” and have information and samples readily available. We expect all goods to be delivered on time, to actually work as promised and be accompanied by appropriate guarantees and service packages, all with clearly defined prices. If optional extras are offered, we assume that they will be appropriate to our needs and not mere costly embellishments. In short we as customers expect a lot – and we take it for granted that our wishes will be fulfilled to the letter.

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www.dmnwestinghouse.co.uk

PROCESS INDUSTRY INFORMER January - February 2015 - SHAPA Supplement

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Solids Handling Industry Awards The Solids Handling & Processing Association (SHAPA) in association with Solids & Bulk Handling magazine are delighted to announce that these new awards to promote success and achievement across our collective industries, will be open to all companies registered in UK, whether or not SHAPA members, who are directly involved in the solids handling and processing industry. This exciting opportunity will comprise awards in three categories: the Export Award, the Innovation Award and the SHAPA Company of the Year Award.Full details about how to enter your company and applicable conditions are available on the Association website at www. shapa.co.uk, but please act quickly â&#x20AC;&#x201C; the closing date for all entries is 28th February 2015 Briefly, the Export Award will go to the company who shows the best achievement relative to their size, with export sales either in one market or across several markets. Imaginitive and novel methods that have brought good results will be considered within the assessment of this award. The Innovation Award will be made to the company or collaborative organisations who have introduced significant new products or services, or valuable modifications that help drive the industry to further success. SHAPA will be looking for truly ingenious thinking, applied with flair. Finally, the SHAPA Company of the Year will be that organisation considered to have achieved the most in any category, relative to their size, by promoting best practice, setting All winners may use their award for their own marketing and publicity purposes as they see fit, provided that they quote the year of attainment. Awards will be announced and presented at the awards ceremony to be held on 14th April 2015. Please contact SHAPA now either via www. shapa.co.uk or by email to info@shapa.co.uk. Remember â&#x20AC;&#x201C; closing date for all entries will be 28th February.

Prevention Venting Isolation Suppression

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YEARS

FOR ALL YOUR EXPLOSION SAFETY NEEDS www.explosionhazards.com +44 (0)1925 755153

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PROCESS INDUSTRY INFORMER January - February 2015 - SHAPA Supplement

Particulate Flow Rates from Vessels in Process Plants By Richard J Farnish, CEng MIMechE, Consultant Engineer, The Wolfson Centre for Bulk Solids Handling Technology

For many plants the consistency and repeatability of discharge or feed rates into a process are critical to the efficiency of the next process step. Inevitably this feeds into not only the quality of the final product but also the overall profitability of the exercise. A feeder exists to moderate the discharge rate achievable from a given bulk solids exiting a vessel into a process. However, where flow limitations occur or transfer rates are unreliable, many operators tend to resort to the time honoured approach of beating the offending vessel into submission. Typically, despite short term intimidation of the equipment to an operating condition, unacceptable behaviour is often lurking just around the corner and soon returns. The mistake made by operators and engineers tasked with ‘sorting out’ is that where irregular flow is occurring the true source of the problem is often not immediately obvious. The reality of the situation is typically that it is the interaction of the vessel or chute with the feeder/flow control device. A common cause of flow rate irregularity is the flow channel that is propagated through the vessel from the flow control device. However even in situations where a vessel discharges in gravity flow the presence of geometries that are inappropriate for the process requirement is also a common issue. If consistent and reliable flow is required (particularly where a high accuracy feed is sought) it is critical that during operation regions of non-flowing are minimised (or preferably eliminated) through careful equipment design with these objectives in mind. Examples of Fig.1: Preferential where non-flowing regions of material might develop draw down on to a include, above fixed capacity feeders (i.e. constant pitch screws, rotary valves), within vessels (i.e. core screw flow or poorly interfaced mass flow bins), through poor feeder interface design (i.e. direct onto vibratory trays, belts or drag link conveyors), or where gravity flow is throttled using slide gates, butterfly or iris valves. As you can see, there is plenty of scope for error. In one recent industrial project pack weights were found to be varying by +/-140g on a 25kg sack fill, resulting in substantial losses through ‘give-away’ on a plant operating 24/7 over a year. At an entirely different scale, a discharge accuracy of +/-2.5te on Fig. 2: Extended non flowing material a 30te fill was occurring at wagon in chute loading operation. In both cases the root cause was similar in that the flow channel that was established during discharge was encouraged to propagate through regions of non-moving material which were supported from the flow control device. Relatively simple modifications (which could have been readily implemented into the original construction) resulted in an improvement to +/45g in the first example and +/-500kg in the second example. The common mistake made when designing or modifying systems through which bulk materials will flow is to make the assumption that provided the granule (or powder) flows from the equipment, then all is well. The reality is that most process problems relating to bulk particulates originate from a failure to take time to understand their bulk characteristics. Most people that deal with bulk particulates will be Fig. 3: Flow against non of the opinion that cohesive (poorly flowing) materials are very difficult to work with – moving product

however, this is usually based on the usually frustrating experiences gained from the use of standard equipment types in conjunction with these types of powders. The reality is that, following characterisation for flow, such powders can be handled very successfully provided that the equipment with which they are used incorporates geometry, interfacing and feeder specifications that are appropriate. By contrast many believe that free flowing materials are much easier to work with – and to a certain extent they’d be correct. However, the presence of constrained flow channels can give rise to unacceptable flow variability even for ‘easy’ to handle bulk materials. The key to controllable and efficient discharge of free flow or cohesive powders lies in the incorporation of an understanding of the bulk characteristics at an early stage in projects to modify or purchase new equipment.

Independent expertise: providing cost-effective solutions to industrial problems

The Wolfson Centre for Bulk Solids Handling Technology is internationally recognised for its expertise in fields associated with bulk particulate handling and in the science and practical application of technologies to deliver improved process efficiencies. Our mission is to help industry to get powders and bulk materials to behave predictably through processes. Industry sectors benefiting from our services range widely and include power generation, chemicals, pharmaceuticals, foods, plastics, paper, minerals and cosmetics. Our clients are predominantly based in the UK, although many European and overseas companies take advantage of the independent and bespoke nature of our work. We have developed our portfolio of services over nearly four decades of interaction with industry, trade associations and professional bodies. We offer consultancy services to industry, conduct industrially focused research related to bulk solids handling issues and offer specialist short courses targeted at industry professionals. For information about these courses please use this link. http://www2.gre.ac.uk. If you have a problem with your plant or process, we have the knowledge and experience to provide cost effective answers that you can rely on. The centre is situated at the University of Greenwich’s Medway Campus, where we are part of the School of Engineering. Our location offers excellent transport links within the UK and EU enabling us to provide a prompt and flexible response to site visit requests and client meetings. Our experts have between them over one hundred man-years of experience of solving problems in the flow and processing of powders, granules and lump materials, in all industries from pharmaceuticals and food to mining and chemicals; from biomass waste and recycling to household goods and pet foods. They concentrate on the needs of the industry and share their knowledge through the provision of technical research papers, articles and editorials through the media and at conference and exhibitions where they often present papers or hold workshops. Our industrial-scale pilot plant is available to test a processing step, or mock up a whole handling process or logistics chain, at full scale or near full scale. This can be used to find and solve the problems off-line, then when you transfer the same process or material to your own or your customers’ plant, you can be confident it will work!

PROCESS INDUSTRY INFORMER January - February 2015 - SHAPA Supplement

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Accurate Feeding and Discharging The GYRO EX Bin Activating Feeder/Discharger is a bin discharger and an accurate feeder, with up to a 100 to 1 turn down ratio, all in one piece of equipment. It produces a controlled gyratory motion to positively withdraw granular materials from bins, storage silos and hoppers. The GYRO EX Bin Activating Feeder/Discharger uses a radial force to create a uniform circular motion on both the upper activation cone and the lower discharge cone. The stored material load is completely supported by the upper bin activation cone, which has a discharge angle less than the discharge cone. This means all material feeds faster from the lower discharge cone than from the upper bin activation cone, preventing the head load from compacting material in the lower cone as sometimes seen in traditional vibrating bin dischargers.

Get Down With Hosokawa Micron Ltd - Leaders in Size Reduction

For more information contact Dynamic Air Ltd, Milton Keynes, Buckinghamshire. Tel: +44 1908 622344 E-mail: sales@dynamicair.co.uk Web:www.dynamicair.com Need to micronise just 1g of material for NPD trials – no problem. Want high throughput milling of 10 tonnes per hour – no problem. Want advice on how to transfer small quantity milling operations to full production rates – no problem. With over 50 years of size reduction experience and an unparalleled range of equipment, Hosokawa Micron Ltd has the expertise and the right equipment to do the job. With a range of equipment from laboratory mills such as the Picojet, capable of processing very small batches down to below 1g to rugged Hosokawa Micron Prebreakers designed for heavy duty size reduction requirements Hosokawa Micron can deliver coarse crushing down to ultrafine milling of submicron particles across a range of wet or dry processing applications in the chemical, food, pharmaceutical, mineral and other industries. In supplying a range of milling technologies including ball mills, granulators and crushers, fine impact mills, jet mills and air classifier mills, with many units available in different sizes from lab to production scale, Hosokawa Micron customers can select the most appropriate milling technology to achieve their required result and benefit from easy production scale up as well as a range of non-standard options that deliver an individual engineering response to processing problems. Powder processors can select mills by particle size production capabilities at http://goo.gl/2WXiRh For further information/reader enquiries, please contact Hosokawa Micron Ltd, Runcorn, Cheshire, Tel: (01928) 755100 Fax: (01928) 714325 Email: info@hmluk.hosokawa.com Web www.hosokawa.co.uk

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PROCESS INDUSTRY INFORMER January - February 2015 - SHAPA Supplement

FLEXICON® WEIGH BATCHING AND BLENDING SYSTEMS

FLEXICON® Automated, Gain-In-Weight Batching And Blending Systems convey bulk ingredients from nearby or distant sources, weigh the ingredients in sequence, blend the batch and deliver it to downstream destinations. Typical material sources include FLEXICON Manual Dumping Stations (shown), TIPTITE® drum dumpers, BULK-OUT® Bulk Bag Dischargers (shown), screeners, rail cars and silos. Typical destinations include downstream process equipment, FLEXICON bulk bag fillers (TWIN-CENTREPOSTTM shown), storage vessels and packaging lines. Weigh batching controls receive weight gain or weight loss information from load cells to automatically actuate conveyors, valves, blenders and other system components. Material can be transferred by integral FLEXICON Flexible Screw Conveyors (shown), FLEXI-DISC® Tubular Cable Conveyors, PNEUMATI-CON® Pneumatic Conveying Systems, other conveying systems or by gravity. Complete engineered systems are available as well as stand-alone components, to food, dairy, pharmaceutical or industrial standards, with FLEXICON’s Lifetime Performance Guarantee. Lab testing on full-scale equipment using customersupplied material verifies system performance.

Rapid Ribbon mixing for Tate and Lyle from John R Boone Ltd John R Boone manufactured a 600 Litre Horizontal Helical Blade mixer for Tate and Lyle. This was constructed to meet the factory’s stringent hygiene and safety standards in stainless steel, with ‘u-trough’ adaptations for rapid discharge, larger batch sizes and fullwidth top doors for easy cleaning that include special safety interlocks. Tate & Lyle manufacture high-purity food additives and ingredients in hundreds of different types. Therefore when they were looking at replacing an old mixer their key objectives included improving the ease of cleaning and speed of changeover. The Horizontal Helical Blade Mixer is ideal for this application as it has four mixing elements forming an interrupted spiral and a short length compared to its width. This combination gives the mixer substantial advantages over conventional ribbon or spiral mixers. The slow-moving mixer arms gently lift and fold the blend end-to end, in an action that is so efficient that ‘trace’ components can be added directly to the mix with no need to pre-mix. This machine is fitted with two full-width doors to make it easy to clean so that cleaning only requires around ten minutes. The Horizontal Helical Blade Mixer is designed to discharge quickly with the two outer spirals sweeping the entire shell with every revolution, so there is only a very minimal amount of material remaining in the mixer after each batch.

For more information contact John R Boone Ltd, Congleton, Cheshire. Tel: +44 (0) 1260 272 894 Fax: +44 (0) 1260 281 128 E-mail:sales@jrboone.com Web:www.jrboone.com

For more information contact FLEXICON (EUROPE) LTD Tel:+44 (0)1227 374710 E-mail: sales@flexicon.co.uk Web: www.flexicon.co.uk

RMIG BRIDGE SLOT SCREENS CUT PROCESS DRYING TIMES An innovative range of drying screens has been launched in the UK by RMIG, one of Europe’s leading manufacturers of precision perforated products. Bridge Slot screens are specially designed for use in drying and storing all sorts of solid materials, such as grains, herbs, and more recently wood-chip, which is now primarily used to fuel biomass boilers. RMIG’s Bridge Slot screens are designed to enable a unique flow of air through the slots. This significantly improves air circulation, reducing drying times and increasing efficiency. With the right heating and storage conditions moisture content in wood-chip for example, can be reduced from an initial 50% to an ideal 18-20% in just 48 hours. The screens are manufactured in mild steel between 2mm and 5mm thick and this makes the screens ideal for use as “drive-on” flooring in large storage areas. With the right support system, the screens can take wide wheeled trucks for bulk loading and off-loading. Offering applicationspecific guidance, bespoke services and short delivery times makes RMIG the ideal partner for providing ventilation solutions for industry and agriculture.

For further information about RMIG’s Bridge Slot screens visit: www.rmig.co.uk.

PROCESS INDUSTRY INFORMER January - February 2015 - SHAPA Supplement

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Choosing the right technology for accurate & reliable solids level measurement In this article Ingemar Serneby, Emerson Process Management, discusses the difficulties of measuring the level of solids in vessels and silos, and reviews some of the available technologies considering their suitability for different applications. Introduction

Selecting a suitable technology to measure the level of solid materials in vessels and silos can be a frustrating experience for many users. The material being measured often behaves in a manner that makes level measurement difficult and the results unreliable. Many applications need to convert level measurements into mass, and accurate results rely on a consistent density of the material being measured, and a complete understanding of the dimensions and characteristics of the storage vessel. The traditional approach to level measurement in the industry has been to use mechanical devices known as yo-yo’s. These are based on a weight attached to a wire being lowered onto the surface of the solids at scheduled times. The device calculates the level of the media based on the length of wire required before the weight makes contact with the surface. However, as the spool mechanism is in contact with the media, these systems require regular maintenance - exposing operators to the hazardous conditions on tall silos. Where continuous measurements are required, there are a number of options

that cover a wide range of applications in the process industries. These include Guided Wave Radar (GWR), non-contacting radar, ultrasonic, acoustic, laserbased technologies and load cells. In addition, for special applications where nothing else works, nuclear technologies can be

Why are solids so difficult to measure?

Surface inclination During the fill and emptying cycles, the surface of solid materials is rarely flat or horizontal, with a tendency to peak under the inlet and ‘rat hole’ above the outlet. The angle of repose, or surface inclination, will change as the vessel fills and empties, and this angle affects the recommended due to signal loss. Dust One of the most common problems for solids level measurement technologies is the effect of dust generated during the fill cycle. Many materials produce large amounts of dust in the silo and this can be problematic for ultrasonic and laser devices. The presence of dust affects the signal strength and subsequently the reliability of the measurement data. As a result, ultrasonic and laser devices are unsuitable for some of these applications. While radar signals are unaffected by dust, the antenna on non-contacting radar systems needs to be protected from dust build up, for example by using a PTFE bag which has non-stick properties, preventing dust from adhering to it. Air purges are also often used to clean dust off the sensor surfaces. Acoustic based systems use low frequency pulse signals that are unaffected by dust, filling noise, humidity, or temperature. In addition, they can be made selfcleaning by using the vibrating membranes to drive out any dust particles that coat the horns. Types of media There are many different types of media and their physical characteristics vary widely. For example, particles can vary in size from fine micron size to large particles, rocks, pebbles or granules. They can be smooth or have sharp edges. Parts that are in contact with abrasive media – such as GWR probes will require regular maintenance. Lightweight aerated materials have sound absorbing characteristics that affect the performance of ultrasonic and acoustic level devices. Some materials are hygroscopic - readily absorbing or trapping moisture and this can cause caking or clumps inside a vessel. In particular, coarser materials are more likely to clump, bridge, leave voids and pile up. Products like grain have variable characteristics dependent on the specific crop and moisture content. This makes it difficult to determine a consistent crop density that will provide accurate volume results. Dielectric Constant The dielectric value of many solids is fairly low. For radar technologies, the dielectric constant is a key indicator of the amount of signal that will be reflected back to the gauge. If the dielectric constant of the measured material is very low (<2), this may require the use of a GWR device that uses signal processing techniques to overcome the effects of poor signal strength. Bulk Density The weight of the material per volume is important when monitoring bulk solids inventories so it is important that the bulk density (usually in Kg/m3) is

Figure 1: Solids particles can vary in size from powders to pebbles and rocks

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representative of the material. Continuous level sensors will convert a distance measurement from the sensor to the material surface, to volume and weight/mass. Any errors in the bulk density will be translated into errors in volume and weight/mass.

Pull Forces

This is a particular problem for GWR where heavier materials can create a pull force that can break GWR cable probes or transfer loads to the silo roof, causing it Fig. 2: to collapse. While Guided this is more likely to be an issue in Wave Radar vessels taller than transmitter 50 ft. (15 m), care must be taken to guard against this possibility. A further consideration is that the weight of the material may push flexible GWR probes towards other structures in the tank, creating false targets.

Electrostatic discharges and Electromagnetic Interference

Guided Wave Radar (GWR)

Guided Wave Radar (GWR) has many applications in the process and manufacturing industries providing an accurate and reliable measurement of level in tanks and vessels. GWR is a top down, direct measurement, as it measures distance to the surface. Since GWR is not dependent on reflecting off a flat surface, it works well with many powders and grains including plastics, fly-ash, cement, sand, sugar and cereals. Radar provides a fast response to changes in level, making it suitable for closed loop process control and safety applications. GWR is based on a low energy pulse of microwaves being sent down the probe, when the pulse reaches the media surface, a reflection is sent back to the transmitter. The transmitter measures the time taken for the pulse to reach the media surface and be reflected back. The on-board microprocessor accurately calculates the distance to the media surface using ‘time-of-flight’ principles. Because there are no moving parts, maintenance costs are reduced and the problems of false readings, which can result in potentially hazardous situations, are avoided. In order to improve the maximum measuring range in low dielectric materials, technologies are available that allow for measurements when the surface pulse is weak. For example, Emerson’s Direct Switch Technology provides an echo signal that is two to five times stronger than other GWR transmitters. The improved signal to noise ratio means enhanced ability to handle difficult measuring conditions like long measuring distances and lower dielectrics.

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Ultrasonics

While ultrasonic level devices can be used for the measurement of solids they do have a number of issues that can affect the way the sound wave reflects off the surface and/or the generation of “false” echoes that can make detecting the true level signal very difficult. These include their inability to make measurements in applications with dusty conditions, vapour space changes, changing angle of repose, large particle sizes, internal vessel obstructions, and coating or formation of clumps on the internal vessel surfaces.

Acoustic

Overview of the Technologies

Non-contacting radar

Non contacting radar needs a clear view of the surface and the best results are obtained with relatively flat, rather than slanted surfaces. However, the specific challenges of sloping surfaces, low dielectric properties and high filling rates can be overcome by the use of specially developed software and algorithms that can manage some of the unique characteristics of the return echoes.

While modern designs and technical innovations have improved the performance of ultrasonic level devices, in many applications, newer technologies such as radar and acoustic will generally provide better results across a wide range of applications.

In some applications, for example the level measurement of plastic pellets, electro-static charges can build up and eventually discharge. It is therefore important to provide a good earth ground to protect the sensitive electronics in measurement devices. In addition, the device must be designed to handle the electrostatic charge and divert the excess energy away from the electronics. This design can help with electromagnetic interference from nearby equipment, which can be a problem with non-metallic silos.

The company also developed Probe End Projection (PEP) which enables reliable measurements to be made with low dielectric materials when the surface pulse is too weak to be detected. This method is based on the fact that microwaves propagate slower through product than through air. By monitoring the position of the probe end echo, an algorithm can calculate the surface position in case of an unavailable surface echo. The PEP function will only be activated as a backup if the surface echo is too weak.

Non-contacting radar devices can be considered as an alternative to GWR for applications where no-contact with the media is required, for example where aggressive and abrasive media can cause damage or wear to the probe. Like GWR, non-contacting radar provides a top-down, direct measurement as it measures distance to the surface. Non-contacting radar sends a signal through the vapour space that bounces off the surface and returns to the gauge.

Acoustic based devices measure level by transmitting low frequency pulses that reflect off the surface of the contents of the silo, bin or container. Because of the nature of the acoustic signal, which transmits over a wide area, it can be challenging to obtain the correct echo from the surface. Acoustic systems such as the Rosemount 5708 3D Solids Scanners, use three horn antennas that detect not only the distance to the surface, but also the direction of the echo to the object reflecting the signal. A Digital Signal Processor then samples and analyses the received signals to provide very accurate measurements of the overall surface of the stored contents, and generates a 3D visualisation of actual allocation of product within the container for display on remote computer screens. Using the silo dimensions calculating the volume is therefore easy. 3D Solids Scanners provide continuous volume measurements that are based on the representation of the material’s surface. They are ideally suited to measuring solids in silos, large open bins, bulk solid storage rooms, stockpiles and warehouses. They can measure practically any kind of material including grain, lime, cement, plastic powders, difficult-tomeasure fly ash and materials with a low dielectric. Self-cleaning designs require minimal maintenance even when used in the dustiest environments.

Laser based technologies

Laser transmitters for level measurement employ the speed of light, using a very narrow beam focused on a small area. They are extremely accurate and can operate over large distances. This makes them particularly suitable for applications that require level information at a precise location, for example at the emptying point of a silo. This provides operators with information about the ability of a storage vessel to deliver material when demanded.

Laser based systems can be used in high pressure, high temperature applications using specialised sight windows that isolate the transmitter from the process. However, an accumulation of dirt, dust or other coating on the laser level transmitter seriously weakens the strength of the laser signal affecting their performance. Regular Fig. 3: Non contacting radar transmitter for aggressive maintenance is important to prevent accumulations and ensure the correct and abrasive media

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functioning of laser level measurement devices.

Specialist systems

Nuclear systems work by directing a fan of radiation across the vessel. As the level rises and falls the amount of radiation received at the detector also rises and falls. Since the measurement system is not exposed to the material, nuclear systems are ideal for corrosive, abrasive, high temperature or high pressure process conditions. However, these devices require special licenses, training and tracking, which add to the operating costs. In addition, serious consideration must be given future disposal and the associated cost implications. Load cells and strain gauge weight systems are usually chosen for applications where certified mass measurements are required, for example in the food, pharmaceutical and aggregate industries. They are used to support accounting applications or where all other technologies have failed. Load cells tend to be built into a system when it is designed and installed, although they can be retrofitted. Systems need to be engineered to individual requirements and are often difficult to calibrate.

the media being measured is aggressive or abrasive. Care needs to be taken with low dielectric solids or where there is long distance to the surface, or where there is a source of electromagnetic interference. These applications require products with technologies such as Probe End Projection which is incorporated in the Rosemount 5300 GWR transmitter. Probe End Protection enables reliable measurements to be made under low signal conditions. For applications where aggressive or abrasive media can cause damage or wear to the GWR probe, non-contacting radar should be considered as an alternative. However, signal reflections are low in the measurement of solids which makes correct installation and the selection of antenna very important. The latest generation products such as the Rosemount 5402 non-contacting radar use advanced software and algorithms to overcome the specific challenges of solids measurement which include inclining or sloping surfaces, low dielectric properties and high filling rates.

For larger vessels and silos up to 70 metres in height, acoustic based systems provide highly accurate measurements of stored contents. They provide continuous volume measurements that are representative of the materialâ&#x20AC;&#x2122;s surface and can measure practically Summary any kind of material including grains, mineral ores and cement With such a wide choice of technologies available, the characteristics materials with a very low dielectric. Devices like the 5708 Series 3D of each application need to be carefully considered to ensure an Scanners map the uneven surface typically found in solids applications accurate and cost effective solution to each solids level application. and can provide the minimum and maximum level, the total volume For example, what are the dimensions of the storage vessel? Will and a 3D visualisation of the surface. The self-cleaning design of such dust in the vessel be a problem? Does the media being measured products require low maintenance even when used in the dustiest have a low reflective characteristic? With the surface of solids environments. being typically uneven, will a single measurement point provide For applications in large areas such as warehouses, several acoustic accurate results? devices can be combined to provide an accurate and reliable As a general guide, for applications in smaller vessels, measurement system for inventory and production GWR radar devices provide an accurate and reliable Fig. 4: Emersonâ&#x20AC;&#x2122;s Rosemount 3D process control in many industrial applications. method of providing continuous level measurement of solids. With their small connection size, GWR systems are Solids Scanners provide level, easy to mount and can adapt to a wide range of vessel volume and mass measurement of Care in selecting the most appropriate technology will minimise maintenance requirements and provide the types and shapes. They have a fast response time for rapid bulk solids and powders longest operational life. Most suppliers offer a range filling applications and the measurements are independent of technologies and their technical and application of moisture, and material fluctuations such as density and temperature. However, the selection of the correct probe type is important and engineers have experience of popular applications and are able to guide users special consideration needs to be given to installations in tall vessels or where through the selection process.

Fig. 5: Emersonâ&#x20AC;&#x2122;s acoustic scanners provide a 3D visualisation of the surface

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New Bulk Bag Emptying Conveyors from Schrage Conveying Systems Discharging bulk bags into a process typically involves elevating materials from ground level to process machinery feed points. Whilst the bags can be transported at ground level with fork lift trucks, elevating the material can be a challenge. In response to these challenges, a new range of tube chain conveyors has been launched by Schrage Conveying Systems. (Exclusively available in The UK from Renby Ltd). With a capability of lifting product from a few metres to as many as 35 metres, the new compact design fits within the legs of a big bag stand. This keeps the space requirement to a minimum. The tube chain conveyor can be operated at any angle from horizontal to vertical. This way, it does not impose any restrictions on the plant designer. Furthermore, with such large lengths possible on a single conveyor, just one tube chain conveyor is used where previously several conveyors would have been needed. All of the original benefits of the tube chain conveyor are retained, such as gentle handling, low energy consumption, dust tight conveying and low wear rates. Variations of the new design are available offering rapid filling / emptying of road or rail bulk tankers directly into your process or into intermediate containers.

Renby Limited, Tarvin, CHESTER CH3 8JF Tel: 01829 740913 Web: www.renby.co.uk Email: info@renby.co.uk

web: www.schrage.de email: info@schrage.de

The Benefits Of Explosion Vents Over Explosion Doors A global leader in providing innovative ATEX certified explosion protection technologies, warns process industries that explosion doors should be selected with caution – and must only be used for specific higher pressure applications. Fike UK, based in Kent, stresses explosion venting is the most common and effective form of explosion protection offering overpressure protection from potential industrial explosions. Keith Avila, General Manager at Fike UK said: “As a progressive company we are constantly developing the most effective and cost efficient explosion protection solutions. Over the years we have researched the attributes and qualities possessed by both explosion doors and vents and have found the benefits of vents significantly outweigh that of doors – and our customers are in agreement.” According to Fike, an explosion vent has proved to be the most effective method of passive explosion protection and can protect processes against the excessive pressures generated by an explosion. The explosion vent will provide an intended route for expanding gases to discharge and, as such, will prevent damage to industrial equipment. Standard explosion vents will open at a defined activation pressure and the vent area will remain open preventing build-up of vacuum pressure on cooling – as such guaranteeing not to fail. Explosion doors will also open at a defined activation point, but will generally reclose after the operation, with a device often being used to keep them closed, which is considered by many in the industry to not be as fail safe as the vent. More recently, however, some explosion vents now have the ability to reclose, but not 100% seal, thus cutting off the majority of the oxygen supply to assist in firefighting but do not allow a vacuum to form on eventual cooling. These types of vents effectively provide all of the advantages of light weight explosion venting, with the reclosing function of doors. Manufactured from thin stainless steel sheets of 1mm to 2mm, explosion vents are extremely lightweight allowing them to open fully almost instantaneously. Also, being classed as a more consumable part, explosion vents will be easier and less expensive to produce from materials compatible with the process. Conversely, doors are much heavier and, in certain instances, have very low efficiency, resulting in a larger venting area, a reduced explosion pressure or low burst pressure (Pstat). Fike’s specially designed explosion vents are passive explosion protection devices – with no moving parts to fail – and because of this they do not require any special maintenance. Easy to install, even in the most awkward and restricted locations, all vents come with optional weather protection covers to eliminate any potential damage from the elements and general debris. Keith added: “Explosion pressure relief is best achieved through the use of devices with no moving parts as they offer the highest venting efficiency and cannot be tampered with. Vents are well known to provide superior process compatibility. “With all of our explosion venting technology, we take into consideration design variables such as normal operating pressures, reduced explosion pressure and vent efficiency to name but a few. As with all Fikeproducts, we follow industry best practice and in many cases exceed industry standards. Fike is fully committed to providing the most cost effective and safest solutions possible.”

For more information contact Fike UK, Maidstone, Kent. Tel: +44 (0) 1622 677081 - E-mail: info@fike.co.uk - Web:www. Fike.co.uk

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Liftvrac - on-site trials from Genesis Liftvrac, the inventors of the amazing conveying systems of the same name recently shown at PPMA, has appointed Genesis Process Solutions as their agents for the UK and Ireland. Phil Cameron is the Sales Director of Genesis Process Solutions: “We started to talk to Liftvrac some months before PPMA and convinced them that taking exhibition space was a good way of introducing the system to the UK markets. The level of good quality response was excellent with the number of companies requesting on-site trials well into double figures. We have now taken delivery of a Model S Liftvrac and already conducted onsite trials with some companies” To state that the Liftvrac conveying system is revolutionary is something of an understatement. It is more efficient, more economic and easier to clean than any other short-range mechanical or pneumatic system currently available for handling powdered, fluid, fragile or sticky products. The key component is a polyurethane belt which forms a tube around the product and carries it the entire length of the elevation. The flat belt is formed into a tube just after the product inlet and this tube then carries the material up to the top of the Liftvrac, where the belt opens flat again. The belt always wants to become flat naturally so doesn’t squeeze the product. Once the speed and belt load is set up the product holds itself in position so there is no stress on the product itself. A lip system effectively seals the tube and holds the product in place until it’s discharged at the end of the line. The seal is so effective that any powdered product, for example, can be conveyed without any risk of leakage into the surrounding environment. But it isn’t just powders that Liftvrac can handle. Fish, cheese, pasta, meat, plastics and a huge range of other products can be conveyed without any fear of blockages or clogging thanks to a scraper located at the discharge end of the belt. With a small motor, ranging from 0.5 – 1.5kW the Liftvrac system is extremely energy efficient and can handle product at rates up to18m3/h. The entire system can be dismantled, cleaned and reassembled in around twenty minutes – ideal if different products are going to be conveyed. Liftvrac is available in two models, C and S which refer to their shapes. C has been designed for tight enclosed spaces where the product needs to be conveyed to a mezzanine while the S model is better where there is more space and the product needs elevating to a mezzanine or overhead production line. Typical installations including the conveying of finished goods to a multi-head weigher, feeding raw ingredients to a mixer or even transferring from one area to another, the beauty of the Liftvrac is how versatile the unit is.

To discuss an on-site trial or a free site survey please contact Phil Cameron on 01270 766300.

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The six guidelines you need to Exponential growth in the use of bulk bags has spawned an entire manufacturing segment dedicated to producing specialised equipment that not only fills and discharges bulk bags, but offers various degrees of automation and integrates filling and unloading operations with upstream and downstream equipment. As the number of equipment options increases, so should the ability of the specifier to evaluate stand-alone equipment and integrated systems against current and anticipated needs. The author addresses the “filler” half of the bulk bag handling equation, offering the six most important parameters to consider when satisfying any individual bulk bag filling requirement with top efficiency and cost effectiveness. 1. Anticipate maximum capacity

such,

The difficult but critical question: How many bulk bags will you need to fill per week during the useful life of your next bulk bag filler? With few exceptions, buying a more costly filler with higher capacity than you now need will be less costly than replacing a filler you outgrow, unless that filler can be retrofitted with performance enhancements at a later date. Capacity requirements run the gamut, from one bag per week to 20 bags per hour. Where your volume falls should, in part, influence your decision to specify a manual, semi-automated or fully automated machine. Generally speaking, the more manual the filling operation, the more output is subject to variation. When gauging the capacity and payback of manual equipment against automated equipment, you need to determine the average pace at which operators can attach, detach and cinch bag spouts, remove filled bags, load pallets and conduct all other filler-related operations. When estimating the time allocated to these manual functions, it is advisable to anticipate a pace that an operator can realistically Fig. 1 maintain throughout an entire shift while avoiding fatigue or injury. For the lowest volume applications, a basic filler operated manually will maximise your return on investment. One example is a medium-gauge Twin-CentrepostTM filler (FIG. 1) which offers the structural integrity of four-post fillers but at significantly lower material and fabrication costs and with less weight. This two-post design also affords unobstructed access to the bag spout and loops, facilitating rapid manual insertion and removal of bags. This class of filler is typically equipped as standard with fill head height adjustment via fork truck to accommodate all popular bag sizes, a feed chute vent port for dust-free air displacement during filling, and an inflatable cuff to seal against the bag inlet spout and ensure it does not collapse on itself during filling. Limited performance options, which can be added initially or retrofitted, include an inflator to expand the bag prior to filling, and a programmable scale system with flow Fig. 2 control valve for filling by weight. The cost of a scale system can be avoided by placing the entire filler onto an all-purpose plant scale, providing the filler is properly equipped for in-plant mobility (FIG. 2). If a forklift is unavailable to remove filled bags, as is required by the above-mentioned fillers, configurations are available with a three-sided base that provides access from the open side using a pallet jack (FIG 3).This lowprofile configuration can also be utilised to conserve height in low headroom applications. The time required to prepare empty bags for filling, and to remove filled bags from beneath the filler, can have as much or greater influence on maximum filling capacity than the rate at which material enters the bag. As Fig. 3

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adding a roller conveyor allows filled bags to be rolled out of the filling area for spout cinching and pallet/bag removal while another bag is being filled. Adding such a conveyor system, however, generally requires a filler with rear posts (FIG. 4) and a cantilevered fill head equipped with hooks that release bag loops automatically, so if higher capacity is in your future, a rear post configuration may be your best choice today. Increasing the capacity of systems equipped with roller conveyors to the next level generally entails adding an automated pallet dispenser (FIG. 5) which places pallets and slip sheets onto the roller conveyor upstream of the filling operation, further Fig. 4 reducing the time required for each filling cycle by limiting manual operations within the filling station exclusively to loading an empty bag. To further reduce the time needed to attach the spout of an empty bag to the filler, this Swing-Down® filler (FIG. 6) lowers the entire fill head to within an arm’s length of an operator standing on the plant floor. Further, it pivots the bag spout into a vertical position, enabling the operator to connect the spout of an empty bag to the inflatable bag spout collar in several seconds, after which the spout pivots back to horizontal, the entire fill head returns to fill height, the bag is inflated, and filling commences. Additionally, when the bag reaches its target weight, the bulk material delivery system deactivates automatically, the spout collar deflates, the fill head raises to decouple from the spout, and the powered roller conveyor sends the bag downstream of the filling area--automatically, Fig. 5 rapidly and safely.

2. Evaluate safety against manual operations required at any given level of capacity

With manual and semi-automated filling operations, the potential for worker fatigue and injury can increase according to required output per shift, relative to the type of bulk bag equipment specified. Consider that the connection points of a conventional filler are often beyond the reach of most operators, even when short bags are being filled. But adding the height of a roller conveyor to the height of a bulk bag to the length of its bag loops puts the connection points for bulk bags of only 122 cm in height at approximately 213 cm above the floor! This requires an operator to stand on a platform, a ladder or on the roller conveyor while straining to reach overhead spout connection points and inserting hands between temporarily disabled moving parts. Difficult-to-reach spout connection points can therefore compromise safety as well as capacity—two problems that can be solved with the addition of a fill head that lowers and pivots to the operator at floor level. Repetitive manual tasks such as releasing bag hooks, placing pallets on a roller conveyor or actuating bulk Fig. 6 material delivery, also increase the potential for error

PROCESS INDUSTRY INFORMER January - February 2015 - SHAPA Supplement

to specify a bulk bag filler By David Boger, Vice President Sales and Marketing, Flexicon Corporation and injury, justifying semi or fully automated equipment for all but the lowest volume applications.

3. Ensure contained

dust

Even the most rudimentary filler is likely to be equipped with an inflatable spout seal (FIG. 7) to hold the bag spout firmly in place during filling. However, not every fill head is vented to a dust collector to filter displaced air and Fig. 7 dust, and to vacuum ambient dust in the operatorâ&#x20AC;&#x2122;s vicinity during disconnection and cinching. It is therefore important to confirm that the filler you are considering is so equipped, particularly when contamination of the product or plant environment cannot be tolerated.

4. Determine your need for multi-function filling If your plant fills drums, boxes or other containers as well as bulk bags, multi-function fillers (FIG. 8) can boost production, undercut the cost of separate equipment and reduce the amount of floor space required. Multi-function fillers can be switched from bulk-bag to drum-filling mode in seconds by positioning the swingarm-mounted drum-filling chute under the fill head discharge port. The chute automatically rotates to deliver material to all four drums on a pallet. Similar adapters for boxes, totes or other containers are also available with varying levels of automation.

5. Match the feed source to your material and your filler

Filling capacity, accuracy and efficiency are often limited by the ability of upstream equipment to feed Fig. 8 material consistently and in sufficient volumes. High capacity, semi- or fully-automated fillers therefore require highcapacity feeding systems that are typically automated and feed material into the filler by gravity or by a metering device. The ability to gravity-feed material depends on whether a material storage vessel can be located above the filler, and on the materialâ&#x20AC;&#x2122;s flow characteristics. The more free-flowing it is, the more accurately its flow can be varied (down to dribble-feed rate) by a slide gate or other valve that must close the instant a precise target weight has entered the bag. Non-freeflowing titanium dioxide (TiO2) for example, may flow in a trickle and then in clumps, and it may bridge above the flow control valve, making it a poor candidate for gravity feeding. For non-free-flowing materials, a metered feeding system is required to feed the filler accurately and consistently. Metering systems can include a flexible screw conveyor (FIG. 9), screw feeder, rigid auger, drag disk, bucket elevator,

rotary airlock valve, or other device that does not rely on gravity alone to deliver material to the filler. The selection of a metering system can hinge on the available space above the filler, since surge hoppers and filter receivers with rotary airlock valves may require more headroom than is available. In these cases the discharge housing of a flexible screw conveyor can often fit between the filler inlet and the ceiling joists, while eliminating the need for a flow-control valve. For products that are easily aerated, pneumatic conveying systems should be avoided, since the conveying process can cause the material to Fig. 10 require a much lengthier densification/deaeration cycle to achieve the desired fill weight and package stability. If sufficient headroom exists above the filler, a surge capacity equivalent to the weight of a filled bag can be employed to reduce cycle times while maintaining accurate fill weights. This configuration allows bag change-over to occur while the subsequent batch is in the process of being weighed. When a pneumatic conveyor is used as the material delivery system, the filter-receiver can be sized to hold the weight of an entire bulk bag (FIG. 10) to apply this method. For the same reason, a surge hopper above the filler can be considered when utilising mechanical metering devices moving material to the filler from both storage vessels and plant processes.

6. Comply with sanitary requirements

While all fillers can be constructed of stainless steel with ground and polished welds, their designs can preclude sanitising according to government standards. If your application must meet sanitary requirements, your choices should be limited to designs that are accepted by the USDA Dairy Grading Branch (FIG. 11) or other agencies to which you must comply, or to which you elect to comply for assurance that sanitary conditions can be maintained.

Fig. 9

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Conclusion

Fig. 11

With an almost unlimited combination of filler designs, features and upstream equipment from which to choose, specifiers have the ability to tailor bulk bag filling systems according to capacity requirements, expandability, safety concerns, plant hygiene considerations, ancillary filling needs, upstream equipment and sanitary standards. While numerous available options can complicate the selection process, they can also yield a highly efficient and cost effective solution to any given filling problem, providing that fundamental steps are taken to evaluate equipment against precise requirements.

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CONTINUOUS WET AGGLOMERATION BY INSTANT MIXING TECHNOLOGY By Stewart Bryan, Commercial Manager, Hosokawa Micron Limited, Runcorn, Cheshire

Agglomeration can be defined as a process of particle size enlargement where fine powder particles are bonded to form large, relatively permanent masses in which the original particles are still identifiable. These agglomerates have a coarse, open structure and a mean particle size ranging from 0.1 to a few millimetres. The process uses agitation in the presence of the required proportion of a liquid phase or other binding agents and is normally followed by evaporative drying. Applications for instant mixing are, for example, found where rapid dissolution, dispersion and wetting are important in the product end use. Powders suitable for processing with this process include most water soluble powders, including sugars, milk powder blends and water soluble chemicals.

APPLICATION: CHOCOLATE DRINKS

Benefits

The goal of any particle size enlargement process is to reliably produce particles exhibiting required end use properties - simple de-dusting, to engineered particle of specific size, shape, density and dissolving rate or compressability.

Instant Mixing Agglomeration

Instant mixing agglomeration is a wet agglomeration method. This means powders and a liquid are required by the process which typically includes mixing, drying, conditioning, size reduction, size classification and material transport.

Mixing

Instant mixing agglomeration maximises control of mixing conditions which give rise to yielding ‘perfectly’ formed uniform granules. With high level mixing intensity, instant mixing agglomeration delivers uniform wetting of particles and uniform particle growth. Because newly formed wet agglomerate is malleable, particles are easily deformed. It is important therefore that residence in the mixer is limited; 0.2 seconds to a maximum of a few seconds. Saturated powders exhibit extremely poor flow characteristics which can cause mixer blockage. A self cleaning mixer offers the answer. However insufficient cleaning of material from the wall can give rise to non-uniform, non-homogenous product characteristics which in application show up as ‘sinkers’ or undissolved, undispersed product. Liquids are introduced typically near the feed end of the agglomerator. The liquid feed stream can be atomised using air; also steam can be injected. The mixer itself can provide the remaining mechanical atomisation to disperse the fluid.

Conditioning

clusters of smaller particles. Because of the irregular surface, the instant agglomerate will have more surface area than a solid ‘regular’ granule – properties which aid dispersibility, fast dissolving and compressibility of the agglomerate. If, however, a more defined shape is required, a secondary forming process prior to conditioning can be done.

The consumption of cocoa in chocolate drinks has increased considerably over the past decades. This is mainly because products have been developed that make it easier to transform cocoa powder into hot and cold drinks. These products must have instant properties. The final product is judged by the following criteria: * bulk density * colour * flowability * wettability * sinkability * dispersibility * homogeneity of product, no segregation * dissolving time in hot or cold liquids * appearance

AGGLOMERATION PROCESS

Before the actual agglomeration takes place, all powdery components will have to be blended. This can be done in different ways, the choice of which depends on the production capacity. For a production capacity between 500 and 1000 kg/h the most practical way is to pre-blend all powdery components in a Vrieco Nauta Conical Mixer After preblending, the mixture is fed to a buffer hopper. From this hopper, the blend is fed to the Flexomix agglomerator, in the correct proportion by a constant weight feeder. For agglomeration with water, 2 - 8% water is generally needed. This is an important parameter to influence the grain size of the product. The grain size of instant cocoa is generally between 300 and 600 μm. The use of water in combination with steam gives special quality characteristics on the end product. Emulsifiers and flavours could be dissolved in water using a liquid premix tank. Part of the sugar can also be dissolved in the water, which influences the instant effect. The wet granules fall directly from the Flexomix into the Fluidbed Dryer. Warm drying air is blown through the perforated base plates. The temperature of the drying air and the maximum temperature of the product during drying are very important factors for the quality and the taste of the end product. After passing the drying section of the fluidbed, the product transfers to the cooling section in the same bed. Dependent on the behaviour of the end product, cooling is done by ambient air or conditioned air. The blow-over air is cleaned by a (cyclone and a) filter and exhausted. The separated dust is either collected in a small hopper or transported directly to the packing line, together with the on-size product. After cooling the product is discharged from the Fluidbed Dryer and passes a sieve to eliminate any oversize particles which may be present. The oversize is continuously crushed and added to the end product stream. The total stream of end product is fed to a storage hopper from where it is transported to the packing lines. The total

Mixed, agglomerated product is discharged directly to a conditioner, typically a dryer, to stabilise the agglomerate. Because of the malleable nature of the wet granule, physical handling will affect ultimate product quality, size, shape, density, etc. Further mechanical handling methods need to be carefully considered in light of desired end product qualities. Options for further processing after the wet agglomeration step include: Drying When no further sizing is required and a dispersible granule with maximum surface area is required for products including chemicals or instant beverages fluidbed drying is preferred, providing minimal mechanical force and maximum drying rate. Wet granules are suspended in and surrounded by drying air. The fluidbed dryer effectively classifies the particle returning fines to the agglomerator for rewetting resulting in a dust free product. Cooling Cooling stabilises the malleable granules. Forming The instant mixing process is most efficient in producing a fine agglomerate in the range of 100 μm to 1000 μm. Due to the instant forming process, the agglomerates are Figure 3: Flexomix Mixing System

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Agglomeration Plant is controlled by a SCADA system as Operator interface.

PROCESS INDUSTRY INFORMER January - February 2015 - SHAPA Supplement

SPIROFLOW’S BULK BAG FILLING SOLUTION BOOSTS BABY FOOD PRODUCTION Spiroflow Ltd, world-leading manufacturer of conveying and weighing systems, has boosted productivity at a household name baby food manufacturer by installing a bulk bag (FIBC) filler and vacuum conveyor system to significantly reduce the need for manual handling. Shifting millions of tonnes of very fine ingredients is part and parcel of the production process for food companies, which must have systems and equipment in place that adhere to regulatory requirements. The company specified a bulk bag (FIBC) filler for various infant formulas and powders. The equipment is manufactured entirely of stainless steel with automatic height adjustment for different-sized bags, and offers bag inflation and a vibration facility for an even, accurate fill and effective compaction – resulting in a stable load for both storage and transportation. Completing the ATEX approved conveying and bulk handling solution is a gas flushing connection and vacuum conveyor system for the safe, accurate and dust-free filling and transportation of powdered milk. Deploying a filling machine for bulk bags and vacuum conveyor system for transporting the product is saving the company the equivalent of 40 25kg sacks per filling and reducing handling downstream, as the product is emptied automatically rather than manually. The firm’s site engineer chose Spiroflow as he had positive previous experience of its conveying equipment, having previously purchased flexible screw conveyors from Spiroflow several years ago - which are still operating satisfactorily to this day. The customer used bulk bags to reduce manual handling and increase hygiene levels: bulk bags are one of the most convenient, cost-effective methods of packaging, storage and transport. Market-leading customers in industries ranging from food and pharmaceuticals to plastics and building products, use Spiroflow’s handling systems for bulk bags, usually for filling or discharging fragile or fine-particle products quickly and with the minimum of fuss. In addition to bulk bag fillers and vacuum conveyors, Spiroflow also manufactures flexible screw conveyors, aero mechanical conveyors, tubular cable and chain drag conveyors, bulk bag dischargers, ingredients handling and weighing systems. The company’s technical and engineering expertise has led to it developing an international reputation for an unrivalled range of products with state-of-the-art control systems.

PS: Spiroflow recently open their new Technical Centre and you can learn about it by turning to page 5 of the magazine. For more information on Spiroflow’s products and services visit www. spiroflow.com or call +44 (0)1200 422525.

Ringing in the Changes for 2015? Does 2015 represent an opportunity to get more performance from your process equipment or simply another year of coaxing the plant along from one problem to the next? Unfortunately, for too many companies, manufacturing rates or product quality are often let down by powder handling equipment that either flows material erratically or not at all. The causes of many of these types of problems have been recognised for many decades, but the knowledge to provide an initial diagnosis is often not available to those tasked with keeping production running. The Wolfson Centre for Bulk Solids Handling Technology has developed just the range of short courses that industrial end users and designers need to keep themselves up-to-date with the latest technologies and established test methods that can be applied to solve many types of flow problems. Pick up the phone, not the hammer

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PROCESS INDUSTRY INFORMER January - February 2015 - SHAPA Supplement

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Powder storage silos – disasters waiting to happen?

The latest silo protection technology provides much more than a safety system to prevent over-filling and over-pressurisation. Introduction

According to Hycontrol’s MD Nigel Allen, many powder storage silos are disasters waiting to happen, putting lives at risk and posing serious threats to the environment. Level measurement specialists Hycontrol have been designing specialist silo protection systems for over 20 years and have extensive experience of the potential problems that exist on sites, especially in the quarrying, cement, bitumen, food, plastics and waste water industry sectors. “Our findings are worrying to say the least and the photos taken by our installation engineers speak for themselves”, says NigelAllen. “Companies just don’t seem to understand the consequences of poorly maintained protection systems. It’s quite frightening that operators accept pressure blow outs via the pressure relief valve (PRV), erroneously citing that ‘It’s OK - the PRV is doing its job’. This couldn’t be further from the truth PRVs are there as a last resort. If the silo protection system is working correctly and is fitted with an automatic shut-off feature to prevent over-filling, the PRV should never be used. If a PRV blows then there’s an inherent problem with the system or the filling protocol and corrective action must be taken.” “Material in and around a PRV is a tell-tale sign that there’s something wrong and a catastrophic blow-out is waiting to happen” continues Allen. “The material blown out from the silos will almost certainly solidify over time and this will, at best, prevent the PRV from working correctly and, at worst, completely clog it up. Unfortunately many Fig.1: A PRV that’s completely maintenance engineers just don’t realise solid! the potential dangers that lurk beneath. They often think that simply cleaning off the material on and around the PRV is good enough. They don’t realise that if the PRV doesn’t lift next time an ‘event’ occurs, the over-pressure could easily rupture the silo or eject the filter housing from the top. On an ATEX rated silo the over-pressure could be sufficient to simulate an explosion and open the protective blast panels, resulting in costly loss of product and silo contents being left open to the elements”. With regard to filter housings, Hycontrol engineers have witnessed another worrying practice at a number of sites where companies fit chains to prevent the housing being blown off the top of the silo, almost accepting the inevitable is going to happen.

What causes problems?

over-pressurisation

Silo protection systems are designed to prevent the damaging and potentially dangerous Fig.2: Believe it or not there consequences of silo over-filling or overis a silo protection system pressurisation when powdered material is being transferred pneumatically from road tankers to underneath silos. Unfortunately, perched out on the top of silos, such protection systems are all too often ‘out of sight - out of mind’ - that is until a major problem occurs! Problems during the filling process usually arise through an inherent problem with the silo protection system or with the air filtration system on top of the silo. Problems can also occur through tanker driver/operator error. Delivery tankers are pressure-tested vessels typically capable of withstanding up to 2 bar (29 psi) pressure. Storage silos are designed to withstand the weight of material stored in them and can rupture at pressures as low as 1-2 psi above atmospheric pressure. The consequences of over-filling or over-pressurisation include: · serious or fatal injury to workers and the public. · catastrophic silo damage · loss of material and production plus · harmful environmental pollution · damage to company reputation A key issue with many silo protection systems is that without adequate ground level testing capabilities, operators don’t know if they will work when needed. Working at height restrictions limit silo top inspections and maintenance, especially in adverse weather conditions. However, the main problem is what can engineers actually do when they are at the top of the silo? How do you physically test a relief valve or pressure transmitter unless you remove them? Even if the protection system does do its intended job and prevents a major incident, companies rarely investigate the root cause of the problem so that remedial work can be carried out to prevent the situation re-occurring. Important ‘near miss’ events

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such as PRV (Pressure Relief Valve) lifts, high level events and high pressure events are routinely not recorded and often conveniently dismissed. Hycontrol have clear evidence that in practice there are more ‘near misses’ than realised and that the situation is a ticking time bomb. Filter housings at the top of the silos are designed to Fig.3: Now you don’t see it! vent the silo during filling, whilst preventing dust escaping into the atmosphere. Normally these are fitted with some form of self-cleaning system to keep filters clear. These are typically mechanical shakers or reverse jet systems. Although filter manufacturers give recommended check routines and filter replacement schedules, in practice it would appear these guidelines are regularly ignored. Faulty operation can be caused by a range of issues, including blockages and the Fig.4: Now you do! fitting of unsuitable or wrongly-sized filters. Most powders form hard compounds when mixed with water from the atmosphere, further exacerbating the problems at the top of the silo.

Effective silo protection

The MPA (Mineral Products Association) publishes comprehensive guidelines for silo protection systems in quarries and cement works, but there are little or no such recommendations for powder silos used in a broader range of industries including food and beverage, chemical, water treatment and plastics. However the primary principles are the same for protecting any pneumatically filled silos. Even with guidelines in place, the bench mark for the effectiveness of any silo safety protection system can only relate to the last time all the components were fully tested.

Optimum solution

The only effective solution is to take an integrated approach to silo protection design whereby the PRV, pressure sensor and high level alarm can be tested at ground level, prior to each fill. Only when all these safety devices have passed the checks should the safety interlock allow the silo inlet valve to open and the delivery to commence. As an added benefit, an effective protection system can serve as a powerful predictive maintenance diagnostic tool by recording critical near-miss events that occur during the filling process. This information allows managers to carry out effective predictive maintenance by means of a logical step-by-step root cause analysis (RCA) process to understand why the problems are arising. For example, high pressure and PRV lift events may be due to filter problems, prompting questions such as: · Are the filters the correct size? · Is the filter cleaning regime fully operational? · Have the filter bags/cartridges been changed as per manufacturers’ recommendations? In parallel the logs will also indicate if the tanker drivers are routinely over pressurising during the fill process. In summary, the optimised silo protection system should incorporate: · Pressure sensor, hi-alarm level sensor and PRV testing (essential) · Simple ‘1’ button press to test all components · Silo filling auto shut-off control · Pneumatic cleaning of pressure sensor · Recording of the number of events on incidents of over-pressure (time /date stamp) · Recording of the number of events of PRV lift and opening (time /date stamp) · Recording of the number of events of high level probe activation (time /date stamp) · Filter ON / OFF output option to check filter status · Filter air supply monitoring alarm option

Conclusion

There is strong empirical evidence that many silos are ‘disasters waiting to happen’. The practical reality is that powder storage silos can split or rupture at pressures as low as 1 or 2 psi above atmospheric pressure. Malfunctioning filter housings can be ejected at similar pressures. Cursory visual inspections of silo protection equipment is woefully inadequate. Therefore it is imperative that any installed safety system must be capable of providing reliable protection that can be easily verified by testing critical components before each and every delivery – without having to climb to the top of the silo. This approach will provide total silo safety; protecting assets, the environment and most importantly site personnel and the public.

PROCESS INDUSTRY INFORMER January - February 2015 - SHAPA Supplement

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