Process Industry Informer Magazine Mar/Apr 2013 Edition by Process Industry Informer

PROCESS INDUSTRY INFORMER.

MAR / APR 2013 Volume 9 No. 2

THE UK’S BIGGEST PUBLICATION SERVING THE PROCESS INDUSTRIES

Bridging the Pressure

In this issue... • 10 Feature Articles

We get vocal about education, take the pressure away with Thermowells, drive automation to the right

• Pump Industry Awards Results

position, re-energise your business by taking control

• 60+ News Stories

plan into place and ask if reliability is above your radar?

with the right management system, we put your HACCP

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

Process Industry Informer March-April 2013

Contents

editorial features

News & Events 4-9

Flat Springs for Safety Control Applications 32

Network Communications 9

Process Engineering & Project Solutions 32

Applications 9-13

Heat Transfer & Energy 32

The need for Apprenticeships 14 Sterile Gas Filtration 17 Specification for Energy Management Systems 18 Energy Management & Purchasing 20 Safe Pipe Expansion Joints 27

Crushers & Shakers 13

Instrumentation 33-37

Filtration & Separation 16 & 19

Calibration 37

Reliable Plant Safety 28/29 Assessing Security Risks 31 Thermowells - performance under pressure 35

Fluids & Liquids Handling inc. Pumps & Valves 22-26

Food Grade Oil 37

The Use of Positioning Drives 36 Ease Maintenance & Reduce

Maintenance 26

Process Control 38-39

Enclosures 26

Weighing 39

Analysers 26

Product Directory 42-43

Cost of Ownership 40/41

Health & Safety 30-32

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

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

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 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.

The 10th Anniversary Pump Industry Awards The 2013 PI Awards held in association with the BPMA, once again achieved its goal in bringing together the entire pump industry for a celebration of business and professional excellence. Sponsored by some of the leading brands in the pumps sector including World Pumps, Sterling Fluid Systems, WEG Electric Motors, Process Industry Informer, John Crane, SPP Pumps, KSB Limited, ABB Limited and Empowering Pumps the 2013 event has been heralded as ‘the best PI Awards yet.’ Held at the St John’s Hotel in Solihull on Thursday 14th March the gala awards evening was attended by some 200 pump industry professionals who raised £1795.00 for WaterAid, the BPMA’s chosen charity. Entertainment was provided by Gareth Chilcott, the ex Bath and England rugby player and as always the evening encouraged a great deal of networking in a competitive but friendly atmosphere, where the 2013 winners were revealed by celebrity compère, BBC World News Presenter, Naga Munchetty.

Meet the Winners The awards focus on key areas of manufacture and supply, including innovation and achievement, energy saving, engineering excellence, customer care and employee motivation. On the night, six companies and two individuals were awarded, and a fantastic night was had by all, as highlighted by some of the testimonials we have already received:Petar Ostojic, Mechanical Engineer at Neptuno Pumps said “We are proud of being the first Chilean and Latin American company to be awarded with the Technical Innovation of the Year - Projects Award and receiving it on the 10th Anniversary of the Pump Industry Awards is a tremendous honor. For our company this is recognition of our 40 years of continuous innovation, passion for engineering and commitment to our customers. We want to thank the Awards Judging Panel and all the professionals that voted for us around the world and also the organizers for putting together this magnificent event.” Terry Newby, Operations Director at SPP Pumps Ltd said “This year’s Pump Industry Awards event was the best yet. It was a fabulous night which was capped when we won the Manufacturer of the Year Award. It is a great award to receive as it is a truly team effort and reflects on all employees. It also promotes our image with customers and vendors.”

• Environmental Contribution of the Year Sponsored by: WEG Electric Motors Winner: Tata Steel - ABB Limited

A £68,000 per year energy saving, with a payback in just 13 months, is being achieved by Tata Steel on a variety of pumping applications including flume flush pumps and filter feed pumps. The savings follow the installation of five ABB industrial drives by Halcyon Drives. The pumps were originally controlled using direct-on-line motors with no speed control. A Halcyon hire drive was used to confirm the potential savings.

• Manufacturer of the Year Sponsored by: John Crane Winner: SPP Pumps

SPP exists to supply engineered pumping solutions focused on markets where application knowledge, service and expertise add value. In our markets we have high levels of technical expertise, experience and many approvals. We are organized on product/market lines with specialist engineers dealing directly with customers. All products are supported by teams of professional Service Engineers, a network of Service Centres and approved parts service. SPP provide the complete service from design through to aftersales support.

• Distributor of the Year Sponsored by: SPP Pumps Winner: Pumps UK

Pumps UK Ltd is one of the south east’s most prominent distributors and service agents. Operating now for over 10 years, the group is still seeing growth and expansion throughout every facet of the business. Improvements in distribution, sales (both direct and on-line), and the continued success of sister company Pumps UK Service, make Pumps UK today one of the most important independent distributors in the country.

• Supplier of the Year Sponsored by: Process Industry Informer Winner: WEG Electric Motors

Russell Maccabe, Sales Manager at WEG Electric Motors (U.K.) wrote “WEG were delighted to receive the prestigious award of Supplier of the Year for the third year running and would like to dedicate it to the hard working staff both here in the UK and at our headquarters in Brazil. We believe this award recognises our commitment to provide our customers with excellent levels of service. We thoroughly enjoyed the evening’s entertainment as did our guests and look forward to next year’s event.”

As one of the World’s leading manufacturers of Electric Motors and Automation equipment, WEG recently received the award for “Customer Value Enhancement to the European Water Industry” from World renowned Frost & Sullivan. With an annual turnover exceeding $3.2 Billion the WEG offering includes Low, Medium and High Voltage Motors, with the LV Motors available as IE2, IE3 or IE4 efficiency ratings and “WIMES” specification if required. A full range of Low/ Medium Voltage Drives and Soft Starters, Motor control and protection devices, MCC’s (Motor Control Centre’s), along with Transformers, Generators and gearboxes.

• Technical Innovation - Products

Engineer of the Year

Sponsored by

Aftermarket services at Schenck Process move to new location From the start of March 2013 all of the Aftermarket service and sales personnel for the UK will be based at new premises in Thorne near Doncaster. The re-location of the offices to the new facility is part of a £1.5m expansion programme the Company is carrying out to move the factory and test centre to the 56,000 sq ft building. Schenck Process UK incorporates the Clyde Process, Redler and Schenck Process products and technologies and also supports the supply of spare parts and replacement machines for a wide number of other brands such as Vac-U-Max, Simon Macawber, Stock and Clyde Materials Handling. The new offices and factory provides an opportunity to centralise the customer contact point for the Aftermarket operation with a low-cost 0845 telephone number and a comprehensive out-of-hours support team. Stocks of spare parts will also be centralised to give improved lead times to our UK and international customers. Tim Carter, the Director of Aftermarket services, is enthusiastic about the move to the new offices. “Having all customer support staff in one location will increase the level of services that we can offer, give greater efficiencies and one point of contact which we know our customers will value” he said. The Aftermarket department has a total of 38 UK based staff including 18 service and commissioning engineers and 12 proposal and customer support staff. All personnel have undergone intensive training on the full range of the Company’s products and technologies to identify and resolve issues that occur during the working life of the equipment. The company offers a full aftercare programme called PASS which stands for Process Advanced Service System, The programme covers product installation, routine inspections, maintenance programmes, on-site spare stock monitoring and the repair, upgrade and replacement of parts. All of these services will be co-ordinated by the new central office which can be reached on 0845 201 4564 or by e-mail at spares@schenckprocess.co.uk

PUMPING Plating Solutions, Acids?

3M Magnetically driven, sealless pumps are perfect for safe and reliable transfer of the most challenging fluids in surface treatment, finishing applications.

• Sealless design and corrosive resistant materials

• Wide range of models,

flow rates up to120 mc/h, heads up to 44 metres, system pressures to 6 bar

• From 3M, the experts in Contact BPMA now for a booking form Phone: 0121 601 6691 or email j.page@bpma.org.uk or download from www.bpma-cpsa.co.uk For more information please visit www.bpma-cpsa.co.uk

Process Industry Informer March-April 2013

mag-drive, sealless pumping

Pick the perfect pump – from Pump Engineering

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

www.pumpeng.co.uk

network & communications ROBUST LIGHTWEIGHT CONNECTOR IS IDEAL FOR OUTDOOR APPLICATIONS

HARTING adds solder bucket contacts to har-link® metric connector range

Han-Eco® Outdoor is a new addition to HARTING’s Han-Eco® connector family specifically designed for outdoor applications. The Han-Eco® Outdoor connector housing is based on robust high-performance plastic material, which gives the added benefit of light weight to the customer. Further weather-resistant features are provided by the specially designed housing profile and the use of flange gaskets in fluorine rubber (FPM). The Han-Eco® connector family is specifically designed for applications that do not require the full range of product features offered by the HARTING Han® B series of hoods and housings, but can benefit from the weight and cost advantages of thermoplastic housing material. Like the Han® B standard series, the Han-Eco® series is available in sizes 6 B, 10 B, 16 B and 24 B. Depending on size, versions of the hoods with straight or angled entries and housings for bulkhead mounting can be supplied. When the connector is closed and locked, it provides a protection level of IP 65 as defined in DIN EN 60 529. The material also meets demanding flammability requirements of UL 94 Class V 0.

HARTING is expanding its space-saving harlink® metric connector range with a version equipped with solder bucket contacts. Up to now, these connectors were supplied with an insulation displacement termination on the cable side only. The addition of solder bucket contacts now makes it easy to assemble harnesses for prototyping and test purposes without the use of special tooling. With this new contact style, wires of sizes from AWG 30 to AWG 24 can be mounted on the cable side of the har-link(R) connection, providing high flexibility and compatibility with a large range of cables available on the market. har-link® is manufactured in accordance with IEC 61076-4-107. To view the data sheet please click here: http://www.harting.com/uploads/tx_news/har_link_Solder_Bucket_E.pdf

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

For more information contact HARTING Ltd, Northampton. Tel: 01604 827500 Fax: 01604 706777 E-mail: gb.harting.com Web: www.harting.co.uk

applications

Cat Pumps pass the pressure test Hydrostatic pressure testing and flushing subsea umbilicals for the offshore oil and gas industry is a relatively complex procedure involving the deployment of specialised equipment. The flushing of umbilicals and hoses is essential to ensure that following manufacturing, any debris or contaminants are completely removed. Pressure testing is performed in order to ensure the integrity of hoses and umbilicals prior to deployment subsea. Any deformation of the umbilicals resulting from their inability to withstand subsea pressures can have an adverse effect on the performance of the hoses contained inside the umbilicals and the umbilicals themselves. Both procedures involve the use of high pressure pumps and for one major equipment supplier, the most appropriate pumping solution is being provided by Cat Pumps Ltd. Aberdeen-headquartered Proserv is one of the industry’s leading experts in flushing and hydrostatic pressure testing services, constructing and supplying pre-fabricated and purpose built rigs to hose and umbilical manufacturers as well as end-users. Key to the successful operation and performance of a flush and test rig is fast and effective filling of the hose or umbilical with fluid and for Proserv, Cat Pumps 3507 Series triplex plunger positive displacement pumps are proving to be the most effective method for most applications. Proserv has elected to use Cat Pumps’ 3507 Series pump (Fig. 1) because it is ideally suited to handling the liquids involved, which can vary from job to job and can be water, water / glycol or hydraulic oil. They also provide the high pressures and flow required, typically around 342 Bar at 30lt/min. This degree of pressure is required in order to circulate the fluid at the required flow rate along hoses and umbilicals, which are typically up to 15km in length. “When we get an application, we look at the fluid being handled, the flow rate, pressure and from there we will decide on which pump type to use,” reports Mick Woolner, at Proserv’s Great Yarmouth site. “The big

advantage that Cat Pumps have is their ability to pump fresh water, so that is one of the main reasons why we specified it for this specific application. In earlier days, most of the subsea fluids used for testing were oil-based, which meant that several types of pumps could be used. The change to water or water-based fluids has resulted in a requirement for a pump type that can handle this low lubricity media and provide the high pressure required to fill the umbilical or hose quickly.” It is Proserv’s Great Yarmouth, Aberdeen and Newcastleupon-Tyne branches which are the main operations for pressure test and hydraulic flushing equipment, as well as accessories such as valves, pipework, tanks etc for the offshore oil and gas sectors. The company’s transportable pressure testing and flushing rigs are self contained and include a holding tank, pressure and return filtration and flow indication. Pressure testing is performed prior to flushing and involves the Cat Pump pre-filling the umbilical or hose with the specified fluid at temperatures varying between ambient and 60ºC at pressures up to 340 bar. When completely filled, pressure testing can be performed and on completion the umbilical or hose is then flushed with the control fluid which is circulated using the same pump at a set pressure. The tank feeds the Cat Pump through a filter, control valve, temperature gauge and flow meter and then into the umbilical or hose. During the flushing process a sample is taken for analysis to ensure that the fluid meets with the required cleanliness specification. The fluid is then returned to the skid via a filter, flow meter, temperature gauge and back into the IBC for subsequent reuse. Proserv has been using Cat Pumps for several years and the 3507 Series is proving effective for handling waterbased fluids. The problem with these fluids is that they tend to dry the seals. However, Cat Pumps incorporate an internal re-circulation of fluid at low pressure to the secondary plunger seals ensuring that they are always cooled and lubricated, which in turn leads to extended

Fig. 1 Cat Pumps’ 3507 Series pump built for Proserv. operating life. “We are confident in the use of Cat Pumps for both filling and flushing jobs using water based fluids,” continues Mick Woolner. “The pumps are robust, very easy to service and they are well supported by Cat Pumps. Our customers have now become accustomed to triplex plunger pump technology and have confidence in their performance.” There is no definitive length of time that the pump is required to operate continuously when flushing, as this is dependent on the length of the umbilical and the levels of cleanliness required. What is important is that a continuous pulse free flow at high pressure is maintained, and that is what Cat Pumps triplex plunger pumps provide. For more product information contact: Cat Pumps (UK) Limited, Church Crookham, FLEET, Hampshire. Tel: 01252 622031 E-mail: sales@catpumps.co.uk Web:www.catpumps.co.uk

Process Industry Informer March-April 2013

applications

Wemco grit and sludge pumps measure up in wastewater treatment Pump blockages resulting from large quantities of grit, debris and fibrous matter is a problem that operators of wastewater and effluent treatment plants face almost daily. For many it is a problem that is on the increase. The fouling of pump impellers is a longstanding problem that costs companies a lot of money in terms of plant downtime, pump repair and even complete pump replacement. Where grit and sand are encountered, the pump can literally grind itself to pieces. Employing pumps that can withstand abrasive materials and deliver trouble-free performance over long periods should be the main consideration during the specification process. At United Utilities’ Sandon Dock wastewater treatment plant Wemco M4C torque-flow pumps have provided low maintenance, trouble-free performance in handling grit and transferring sludge for many years. The current water treatment works at Sandon Dock, Liverpool were commissioned in 1991 and it is the second largest wastewater treatment plant in the North West of England. Receiving flows from the 29km Liverpool Interceptor Sewer, the plant is capable of treating up to 950million litres, or 11,000l/sec, of sewage a day. The removal of grit at the wastewater intake stage is where the Wemco pumps are first employed. Here the pumps in an ‘operating and standby’ configuration run 24 hours a day, delivering a flowrate of 47m3/hr and head of up to 15m in order to remove the settled grit from the four wastewater intake tanks. In spite of the considerable and aggressive solids content, United Utilities reports that the only maintenance that these grit pumps require is the occasional replacement of the mechanical seals. Further along in the treatment process, the grit-free wastewater is transferred into six settling tanks where it is held for up to 10 hours to allow the agitator blades to move solids to the bottom where they settle as sludge. Each tank is equipped with three Wemco M4C pumps (Fig. 1) for the purpose of removing the sludge from the tanks and transferring it to the dewatering plant. These pumps are virtually identical to the models used for grit transfer and maintenance only involves routine oil changes, plus the occasional mechanical seal replacement. Maintenance is easy and can be undertaken in situ as the pumps are simple to strip down, due to the pump Fig.1 Wemco M4C sludge pump. design which allows the casing to be removed from the front end and giving ready access to all internal components. In the decade that the sludge pumps have been operating, no refurbishment work has been performed on the impellers. The Wemco Model C torque-flow pump has the ability to withstand the harshest of conditions due to its hydraulic vortex pump technique which is based on the principle of a whirlpool. The vortex is created by the rotating recessed cup-shaped impeller extending into the suction line, drawing the liquid / solids into the pump and then quickly through the discharge, whilst minimising the fluid / solids contact with the impeller and volute (Fig.2). This simple design allows solids to pass through the pump without choking the impeller, so considerably reducing pump wear and the potential for blockages.

Process Industry Informer March-April 2013

“The fully recessed cup-shaped impeller and free passageways within the pump casing offer almost total freedom from blockages when handling rags and fibrous solids typically encountered in waste water treatment plants,” comments AxFlow’s Wemco pump manager Mark Redgrove. “The standard option of High Chrome Iron for the wet end, the hydraulic design and thickened wear sections provide a more than adequate combination to deal with grit and silica sands carried into the treatment works.” With radial impeller design pumps, grit is discharged at high velocity Fig. 2 The vortex is created by the against the pump casing or the wear rotating recessed cup-shaped impeller ring. Unlike radial impeller vortex extending into the suction l.ine, drawing pumps, the cupped impeller action the liquid / solids into the pump and of the Wemco pump deflects material then quickly through the discharge. away from the case and back into the flow stream towards the extra-thick sacrificial suction piece. Behind the impeller is a High Chrome Iron wear plate which can withstand the grinding action of grit. To further maximise performance and minimise wear, the large diameter impeller design is the key to pump’s considerable durability and nonclogging performance. Because the suction end of the pump is exposed to the greatest abrasive wear, Wemco designed the pump case in two parts. The replaceable suction piece is sacrificial, even though it is designed for long wear life. Replacing it is an easy operation involving breaking the suction flange, removing the slotted bolts and then installing the new suction piece. The job can be performed in just a few hours and is considerably cheaper than a completely new pump case. “The WEMCO Torque-Flow range comprises various configurations, including close-coupled, horizontal or vertical mounting, cantilever designs and a small range of submersible units,” says Mark Redgrove. “As a result, we can satisfy many of the challenging wastewater and effluent pumping applications that face both the water utilities and companies which generate large volumes of solidsborne waste liquids.” AxFlow has also recently introduced the Wemco WSP, a heavy duty self-priming pump that is equally at ease with clean and solids laden liquids. This new pump is seen as having great potential in the water and wastewater treatment sector where self -riming pumps are ideally suited to any duty with a suction lift where ease of access to the pump is necessary for maintenance purposes. The Wemco WSP pump contains an open type, two vane impeller manufactured in a choice of cast iron or CD4MCu. The wear plate is also made from cast iron and the casings are in ductile iron. It is this build quality that enables the pump to handle both clean and aggressive fluids, the solids handling being excellent for this range with the maximum for a solid sphere being 38mm on the 50mm pump and 75mm on the 250mm pump.

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

applications

Demag cranes are a crushing success for CMS Cepcor • Engineered material handling solution • Precision movement and positioning of crusher components • Reduced set up times for production efficiency Terex Material Handling has supplied two Demag overhead travelling cranes for CMS Cepcor’s Technical Centre, located near its Head Office in Coalville, Leicestershire. CMS Cepcor is Europe’s largest aftermarket supplier of premium crusher components to the mining, quarrying, aggregate, demolition and recycling industries. The company exports to over 100 countries and has recently received the Queen’s Award for Enterprise: International Trade 2012. To meet CMS Cepcor’s specific material handling requirements, Terex Material Handling supplied two Demag 24.5 m span, 12.5 t SWL single girder overhead travelling cranes, each with a Demag DR-Pro 10 electric wire rope hoist. The crane systems have two long travel speeds of 20 and 5 m/min, variable cross travel speeds of 5 to 30 m/min and hoisting speeds of 4.0/0.7 m/ min. Operation is via a Demag DRC-10 radio remote control, for smooth movement and accurate positioning of components within the CNC machining centres. CMS Cepcor’s Technical Director, Chris Sydenham, said “the crane systems had improved manufacturing efficiency considerably and we have been very impressed by the high standards of customer service and attention to detail, which we have received throughout the process.” For more information contact Demag Cranes & Components Ltd, Banbury, Oxfordshire Tel: 01295 676202 Fax: 01295 271408 E-mail: help@demagcranes.com Web: www.demagcranes.com

MAINTENANCE ADVANTAGES HELP NOV® MONO® MAKE ITS MARK AT DANISH WASTE WATER PLANT

GAME SECURE BAGGING & CONVEYING CONTRACTS AT ASSOCIATED BRITISH PORTS

The benefits of NOV® Mono®’s EZstrip™ technology were highlighted by a new order from a Danish wastewater treatment plant. When sourcing pumps for a new sludge dewatering process, the Odense WWTP chose 8 Mono EZstrip™ cake pumps and 16 Compact C Range progressing cavity pumps. The decision was based on the reduced maintenance time the pumps offer, together with speed of delivery from Mono. The same advantages also led the plant’s engineers to specify Mono’s EZstrip™ and Compact C Range pumps for use on new polymer dosing equipment that was being ordered, rather than the competitor pumps which were offered as standard. “When we were invited to tender for the sludge dewatering process, we took an EZstrip™ demonstration pump to the plant,” explains Product Manager Michael Roug, from AxFlow A/S, Mono’s Danish distributor who supplied the pumps. “We explained how it could be disassembled, de-ragged and maintained in-situ, all in a fraction of the time that process normally takes. Coupled with the fact that Mono was also very competitive in terms of cost and speed of delivery, this made it an easy decision.” Mono’s EZstrip™ pumps incorporate the best aspects of Mono’s thoroughly proven Compact C Range pumps, and can reduce the time needed to replace a rotor, stator, coupling rod and drive train by up to 95%, cutting the typical day-long maintenance operation to just 30 minutes. For more information contact Nov® Mono® Audenshaw, ManchesterTel: +44 (0)161 339 9000 Web: www.mono-pumps.com

Spirax Sarco systems help ReFood save over 10MWh per day at waste-to-energy plant ReFood UK Limited is recovering more than 10MWh a day of energy and saving over £80,000 a year thanks to the use of heat recovery systems from Spirax Sarco at its new anaerobic digester (AD) facility at Doncaster. The site’s two CHP units generate hot water as well as electricity, and this is used to drive the AD process. The AD process in turn breaks down 45,000 tonnes per year of food waste to generate methane gas and run the CHP engines. But the engines actually generate more hot water than needed, and that’s where the Spirax Sarco systems come in. The three heat recovery packages take the excess hot water at 90°C and use it to carry out three different heating roles within the plant. Without the systems, the site would otherwise need to meet its hot water needs from the steam boiler, so they are effectively helping ReFood to save money and reduce emissions that would otherwise arise from its new facility. For more information contact Spirax Sarco Ltd, Cheltenham Glos. Tel: 01242 521361 Fax: 01242 573342 E-mail: WebEnquiries@SpiraxSarco.com Web: www.SpiraxSarco.com

GAME Engineering has recently been awarded two contracts at Associated British Ports’ (ABP’s) Port of Immingham. GAME has worked with ABP on projects at several locations recently, so this reinforces the successful working relationship we have created with the largest and leading port operator in the UK. GAME secured the contract with main contractor, PK Construction, to design, supply and install a 500tph fertiliser transfer and distribution conveyor system from quayside to storage building, which is being installed as part of the ABP Fertiliser Terminal Regeneration Project. The system consists of two external overland conveyors, which are of totally enclosed design, the first being over 160m in length and the second link conveyor 48m o/a. These conveyors through a system of a diverter valve and transfer chutes feed two internal distribution conveyors complete with tripper carriages both of which are over 76m in length and feed the product into the desired ground storage bunker in the new storage shed. All of the conveyors will be manufactured in stainless steel for protection from both the coastal environment and corrosive nature of the product. The second contract was awarded directly from ABP and involves the design, manufacture and installation of a 90tph minimum Fertiliser Bagging Plant, located in a new fertiliser storage building. The new bagging plant suitable for bagging 500,600 & 1000Kg FIBC bulk bags, will consist of both single product and blending reception hoppers, from here the fertiliser is transferred using belt conveyors, vibratory tray feeders and bucket elevators through a screening system, with the overs and fines being collected in FIBC bulk bags or tote bins, once screened the product is ready to be bagged through a state of the art twin head 1Tonne Net weigher system with the filled bags being removed from the two stacking conveyors using large fork lift trucks. Again the handling equipment is to be constructed in stainless steel with all support and access structures in mild steel, hot dip galvanised and then overcoated in a marine grade paint system. GAME also has responsibility for the design & installation of the electrics and control system of the bagging plant. GAME look forward to working with ABP in 2013 and hope to secure further work in the future. If you would like to discuss a similar project please call one of our qualified engineers on 01522 868021. Alternatively, please email sales@gameengineering.com. For more information contact GAME Engineering Ltd, Witham St Hughs, Lincoln Tel: +44 (0)1522 868021 Fax: +44 (0)1522 868027 Web: www.game-engineering.com

Process Industry Informer March-April 2013

applications

Qdos METERING PUMPS SOLVE TURBIDITY TESTING DILEMMA FOR WELSH WATER

Enhance production efficiency without compromising safety

Until recently, turbidity testing at the Pontsticill Water Treatment Works in the Brecon Beacons National Park relied on the use of bellows pump technology. However, the inherent introduction of air in the samples was undesirable and led to false readings. Now though, relief has arrived in the shape Watson-Marlow’s new Qdos 30 metering pumps, which not only provide excellent suction lift, but do so without air locks. “This is a clean water site and the quality of sample is very important,” states Marek ˆ Cymru Welsh Water. “In the past Cegielski, a process scientist and manager at Dwr we’ve tried other types of turbidity monitoring devices, such as dip probes, but without much success. We’ve even used bubble traps in conjunction with our bellows pumps, but we still fell short of 100% reliability. Of course, eliminating the need for bubble traps was one of the attractions of replacing one of our bellows pumps with the new Qdos 30 from Watson-Marlow.”

Upstream benefits

Located around 3 miles north of Merthyr Tydfil, the Pontsticill Water Treatment Works draws its water from the Pontsticill Reservoir, a large body of water measuring some 102 hectares in surface area, and holding up to 3400 million gallons of water for supply to industry and the populous of South Wales. Completed in 1927 and served by the Taf Fechan river, Pontsticill is among the biggest and most important resources in the ˆ Cymru Welsh Water portfolio. With this Dwr in mind, successful turbidity testing is vital. Turbidity is a key test of water quality. It is defined as the cloudiness or haziness of a fluid caused by individual particles (suspended solids) that are generally invisible to the naked eye, similar to smoke in air. Water can contain suspended solid matter consisting of particles of many different sizes. While some suspended material will be large enough and heavy enough to settle rapidly to the bottom of a container if a liquid sample is left to stand (the ‘settleable’ solids), very small particles will only settle slowly or not at all if the sample is regularly agitated or the particles are colloidal. These small solid particles cause the liquid to appear turbid. In drinking water, the higher the turbidity level, the higher the risk that people may develop gastrointestinal problems.

Crystal clear solution

The Qdos 30 metering pump at Pontsticill is taking elutriant from a DAF (dissolved air flotation) filtration plant and lifting it approximately 3 metres before it passes through a turbidity meter and returns by gravity back into the flow. At this point the water has already been subjected to coagulation, flocculation and flotation, and is ready for final filtration processes. Capable of delivering flow performance from 0.1 to 500 ml/min, the Qdos pump gives ˆ Cymru Welsh Water a steady flow speed of 280 ml/min - and the emphasis here is Dwr very much on ‘steady’. “Our main requirement is for a constant, pulse-free flow,” says Mr Cegielski. “Previously we had tried fitting back valves to bellows pumps to stop the pulsing but in truth we couldn’t properly buffer the effect and still ended up with false readings.”

ABB provides an extensive portfolio of measurement products for use throughout the downstream chain. From refining through to petrochemical production, ABB’s measurement products provide the accuracy and durability needed to help operators optimize the efficiency and performance of their processes. With certifications including TÜV, NACE, ATEX, FM, FMC, IECEx, CSA, SAA, GOST, INMETRO, PCEC and KGS, ABB’s measurement products provide safe performance in oil, gas, refining and petrochemical operations worldwide. For more, visit www.abb.co.uk/measurement or email moreinstrumentation@gb.abb.com, ref. ‘Oil & Gas’.

Plain sailing

Installed in July 2012, the Qdos 30 is working well without any signs of air introduction or flow variation. Watson-Marlow’s innovative new Qdos range has been purposely designed to eliminate ancillary equipment and enhance productivity by delivering more accurate, linear, and repeatable metering than typical solenoid or stepper driven diaphragm pumps. “So far, so good, as far as we’re concerned - when new technology comes along that has a clear advantage over existing market solutions, then we are always willing to give it a try,” concludes Mr Cegielski. “In total we have four streams to monitor at Pontsticill, so if our existing Qdos 30 continues to meet expectations then we’ll place an order for a further three pumps.” Featuring all-new hardware and software, other water-related applications for Qdos 30 include disinfection and pH adjustment of drinking water and industrial process water, flocculation, and industrial cooling water preparation to list but a few. For more information contact Watson-Marlow Pumps Group, Falmouth, Cornwall. Tel: 01326 370370 E-mail: support@watson-marlow.co.uk Web: www.wmpg.co.uk

Process Industry Informer March-April 2013

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applications

KOREA’S HITE BREWERY COMPANY TRUSTS ITS WATER TO HANOVIA UV As part of its environmentally conscious approach to brewing, Korea’s Hite Brewery Company has recently installed 25 Hanovia UV water disinfection systems at its Massan and Gangwan plants. The UV systems ensure water used in the production processes remains free from microbial contamination, ensuring a high quality, pure final product. Seven units are installed at Massan and 18 at Gangwan. In Massan the UV is used to treat clean-in-place (CIP) water (three units), cooling water injected after the CIP (three units), and activated carbon-filtered water (one unit). At the Gangwan plant three UV units are used to treat water after deaeration and the remaining 15 units treat activated carbon-filtered water. CIP is used for cleaning the interior surfaces of pipework, vessels, filters and other process equipment. CIP water must be completely free from microbial contamination, otherwise it could infect the whole system. As CIP uses very hot water, pipework and vessels need to be cooled down afterwards and before beer production can recommence. Cooling water also helps flushes out the remaining CIP water, which contains acid and caustic soda. The purity of the cooling water is therefore extremely important to prevent any residual contamination. Activated carbon is commonly used in water treatment for decolouring and deodorisation, due to its strong adsorption properties. This adsorption can also remove residual chlorine from the water, leaving the post-filter water vulnerable to microbial contamination. UV therefore plays a vital role in ensuring the post-filter water is

adequately disinfected. Deaeration removes dissolved oxygen from water prior to the addition of yeast, a key part of the brewing process. Any contamination of the deaeration water could kill the yeast, meaning the whole batch would have to be destroyed. UV is ideal for this step as it is quick acting and effective without producing any unwanted disinfection by-products which could affect the yeast. “When Hite was considering UV for the first time it looked at a number of UV system suppliers,” commented Ying Xu, Hanovia’s Asia Pacific Sales Manager. “We were selected as our UV systems not only produced the highest microbial reduction rates, but we also offer a comprehensive and cost-effective spare parts and maintenance service. Hite now uses over 45 Hanovia UV systems in its breweries across Korea, including the latest project at Massan and Gangwan.” “According to the company it also needs to do CIP less frequently, it uses less preservative in the finished product, and the final water has no unwanted residuals, so the taste and colour is not altered in any way. This all adds up to a cleaner, greener process and product,” she added.

The benefits of UV

Meeting the increasingly rigorous hygiene standards required in the brewing and beverage industries is a real challenge. If improvements need to be made to plant and equipment, they need to bring quick returns on the investment and measurable improvements in product quality.

For manufacturers seeking to improve the quality of the end product, UV is an economic, realistic option. It is an established method of disinfecting drinking water throughout the world, and is also widely used for high purity applications such as pharmaceutical processing and microchip manufacturing, where water of the highest quality is essential. There are no microorganisms known to be resistant to UV - this includes pathogenic bacteria such as Listeria, Legionella and Cryptosporidium (and its spores, which are resistant to chlorination). UV disinfection systems are also easy to install, with minimum disruption to the plant. They need very little maintenance, the only requirement being replacement of the UV lamps every 9 - 12 months, depending on use. This is a simple operation that takes only a few minutes and can be carried out by general maintenance staff. For more information contact Hanovia Ltd, Slough, Berks. Tel: +44 (0) 1753 515300 Fax: +44 (0)1753 515301 E-mail: gunvinder.bhogal@hanovia.com / sales@hanovia.com Web: http://hanovia.com

Spiroflow exceeding expectations Founded in 1920, Thomas Dudley Ltd has established a reputation for manufacturing high quality bathroom products, plastic toilet cisterns, and ferrous castings that are both innovative and extremely reliable. Today, this commitment is as strong as ever, resulting in the continued introduction of new toilet cisterns, and ferrous castings that challenge conventional thinking. It was these commitments which, in 2012, led Thomas Dudley to develop ‘Resan’, a range of resin cast vandal-resistant sanitary-ware products for use in high security units and public areas. In the early stages of the ‘Resan’ product development, additives were delivered in bulk bags yet were hand-weighed and mixed to the correct consistency before being poured into castings. This process was time consuming and created high levels of dust, hence, the need for an effective bulk bag discharge system. After evaluating various bulk bag discharger manufacturers, Spiroflow was identified as the preferred supplier; they were able to meet the required delivery, guarantee performance and supply loan equipment during the manufacture process. Tests witnessed Mike Mohr, Works Director and Neil Ward, Production Engineer, at Spiroflow’s Test Centre confirmed that a ‘Spiroflow’ T5 Bulk Bag Discharger and 67 Flexible Screw Conveyor was the correct combination to unload the bulk bags and deliver the additives to the inlet at the top of a continuous casting machine where bulk material is mixed with solid fillers and liquid binders. The ‘Spiroflow’ T5 Bulk Bag Discharger is designed for installations where restricted headroom causes problems in lifting bulk bags in to position on the discharger or where only a low lift forklift truck is available. The discharger can be coupled directly to a flexible spiral or other suitable conveyor to meter product from the bulk bag either volumetrically or by weight. Materials may then be fed direct to either mixing or other process equipment to provide a fully automatic powder unloading, proportioning and transfer system. Mike Mohr, Works Director, confirms, “Our biggest worry was dust control and air contamination, the ‘Spiroflow’ Bulk Bag Discharger has surpassed our expectations, created a safer working environment and increased our flow of production. Once Spiroflow had commissioned the conveyor their service engineer spent a day training our operatives on the correct usage and preventative maintenance procedures to ensure we continue to receive optimum performance from our equipment.”

‘T5’ Bulk Bag Discharger with 67 Flexible Screw Conveyor delivering Additives to the continuous casting machine. For more information about Thomas Dudley, their history, their products and their environmental commitments, go to www.thomasdudley.co.uk To learn more about ‘Spiroflow’ Bulk Bag Dischargers and Flexible Screw Conveyors plus their ranges of Aero-Mechanical Conveyors, Tubular Drag Conveyors and Vacuum Conveyors and also about their Bulk Bag Fillers please visit www.spiroflow.com or E-mail: sales@spiroflow.com or call +44 (0)1200 422525 to discuss your specific requirement

Process Industry Informer March-April 2013

CRUSHERS & SHAKERS

A WELL PROVEN, Would you like Outstanding HIGH REDUCTION Control on a PRIMARY JAW CRUSHER Heavy Duty Shaker? The JC3000 is a well proven single toggle, high reduction jaw crusher that readily accepts soft to very hard ore, drill core, rock and similar particulate up to 85% of its jaw opening. This heavy duty, low maintenance, machine is suitable for use with large batches or for continuous operations. Typical applications include general primary crushing of lump ore in analytical and metallurgical laboratories, sampling stations and pilot plants. Standard Features - Rugged, fabricated steel construction - Roller bearings used throughout - Electric pre-wiring with IP55 enclosed stop/start and motor protection station - Feed hopper, sample drawer and dust extraction points Technical Data - Jaw Inlet 300mm x 200mm - Maximum Feed Size 170mm i.e. 85% of jaw inlet - Usual Product Sizing Nominally 25mm (but ranges from 10mm to 40mm) - Maximum Product Size Nominally 50mm - Throughput 3,000kg to 8,000kg per hour - Electrical Requirements (3 phase) 7.5kW - Toggle Speed 350rpm For more information please contact: E-mail: enquiries@glencreston.com Tel: +44 (0) 208 545 9140 Web: www.glencreston.com

Process Industry Informer March-April 2013

Why not use the D450 digital sieve shaker?

Features include: • Accommodates up to eight 300mm / 450 mm diameter sieves • Digital Display • Variable Amplitude • Electromagnetic = Whisper Quite • Designed for heavier aggregates and larger scale applications • Unique clamping system providing fast and efficient clamping • Wet and dry sieving operation • 0 - 99 minute timer • Remote control The D450 is a powerful Sieve Shaker designed to accommodate up to eight 300 mm and 450 mm diameter sieves. The D450 Sieve Shakers are fitted with a unique clamping system which ensures sieves are held firmly without over tightening and allows them to be quickly removed and replaced. The D450 Sieve Shaker is powered by an electromagnetic drive which has no rotating parts to wear making it virtually maintenance free and extremely quiet in operation (subject to material being analysed). For further details on Endecotts products please contact: E-mail: sales@endecotts.com Tel: +44 (0) 208 542 8121 Web: www.endecotts.com

GETTING READY FOR While our present and future needs in the UK for more engineers and skilled technicians are now broadly acknowledged, Brian Holliday,

WORK?

Divisional Director from Siemens Industry Automation, a division of Siemens Industry, argues that more could be done to feed new candidates into engineering education schemes at all levels supported by vocational training which improves work readyness outcomes for employers.

The national requirement to address the shortage of skilled technicians and engineers is clear. Of the 300,000 graduates emerging each year from our education system, only 24,000 do so with an engineering-related degree. Our engineering sector also requires at least 235,000 apprentices and technicians over the coming decade and the pipeline appears to be around 50% short of demand in both numbers and disciplines. Some of the most acute issues are being faced in power and process engineering. So the challenge of attracting younger people to the industry continues. But this only tells part of the story. Just as important is the early exposure engineering students have to quality academic study combined with real world activity, a grounding which arms them earlier with skills, experience, and enthusiasm to join a workforce and make a real contribution. Vocational training or learning by doing lies at the heart of this challenging objective and is one that Siemens passionately believes in. When it comes to recruitment, our own company experience highlights a paradox. While Siemens continues to highlight the numbers shortage for the industry, our own entry programmes such as our European scholarship and domestic apprentice and undergraduate schemes are consistently oversubscribed. Put simply, candidates appear more attracted by the brand of the company than the generic rewards of an engineering career. However, when it comes to sourcing candidates for engineering roles requiring specialist experience, the picture is difficult for big business and SMEs alike. Siemens are typically challenged finding domestic talent in high voltage, power electronics and many project and technical roles and often fill such vacancies from overseas. Our supply chain partners too, a rich network of industrial system integrators consistently tell us that they could grow if they could recruit more engineers with the right mix of control system, sector and site experience. Education can’t be held soley accountable for this, yet when you consider the PLC1, the workhorse of manufacturing and infra-structure, I find it incredible how little curriculum or practical coverage control systems still get even in further and higher education engineering courses.

Employer input to education is particularly important to help students transition into the engineering sector, one that the numbers alone tell us is now a good long term bet. Here, we are supporting some notable developments that should improve outcomes for the next generation. No significant awareness for engineering where it matters... Many of us have concerns about education in our schools; the decline in students selecting STEM subjects; the de-emphasis of Design and Technology in the curriculum; the lack of informed careers advice as a guide to future employability and the equivalence debacle over the Engineering Diploma to name a few. But our research shows we have an engineering image problem that starts young too, with only 1 in 10, 11-14 year olds thinking ‘engineering is important’ and perhaps worse, 4 in 10 thinking it to be ‘dirty or smelly’. Engaging with schools and helping stretched teachers in a practical way to introduce positive examples of engineering’s contribution to society will help. The Department for Business Innovation and Skills agree and on Feb 28th supported the launch of the Siemens Education Portal* at their annual Manufacturing Summit. It aims to reach over 5000 schools with easily accessible content to aid a journey in the classroom for learners to understand more about the role of engineering and its career possibilities. 2011 saw the opening of a 2nd University Technical College in the UK, a technical school for 14-19 year olds. Siemens became the major employer partner for the Black Country UTC which in common with the 33 further planned UTCs provides a vocational alternative, with the support of employers, an FE college and a university. Each has a regional specialism and will expose learners to real world experiences and academic study. With full teaching days, business attire and mandated, employer led projects using the latest technologies, UTCs will do much to better prepare students for the workplace, filling a much needed gap in our workforce for vocationally trained technicians. The Baker Dearing trust would like to see more than 300 UTCs in the UK, and Siemens are actively planning to support them near all our major locations.

Industry training on the up... Encouragingly, apprenticeships are once again in their ascendency having been undervalued and under offerred over the last 20 years. The name has arguably been dented through the branding of shorter courses that lacked employer input. But part driven by structural change in the university fee system, quality apprentiships are back and in 2012, Siemens took on more engineering apprentices than graduates, placing us third in the UK for number recruited. Many employers are now recruiting apprentices for future needs but there is much to be done, helping SMEs in particular shape required learning outcomes. Fortunately, Semta recognise this and through the Employer Ownership of Skills scheme have made funding available. Siemens are playing a role here, also training apprentices on behalf of its supply chain. Notably too, the introduction of the higher-apprentice framework is welcomed by engineering employers, providing yet more vocational training scope for employer and employee alike. Beyond the early entry routes into our company, Siemens remain active supporters of the E3 Academy and Power Academy, schemes which expose under-graduates to our organisation and its practical challenges. We actively encourage professional registration for all eligible employees too, through the IET and IMechE to promote Continual Professional Development and life-long learning. At the heart of the work readyness and contribution debate lies exposure to practical problems. The employer rewards for embracing a vocational training approach should include greater employee alignment, higher retention levels and elevated contribution levels. In the author’s view, wider adoption of vocational training will not only improve employability outcomes, but could attract and engender aspiration in greater numbers of the next generation on whose contribution we will so clearly now depend. * www.siemens.co.uk/education 1 Programmable Logic Controller For more information please check out the website above. For general information please go to www.industry.siemens.co.uk

Process Industry Informer March-April 2013

At WAGO, fresh ideas flow naturally ADVANCED AUTOMATION CONTROL SOLUTIONS FROM A SINGLE SOURCE With a range of over 25,000 products, WAGO is the world leader in advanced interconnection technology solutions. Whatever the process, we have a comprehensive range of automation control systems which will deliver optimum product quality, easier operation and lower costs

Intelligent I/O – compact, modular, fieldbus independent systems for decentralised solutions. Suitable for all process industry applications

JUMPFLEX® – ensures safe, secure field signal processing. Compact design and suitable for temperatures from -25°c to 70°c

SPEEDWAY – the new standard for cabinet free automation. Compact IP67 modular I/O delivers unique benefits in the toughest environments

TO-PASS® – delivers advanced telecontrol solutions including fault detection via GSM connection. Option of IP66 protection

TOPJOB®S – Ex approved DIN rail mounted terminals offer 30% space savings. Robust, dependable and economical

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

For more information, call 0870 264 0773 or email ukmarketing@wago.com Process Industry Informer March-April 2013

filtration & separation

Bosch Rexroth expands into filtration market Bosch Rexroth has expanded its product portfolio in the UK market to include its own range of filtration systems. The range expansion is the result of Bosch Rexroth’s acquisition of K & H Eppensteiner GmbH & Co in 2009, one of Europe’s most established filter manufacturers. As a result, the Eppensteiner range of filtration products is now being rebranded Bosch Rexroth and being made available in the UK. The breadth of the range covers all aspects of filtration with high flow rates and several pressure ranges in return and pressure types such as inline, manifold, tank mounted, duplex and all with indication options. They can be applied to a range of applications, from agriculture through to rail, mobile and industrial. The new product portfolio also contains all filter accessories, including filter programs, oil purification, measuring instruments and specific condition monitoring systems. Crucially, the expanded range will include the award winning LE (N) 0040-0400 series filtration system, which has an innovative filter head design resulting in a ‘cyclone effect’ which diverts the inlet flow in a specific direction which enhances the flow properties and dirt absorption capacity. In addition, the filter also boasts a newly designed bowl which improves element mounting and stability which keeps the element in place ensuring constant pressure distribution. Chris Gray, Filtration Product Manager for Bosch Rexroth, commented: “The expansion of the Bosch Rexroth product portfolio into filtration enables our UK customers to access a complete hydraulic package from a single source. Filtration has been a clear gap in the Bosch Rexroth hydraulics portfolio which I am delighted to say has now been filled with the highest quality filtration products.” Further information on Bosch Rexroth’s Filtration range can be found at www.boschrexroth.co.uk/filtration.

Purity through innovation

Global sieving and filtration specialists

The Self-Cleaning Russell Eco Filter® ... • Improves product quality • Protects operators & environment • Increases productivity

What makes us specialists..? Customized solutions - Applying innovation to meet your requirements Comprehensive customer service - Technical support & global stocking Specialized testing facilities - Trial your products for total peace of mind

Call us on: +44 (0) 208 818 2000 16

WHITMAN LABORATORIES REDUCE WASTE AND MAKE SUBSTANTIAL COST SAVINGS Whitman Laboratories Ltd, a centre of manufacturing excellence for the Estee Lauder Group of Companies, is making substantial cost savings since installing a number of Axium Process’ Pure-Screen Compact Wedge Wire filters, by reducing downtime and recovering up to 6kg of high value skin care product per batch, per day which was previously wasted. The company, traditionally used Filter Socks during their batch manufacturing of skin care products which required changing at the end of every batch resulting in considerable wastage of expensive product and costly downtime. Axium’s range of 316L Pure-Screen filters, which are being widely used throughout the pharmaceutical, food, beverage, dairy and cosmetic industries, require minimal maintenance and are quick and simple to maintain as they have no moving parts and do not require tools for access or cleaning. The filters, which can be fabricated to customer requirements are available with interchangeable wedge-wire filter elements ranging from 25 micron up to 6000 micron as standard, and are suitable for backflushing, CIP (clean-in-place) and SIP (steam-in-place). For more information contact Axium Process Ltd, Hendy, Swansea Tel: +44 (0) 1792 883 882 Fax: +44 (0) 1792 886 049 E-mail: info@axiumprocess.com Web: www.axiumprocess.com

ULTRA-LOW-PROFILE SIFTER FITS TIGHT SPOTS Kason has introduced an ultralow-profile 1016 mm diameter Flo-Thru Vibroscreen® sifter with flat dust cover that fits tight spots between storage and process equipment. The sifter employs two imbalanced-weight gyratory motors mounted on opposing exterior sidewalls of the unit, instead of one motor positioned beneath the screening chamber, reducing overall height significantly. The design also allows vertical alignment of the top inlet and bottom outlet, causing on-size material to descend through the screen in a straight-through path at high rates. Oversize material is ejected through a spout at the periphery of the screen. The unit is intended for installation above or below storage vessels, bulk bag and drum unloaders, bag dump stations, blenders/mixers and other process equipment, and can be installed with minimum alteration to existing layouts. All material contact surfaces are of stainless steel with continuous welds polished to cGMP, 3-A, USDA and FDA standards. The company also manufactures other circular vibratory screeners, as well as centrifugal separators, and circular fluid bed dryers, coolers and moisturisers. For more information contact Kason Corporation Europe, Road, Stoke-on-Trent, Staffordshire. Tel: +44 (0)1782-597540 E-mail: sales@kasoneurope.co.uk Web: www.kason.com/

Process Industry Informer March-April 2013

Assuring the Performance of Sterile Gas Filtration in Drinks Packaging By Daniel Vecsey, Product Manager - Food and Beverage - Parker Hannifin Manufacturing Ltd - domnick hunter Process Filtration - Europe

Summary The performance of sterile gas filter systems is critical to a plant’s Quality Assurance objective of protecting their product from contamination during production and packaging. The on-going performance of a plant’s sterilizing grade gas filters can be checked by routine integrity testing as part of their HACCP plan. Most integrity testing methods are time consuming and difficult to perform, thus conflicting with the demand for efficient operation for leading beverage processes. The aerosol challenge test method provides a number of process advantages by being capable of testing both depth and membrane style sterile gas filters in-situ, quickly and easily4.

Introduction The growth of aseptic filling within the soft drinks industry has seen a significant increase in recent years, driven by a demand for fresh, healthy, natural products which are low in fats, salts, sugars and preservatives. Unfortunately, reducing the level of these constituents provides the ideal environment for bacterial growth. Bacterial contamination presents a significant processing problem which, if not addressed appropriately, could result in product re-work, wastage or recall, all of which contribute to significant processing costs. As a result, manufacturers employ microbial stabilization or sterilization techniques throughout their production processes to eliminate contamination and reduce the levels of microorganisms in their products for safe consumption. In aseptic filling, the microbial content of the product is stabilized before it is packaged, typically using one or a combination of methods such as pasteurisation and filtration. Stabilizing the product before packaging creates the need for a completely sterile environment when packaging, to prevent any other microorganisms from entering the product. A key consideration in doing this is the compressed air or other gases that come into direct contact with the product or packaging. The gas used to dispense the product into its container and the gas used to blow containers serve as the two key examples of where sterility is absolutely essential to maintain product quality (see figure 1). To achieve food grade compressed air sterility, a range of filtration and separation techniques are typically employed to remove each contaminant before final sterile filtration2 (see table 1 below).

Table 1. Summary of purification technologies applicable to the main contaminants of compressed air2

The sterile filtration of compressed gases is an essential consideration in the HACCP (Hazard Analysis of Critical Control Points) framework. HACCP is an internationally recognised approach for the systematic identification, control and on-going monitoring of potential hazards in a beverage production process, principally aimed at protecting consumer health. Sterile filtration of gases which come into direct contact with the product or packaging are highlighted as Critical Control Points in the HACCP plan. As such, a monitoring programme is required to make sure the filter system is fit for purpose and is capable of delivering sterility throughout its entire service life.

Sterile Gas Filter Integrity Testing - Assurance of Hazard Elimination

Figure 2. Summary of HACCP plan adopted by leading beverage processes

The ability of sterile gas filter systems to provide sterility during use will have been validated by the filter manufacturer. Typically, this will have been done through extensive bacterial challenge testing, where the filter will have been exposed to high levels of bacterial cells per square centimetre (typically 107 cfu B.diminuta or B.subtilis

Process Industry Informer March-April 2013

per cm2). This validation is used to demonstrate that a sterile gas filter will deliver sterility under set operating conditions1. However, gas filters can be damaged in situ, termed as having ‘lost their integrity’, if exposed to conditions outside their validated limits. Various factors can cause or contribute to filter damage, such as mishandling on installation, stress during steam sterilisation (SIP), contact with aggressive chemicals or puncturing from finings in the pipework. In order to reduce the impact of processing with a filter failure as best possible, any filter failure needs to be detected as soon as it occurs. This is done through integrity testing; a means of verifying the ability of a filter to provide the required quality of filtrate. Through correlation of an integrity test to a live bacterial challenge, integrity testing is used to give assurance of filter performance within an application1. Currently, sterile gas filter systems are engineered to provide extended service lifetimes to suit the demand for increased process efficiency and reduced operational costs required by leading beverage processes. An increase in service lifetime of the filter further drives the need for routine integrity testing, so that the performance of the filter system can be monitored and assured throughout its complete operational life. As most beverage processes are also fast paced production environments driven by efficient operations, there is also a demand for filter integrity testing to be a quick procedure, requiring little process downtime or operator input. There are various traditional integrity test methods available to monitor the performance of a sterilizing gas filter. Such methods (Diffusional Flow, Pressure Decay, Bubble Point, Water Intrusion) are widely accepted methods which have been developed in line with pharmaceutical processes1. Although they are reliable in terms of determining filter integrity, they have significant disadvantages when employed to integrity test sterile air filters for fast paced beverage production. The main disadvantage of these methods for the beverage industry usually arises from the time consuming operations required to prepare the filter for the test and to restore the filter system back to process. Such operations include wetting the filter medium with a suitable solvent and the subsequent flushing and / or drying of the filter after testing. Another disadvantage of the liquid based methods is that they are not compatible with sterilizing gas filters which use a depth style filter matrix as opposed to a membrane as the filter layer. Gas sterilizing filter systems which use depth style media as the filtration layer, such as Parker domnick hunter’s HIGH FLOW BIO X4, are suited to beverage operations due to the superior flow rates which can be achieved over membrane style filters, such as Parker domnick hunter’s HIGH FLOW TETPOR II5. A superior flow rate per given pressure drop will improve filter system and process economics by two main mechanisms: 1. Smaller filter systems can be used for a given

flow rate, which can reduce replacement element costs. 2. Reduced demand from the compressors will yield a reduction in energy costs. As many beverage production processes use sterilizing grade filters which have a depth media as the filter layer, there is a need for an integrity test which can also be used for this format of filter too. The aerosol challenge test method satisfies this requirement as the method is applicable to filters using both membrane and depth materials.

Figure 1. SEM images of sterile gas filter media, PTFE membrane (left) and depth media (right)

Aerosol Challenge Testing with Parker domnick hunter’s Valairdata 3 Test Principles During the aerosol challenge, test filter is challenged with a high concentration of aerosolised oil droplets (FDA approved for food use) to simulate an aerosolised bacterial challenge under high loading, worst case conditions. As the retention ability of the test filter is actually tested during an aerosol challenge, the method can easily be applied to both depth and membrane style sterilizing grade gas filters and returns a quick, accurate method of testing gas filters.

References: 1. PDA Technical Report 40, Sterilizing Filtration of Gases 2. High Quality Compressed Air for the Beverage and Bottling Industries, Parker domnick hunter 3. Valairdata 3 brochure, Parker domnick hunter 4. HIGH FLOW BIO X data sheet, Parker domnick hunter 5. HIGH FLOW TETPOR II data sheet, Parker domnick hunter Parker Hannifin Manufacturing Limiteddomnick hunter - process filtration Europe Birtley, Co. Durham Can be contacted on: Tel: 0191 4105121 Fax: 0191 401 5312 E-mail: dhprocess@parker.com Web: parker.com/processfiltration

When environmental standards make perfect business sense:

ISO50001 Released by the International Organisation for Standardization (ISO) in June 2011, ISO 50001:2011 (Energy management systems - Requirements with guidance for use) is a specification for energy management systems. Steve Brambley, deputy director of GAMBICA, explains why ISO50001 makes perfect business sense for all organisations, irrespective of their size, sector or location. ISO50001 specifies the requirements for establishing, implementing, maintaining and improving an energy management system. Its purpose is to enable businesses to apply a systematic approach to achieving continual improvement of energy performance, including energy efficiency, energy security, energy use and consumption. The standard aims to help companies continually reduce their energy use, and therefore their energy costs and carbon emissions. Thanks to their framework, ISO standards offer organisations the tools for bettering their processes and improving their systems. The plan/do/check/act steps make it easy for companies to apply the philosophy to their business. The immediately obvious advantage of decreasing energy consumption is the consequent reduction in electricity bills - which sends savings straight to the bottom line. By reducing energy consumption companies can lessen their reliance on the rising cost of fuels. It is in a way, the only insurance SMEs can make against future changes to the energy supply and tariff rises. Secondly, by minimising the amount of electricity consumed on monthly basis, organisations, regardless of their size can make a positive environmental impact. Aiming to comply with ISO50001, rather than taking an ad-hoc approach to energy saving is proven to be significantly more effective. The continuous improvement cycle imposed by the standard compels business owners to follow procedures and remain focused on achieving their energy goals. Furthermore, ISO standards often require a thorough evaluation of current business procedures and systems. This objective analysis alone can prove extremely useful, as it points out areas that need systematic improvement. Thus, benchmarking can instil best practice amongst employees and create a sense of inclusion and participation.

Thanks to the framework provided by ISO certifications, everyone can get involved and have an input. This can lead to increased staff morale and better work relations, as employees may well enjoy contributing and doing their bit for the standard. Given that many people, particularly young people, regard generating a positive environmental impact as a passion, ISO50001 can affect the satisfaction such people get from their jobs. Another reason why adhering to ISO50001 may be a wise business decision is the reputational value and kudos that comes with achieving accreditations. Showing that you are a proactive company that makes sensible decisions has its advantages. Businesses with accreditation will usually have a better standing in tender negotiations for instance. Similarly, cost-cutting strategies always appeal to potential customers, as they see the direct benefit in decreased fees for your products or services. Moreover, showing clients, suppliers and collaborators that employees follow policies and procedures helps instil trust. Adopt a responsible and environmentally friendly stance also helps improve relationships with the community and paint a picture of a company that acts with the best intentions. Corporate social responsibility is not reserved for major international players; smaller businesses can show that they care too. This is especially true if they want to win contracts from major international players!

Generation must improve There is no doubt that we need to develop sustainable forms of generation, whatever the source. In fact, developing new technology is fundamental to providing innovative solutions to the UK’s energy problem. But, as well as finding ways to keep the lights on, we should start by turning lights off when they’re not needed - both metaphorically and literally. With the serious threat of energy rationing on the 10 year horizon, using less energy is a smart move from both a cost and continuity perspective. There are a number of ways that businesses, irrespective of their industry sector can reduce energy consumption. To begin with, all organisations use on their premises a few (if not all) of the following: lighting, heating, ventilation, refrigeration, air movement and air conditioning. As the great majority of these applications use electric motors, they can be rendered more efficient through the addition of a variable speed drive. Electric motors can consume huge amounts of electricity, so it’s no wonder that 60% of all energy consumed by UK Plc is used for driving various types of motors. Even a simple electric motor, used for an office ventilation unit can be expected to consume many tens of thousands of pounds worth of electricity over its useful lifetime. Using a variable speed drive allows the speed of these motors to be accurately controlled and optimised for the

application, resulting in typical efficiency improvements of 30%. The cost of energy is important, but the security and continuity of energy is crucial. Maintaining a reliable energy supply requires both businesses and individuals to consume less - and this is exactly what VSDs can help achieve. They both reduce the bill in proportion to its overall size and improve the long term business model of the energy industry by increasing the likelihood that it will be able to help Government meets its energy reduction targets. Another way in which energy consumption can be controlled more effectively is through other forms of control automation. The main benefit of this in your premise comes from being able to switch things off or turn them down in response to their environment. Most of the highest profile energy efficient technologies of the last few years, such as lean burn car engines and domestic boilers, have been largely the result of the incorporation of modern automation, sensing and control technology into the equipment. Installing sensors that automatically switch off the lights when no one is in the room or turn down heaters at the weekend can be part of a sensible automation strategy. The cost of such control devices is affordable for businesses of any size and it can translate to a significant energy saving.

Rewarding compliance Adhering to ISO5001 is one of most rewarding and worthwhile compliance activities a business can engage in. Not only does it help simplify environmental compliance issues, but it also has a direct financial benefit in the form of reduced energy bills. For those companies wishing to align to other international standards, ISO50001 can provide a good foundation. Regardless of your company’s size, scope, ambitions and goals, using energy sensibly and responsibly can help raise the profile of your business and help cut running costs. Complying with energy saving standards shouldn’t be regarded as yet another hoop to jump through, but rather as a crucial part of your business strategy that will reduce expenditure and increase profit.

The Association for Instrumentation, Control, Automation & Laboratory Technology (GAMBICA), London Can be contacted on: Tel: +44 (0)20 7642 8080 Fax: +44 (0)20 7642 8096 E-mail: sbrambley@gambica.org.uk Web: www.gambica.org.uk

Process Industry Informer March-April 2013

filtration & separation The New Russell Compact Sieve® meeting Fine powder handling through requirements of the 3-A sanitary standards food grade textile connectors Users of processing equipment within sectors such as dairy, meat and other food industries require complete peace of mind that their equipment is designed and manufactured to the highest possible standards. The New Russell Compact Sieve meets the requirements of the 3-A sanitary standards. These standards have been put in place to ensure that sanitary standards are continued while developing and producing hygienic equipment design for the food, beverage and pharmaceutical industries. Russell Finex, market leaders in separation and filtration technology, continually ensures equipment effectively complies with industry standards and guarantees the highest product quality available. Therefore in order to meet the requirements of the 3-A standard, Russell Finex have made modifications to one of their most popular vibratory screeners, the Russell Compact Sieve®. First invented over two decades ago, the Russell Compact Sieve® was the first straight-through vibratory screener on the market and since then has been installed within a wide range of food and pharmaceutical applications across the world. Renowned for its compact and easy-clean design, this unit has evolved to become the most successful vibratory screener throughout the process industry. With its hygienic design including fully stainless steel construction, FDA approved materials and gap free mesh screens, with a few refinements the Russell Compact Sieve® range now meets the requirements of the 3-A sanitary standards.

and transfer chutes

Having the Russell Compact Sieve® meeting requirements of the 3-A sanitary standards not only reduces validation time but also provides numerous functional benefits compared to other 3-A sanitary screeners. Having a low profile straight-through design enables these screeners to fit neatly into production lines, boosting productivity of the screening processes without requiring excessive headroom. Its innovative design means that the screener is less than half the height of a traditional screening machine. The most important feature of the Russell Compact Sieve® is its unique quick-release clamping system. Unlike conventional screeners using band-clamp arrangements, these can be more difficult to dismantle and often require tools. However, the Russell Finex quick-release toggle clamps offer the ability to perform screen changes without tools, reducing operator involvement and increasing productivity. Key benefits of the Russell Compact Sieve®: • Unique quick-release clamping system allows for fast screen changes without tools. • Quiet operation (typically less than 70dBA) is achieved with a solid rubber suspension system. • Easy to clean crevice-free design, meeting the requirements of the 3-A sanitary standards.

Safe transfer of fine, sticky or wet powders can prove difficult however the right textile chutes and connectors can help to ease the process by minimising loss of powder thanks to membrane technology. Airborne dust can compromise the safety of the working environment and the validity of other products. Blocked filters can constrict the airflow making correct ventilation essential to disperse displaced air during filling. To ensure optimum performance the filter cleaning system should operate effectively - either through washing or by regular replacement. We can manufacture a high quality connector/ chute from FDA approved materials that offer several advantages: • Good cake release • High particle retention through membrane technology • Antistatic properties • FDA Certification Thanks to over 40 years of experience in the Filtration Industry our expert team produces high quality and reliable textile filters from FDA Certified Materials.

For more information contact Russell Finex Ltd, Feltham, Middlesex. Tel: +44 (0) 208 818 2000 Fax: +44 (0) 208 818 2060 E-mail: admin@ russellfinex.com Web: www.russellfinex.com

For more information contact DRM Industrial Fabrics Ltd. Tel: +44 161 763 1776 E-mail: info@drm.co.uk Web: www.drm.co.uk/filtration

Consistent and Reliable Quality since 1970 Manufactured in the UK

Together, we can take control of your process … for accurate and reliable results

The Fast Solution

The Accurate Solution

The Portable Solution

Sterile Gas Filter Integrity Testing State-of-the-art technology and lightweight, portable design underpins the performance of this new aerosol challenge test instrument. Feature upgrades include touchscreen operation, enhanced-life and lightweight battery, and USB transfer of test data. These features combine to improve the usability, data handling and ultimately reduce the time taken to perform filter tests.

Europe: phone +44 (0)191 4105121 - email: dhprocess@parker.com North America: toll free: +1 877 784 2234 - email: dhpsales.na@parker.com

www.parker.com/processfiltration

Process Industry Informer March-April 2013

Get your business The right approach to energy management and purchasing can bring multiple benefits to a business. Wayne Mitchell, industrial and commercial sales and marketing director at npower explains how businesses can do this with a few simple steps.

energised At npower, we feel it’s important to work in partnership with businesses to offer them the right solutions to take control of their energy. Regardless of size, there are certain pointers that every business can follow to ensure they’re getting the most out of their energy. It may involve changing the way you approach energy management and purchasing, but just a small change can really pay dividends for the future. With this in mind, we have put together a three-step guide to help businesses review their energy use and implement changes for the better.

Step one: It’s all about strategy Businesses require shrewd strategies and careful planning to become successful. Great energy management is just the same, and a little planning can go a long way to help reduce costs. The first step is ensuring energy is recognised as and treated as a strategic issue of prime importance to a business. Working with senior management to elevate energy as a strategic concern for an organisation can help ensure there is awareness and support from the top. When it comes to developing a specific energy strategy for your business, there are potential efficiencies and savings to be identified, both in procuring energy and using it. However, there are other factors to be aware of throughout the planning process. It is important to keep abreast of the latest energy and climate change legislation that is affecting your business, as it is likely this will help inform your energy strategy. For example at npower, we regularly work with businesses to help them have their say on the energy legislation affecting them and have presented a number of reports on business views to government that have helped inform policy decisions ranging from the Feed-in Tariff scheme to the Carbon Reduction Commitment Energy Efficiency Scheme. While some businesses may feel having an energy strategy is only suitable for the largest organisations, medium sized businesses (MSBs) can also benefit from giving it some thought. In fact, an npower report into MSBs found they see energy as one of their highest risks, second only to sales. However, as MSBs are often hard pressed to put their resources behind energy management, only one fifth (21%) has an energy strategy in place. When it comes to energy expertise, less than 5% are likely to have a dedicated energy specialist, despite average MSB annual energy spends topping £180,000.

Step two: Smart purchasing In the past, buying a year’s energy via a single transaction was the norm. But

buying a large amount of energy in just one transaction can be risky, as you could end up buying when the energy market price is high. The easiest way to minimise the risk is by spreading your energy purchasing decisions across the year.

can be useful to achieve this, and many organisations find it useful to appoint an accountable ‘energy champion’ to promote energy efficiency within the business.

Large industrial and commercial businesses will already be buying energy flexibly, in smaller amounts to try to get the best deal and spread their energy risk. Purchasing energy this way means businesses can use the latest energy market information to get the best deal. To help businesses better understand developments in the energy market, npower’s Optimisation Desk releases a weekly energy market update video.

Businesses should be doing everything possible to maximise their growth potential. So, energy managers and those responsible for energy can help give their organisations a competitive edge by taking simple steps to better control their energy costs. This means planning your energy strategy and getting smarter with procurement, combined with reducing your energy use. After all, the cheapest energy is the energy you do not use.

Until recently, flexible energy purchasing has only been accessible to large industrial and commercial businesses which have the time and expertise to take advantage of price fluctuations in the wholesale energy market. MSBs have historically been restricted to fixed contracts due to a lack of time and energy expertise, and both of these factors were cited as the biggest obstacles to more sophisticated energy purchasing in npower’s report. However, with the latest energy purchasing tools, MSBs can tap into changes in wholesale energy prices without needing to become experts in the energy market or dedicating large amounts of time. For example, many businesses renew their contract just before the previous fixed-price period expires. This means they have little control over whether the new price reflects a peak or trough in the energy market, which can make it very difficult to budget ahead. However, many energy suppliers now allow businesses to renew contracts further in advance, so they can secure energy at a potentially more opportune price point in the market. For companies that do not have the required level of energy expertise in-house, it is important to work in partnership with your energy supplier to make the best of the purchasing opportunities available to your business.

Step three: Minimise usage Making your business as energy efficient as possible should always be front of mind, from the boardroom down. To help achieve this, the best tool you can have is accurate information on how, when and where energy is being used within your organisation. If you know exactly how energy is being used, you can put effective measures in place to improve efficiencies. There are ‘quick win’ measures you can implement as well, including turning lights and equipment off when they are not needed and getting staff on board with energy reduction goals. Staff engagement initiatives

Planning for success

For more information on how npower can help your business’ energy management in 2013, email business@npower.com.

Take control of your energy with a strategy 1. Have a realistic budget When setting a budget, it is important to be realistic about your energy needs so you do not find yourself with unexpected costs later on. 2. Know your volume It may sound obvious, but it is important to know how much energy you are using as this will inform the best way to procure your energy. 3. Take a long term view Taking a longer view will mean you can set long-term goals and give you a realistic amount of time to meet them. 4. Work with your supplier There is a wealth of energy expertise on hand to help your business manage its energy as effectively as possible, so make sure you take advantage of this. 5. Don’t stop focusing on the three M’s - Measure, Monitor, Minimise Using the latest energy monitoring tools, you can track where, how and when your energy is being used within your organisation. This insight will help you identify where efficiencies can be made.

npower, Solihull, Birmingham, West Midlands Can be contacted via E-mail: business@npower.com

Process Industry Informer March-April 2013

Industrial Air Filters The Smart Process Solution

Schenck Process offer a unique combination of over 40 years of industrial air filtration experience, extensive process systems knowledge and worldwide, local customer support. Schenck Process have unrivalled material testing facilities and results database within the industrial filtration industry. These facilities are available for clientâ&#x20AC;&#x2122;s materials testing and assessment to specify and design the ideal filtration system for their requirements. The improved range of air and dust filters from Schenck Process has been developed to provide maximum installation flexibility and easy access for filter replacement. The innovative product designs offer reduced life-cycle costs by the use of energy saving features and can be supplied as stand-alone units or as part of a turnkey process solution in combination with other material processing equipment.

Contact your local Schenck Process office to discuss your industrial air filtration requirements and the solutions that we can offer. Schenck Process UK Limited Carolina Court, Lakeside Doncaster, South Yorkshire DN4 5RA Tel: +44 (0) 1302 321313 Fax: +44 (0) 1302 554400 enquires@schenckprocess.co.uk www.schenckprocess.co.uk

FLUIDS & LIQUIDS HANDLING inc. pumps & valves ASCO NUMATICS STAINLESS High reliability spray drying pump - Hydra-Cell STEEL FILTER REGULATORS COMPLEMENT ITS RANGE OF excels in spray drying AIR PREPARATION EQUIPMENT ASCO Numatics introduces a new range of Series 342 Stainless Steel Filter Regulators to complement the existing range of air service equipment. Suitable for inlet pressures up to 10 bar, the 1/4” and 1/2” NPT filter regulators have a fully stainless steel construction and comply with the requirements of ASTM A351/NACE MR 01.75. The moulded reinforced diaphragms offer a large flow and the fine pitch/dual springs ensure accurate and steady regulation, regardless of input or output pressures. With a 316L stainless steel filtering element (25µm & 5µm), the regulators are suitable for compressed air and gases. A finned diverter guarantees effective moisture removal. The regulator bowl has a manual bleed to drain condensate. An automatic drain is available as an option. The smooth design facilitates easy mounting and there is a separate connection for the optional pressure gauge. In addition to an impressive flow rate ranging from 2380 to 4430 l/min, the filter regulator is suitable for ambient temperatures from -40°C up to +80°C (-50°C for arctic conditions is available on request). The series 342 stainless steel filter regulator can be installed across many industries, including chemical, petrochemical, offshore and oil & gas, refinery, power generation, pulp & paper and process plants. For more information contact ASCO Numatics Ltd, Skelmersdale, Lancashire. Tel: +44 (0)1695 713600 E-mail: enquiries.asconumatics.uk@emerson.com Web: www.asconumatics.co.uk

Feed pumps are critical components in spray drying, a unique process for converting a solution, suspension or emulsion into solid powder or granules in a single step. Hydra-Cell® high-pressure spray drying feed pumps are reported to offer outstanding heavy-duty reliability, even in 24/7 operations. Many feed materials are pre-concentrated to form viscous liquids or slurries that can be abrasive and cause severe wear to pumps with mechanical seals. Hydra-Cell pumps eliminate seal maintenance as they have no such dynamic seals and are designed to accommodate solid particles up to 500µm in diameter. Other maintenance is minimal and easily carried out in-situ. Compact and with a small footprint, Hydra-Cell pumps are also designed to run-dry without incurring damage; further system protection should the feedstock run out and a guard against operator error. They can pump feed materials with a wide viscosity range and can also handle corrosive liquids. Being positive displacement pumps, Hydra-Cells are exceptionally energy efficient, a factor that significantly reduces their overall lifetime cost. The multi-diaphragm arrangement produces a virtually pulse-less flow and unlike piston and plunger pumps, Hydra-Cell pumps do not generally require flow dampeners to achieve satisfactory atomisation results.

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

• Single operator • NO tools required • 4 Minute change-over • Easy access “external” seals 1” to 100” Blinds 150 to 2500 ANSI

Marven House, 1 Field Road, Reading RG1 6AP England Tel: (0118) 950 3707 Fax: (0118) 950 4066 International Dialling: (44-118 + Tel/Fax No.) Email: info@mvfh.co.uk • www.mvfh.co.uk

ONIS “Quick-Action” Lineblind

Making light work of a heavy maintenance process...

GRIP COUPLINGTM FOR ALL METAL PIPES MV Fluids Handling’s Straub Grip Coupling simplifies pipework, design and installation over traditional pipe-joining techniques. Metal pipe from 3/4in to 24in can be joined in minutes. The Straub Coupling joins plain-end metal (black, cunifer, galv., or stainless) pipe with axial restraint and without the associated risks of ‘hotwork’, welding, or burden of expensive grooving/ threading machines. The slim-line coupling encases a patented sealing gasket that is progressively activated by the media pressure in the line, whether it be gas or liquid. Since Straub’s progressive seal encapsulates the line medium, ensuring no contact with the coupling’s metallic casing, it provides a cost-effective means of joining stainless or exotic alloy pipes in chemical applications. Straub’s unique patented design guarantees full re-usability performance in joining plain-end pipework in high maintenance applications, such as frequent blockages and eroding bends, without call for preparation (machining), pipe setting-up, or coded welders and other complicated procedures involving safety permits. Increased coupling range now available from Ø26 to 609mm. Temperatures -30°C to +125°C in the range Ø26 to 60mm, and -30°C to +100°C up to Ø219mm, and beyond to 80°C. For more information contact MV Fluids Handling, Reading, Berks Tel: 0118 9503707 Fax: 0118 9504066 E-mail: straub@mvfh.co.uk Web: www.straub.co.uk

Process Industry Informer March-April 2013

FLUIDS & LIQUIDS HANDLING inc. pumps & valves SELF-DIAGNOSTIC VALVE New ABB app highlights POSITION MONITOR potential compressed

The Type 3738 electronic valve position monitor from SAMSON CONTROLS can be used on on/off valves across a wide range of applications and enables valve position monitors to be configured at the push of a button. This robust, innovative device is a contactless, magneto resistive sensor system that works with a NAMUR signal in compliance with IEC 60947-5-6 and is powered by a two-wire supply. As a result, the valve position monitor can replace existing solenoid valves and limit switches without the time consuming process of changing wiring or signal levels. At the same time, it includes functions like self-tuning and diagnostics, which opens up a wide range of opportunities for control and asset management. The supply air for the actuator is routed through bores at the bottom of the housing, making additional tubing unnecessary. This makes it suitable for integrated attachment, which facilitates mounting and guarantees exceptional ruggedness. The contactless position sensor makes adjustments as well as moving levers redundant.

Grundfos meets the energy challenge now

Users of pneumatic valve positioners can now assess the energy efficiency of their valve installations with ABB’s new compressed air calculator app for the Apple iPhone and iPad. Based on the amount of compressed air consumed by conventional positioners, the app shows how using the latest smart positioner technology can help operators to dramatically reduce their energy costs Easy-to-follow instructions show the user exactly what parameters are needed to calculate any potential savings. The user is prompted to enter the number of pneumatic positioners on site, air cost per standard cubic foot and the percentage of time spent at a steady state to calculate the user’s current compressed air energy costs. These costs are then compared to the potential savings that could be achieved using ABB’s TZID-C and EDP300 intelligent positioners, where compressed air is only consumed when required. The app also allows you to measure savings in different currencies, including Sterling, Euros and US Dollars.

For more information or literature request contact Samson Controls, Redhill, Surrey. Tel: 01737 766391 Fax: 01737 765472 E-mail: Sales@samsoncontrols.co.uk wmb-630_Layout 1 21/03/2013 13:20 Page 1 Web: www.samsoncontrols.co.uk

To find out more information call 0870 600 6122 or email moreinstrumentation@gb.abb.com, ref: ‘Compressed air calculator app’. To download the ABB app, please visit the Apple App store and search for “ABB Compressed Air Calculator”.

Today pumps consume 10% of the world’s electrical power, so focusing on optimising the amount of energy they use makes a lot of sense both from an environmental perspective as well as to save energy. Pumps are vital to us, as without them we would have no hot water, heating or air conditioning, nor could we access clean water or dispose of wastewater, not to mention that manufacturing and the process industries would grind to a halt. So making sure the best pump option is selected for a specific task can mean an 80%+ energy savings. The Meet the energy challenge NOW this portal from Grundfos Pumps has become an umbrella for a broad range of energy information that encompasses topics such as: facts on pumps; future legislative demands; technological advances; a broadcast centre and much, much more. Find out more for yourself by visiting energy.grundfos.com To us at Grundfos, pumps are not just our business but are our passion. Sustainability is one important cornerstone that our business is built on, so presenting the facts about pumping and how to improve efficiencies is not just business to us, but a way a life. Visit us and become part of our crusade!

air energy savings

For more information or Literature request contact Grundfos Pumps Ltd, Leighton Buyzzard, Beds. Tel: 01525 850000 E-mail: uk-sales@grundfos.com Web: www.energy.grundfos.co.uk

Bredel pumps save water, chemical and maintenance costs • Average 71% water savings* lowers chemical costs • Glandless design, no costly valves, seals or liners to replace • Can easily handle SG 4.0 and 80% solids • Metering to ± 0.5% accuracy 50 years of innovation in pump technology

* vs centrifugal pumps

wmpg.co.uk/bredel 01326 370370 wm-630

Process Industry Informer March-April 2013

FLUIDS & LIQUIDS HANDLING inc. pumps & valves

EasiDrive Provides a Practical and Safe Solution to Portable Valve Actuation across all Water Applications Managing water and waste water plants is a complex operation where safety and efficiency are key considerations for water operatives. Smith Flow Control’s EasiDrive is a portable valve actuator that allows effective and secure valve operation across all water applications, without the need for permanent dedicated valve actuators. EasiDrive is a practical and cost efficient solution that supports the operation of multiple valves across the water network. It is effective on valves that are infrequently used and those that are difficult to operate, providing the user with absolute control when working different size valves with varying torque requirements. SFC’s EasiDrive system protects personnel by preventing injury and operator fatigue as movement is fully controlled by the EasiDrive tool. It provides complete protection from the ‘kick’ typically associated with other torque devices through its specialist proven reaction device; the operator experiences no jolt effect when using this system. EasiDrive also features a variable output torque, controlled by a choice of limited pre-set Filter Regulator Lubricator (FRL) packs, which prevents excessive torque being applied and ensures proper and safe operation, even in situations where operatives are under pressure to respond quickly. For more information contact Smith Flow Control Ltd, Witham, Essex. Tel:+44(0)1376 517901 E-mail: sales@smithflowcontrol.com Web: www.smithflowcontrol.com

NEW GENERATION OF THE WORLD’S BEST-SELLING STANDARDISED WATER PUMP KSB Aktiengesellschaft, Frankenthal, Germany, has launched the latest generation of its Etanorm series, which has been produced non-stop since 1936. The type series of the new generation comprises 43 pump sizes, which can be driven by either 2-pole or 4-pole motors. The selection chart has been extended by additional pump sizes, so that sizes can be selected even closer to the best efficiency point. In intensive work with CFD (computational fluid dynamics) for flow simulation KSB’s development engineers have optimised the hydraulic contours. The results were verified in comprehensive tests. Thanks to the efficient hydraulic system the pump sets already meet the EU requirements of Commission Regulation 547/2012/EC for water pumps, which will enter into force in 2015. The engineers placed a particular focus on an excellent suction behaviour and a low NPSH value, thus minimising the risk of cavitation and obtaining a smooth and stable pump operation even in difficult operating conditions. This means the pumps run reliably and contribute to a greater availability of the overall system. Confined casing gaskets ensure reliable sealing between pump casing and casing cover even in highly varying operating conditions. The finite element method (FEM), a calculation method for solids simulation, was employed to improve the rigidity of the pump sets. This has increased the permissible forces and moments of external loads

acting on the casings. The material range comprises cast iron, bronze and nodular cast iron as well as stainless steel. The diversity of materials and a large choice of seal variants have extended the suitability of the new type series to applications beyond those of water. The space allocated to the mechanical seal has been enlarged to enhance venting in this area. The new, spacious design also facilitates dismantling and reassembly of the mechanical seals. In line with KSB’s common practice for industrial pumps, every pump will be supplied to the customer with the impeller diameter trimmed exactly to the duty point. Impeller trimming combined with the large range of pump sizes available for selection is the only way of keeping the energy consumption of the pump to the minimum necessary. Operators benefit from the type series being manufactured at four different sites - in Germany, India, China and South Africa - which all comply with the same quality standards. This makes global procurement much easier; pumps and spare parts are readily available. The Eta type series is the global best-seller among standardised water pumps. Since 1936 more than 1.5 million Eta pumps have been produced worldwide. For further information contact KSB Limited, Loughborough, Leicestershire. Tel: +44 (0) 1509 231 872 Fax: +44 (0) 1509 215 228 E-mail: sales@ksb.com Web: www.ksb.com

Valveless, Ceramic Pumps from Fluid Metering, Inc. (FMI) provide the solution for metering high viscosity grease at low pressure for precision lubrication of industrial robot gearboxes To maximize productivity and eliminate downtime, industrial robots require continual lubrication. The PDS-100 Programmable Dispensing System utilizes FMI’s unique valveless pumping design to accurately deliver gearbox lubricating grease, independent of viscosity. But more importantly, the PDS100 accomplishes this at pressures low enough to prevent any seal damage to the gearbox. The PDS-100 is available in both single and dual channel configurations and is easily integrated with industrial process controllers. Dispense and metering rates range from a few microliters per dispense up to 768 ml per minute continuous metering. Fluid Metering’s valveless, ceramic pumps have only one moving part in contact with the fluid. The sapphire-hard internal components and valveless design of FMI pumps eliminate accuracy drift typical of pumping systems that rely on valves, diaphragms, peristaltic tubing, and pressurized feed lines for fluid delivery. For over 50 years FMI pumps have been used for industrial automation, medical instrumentation, laboratory R&D, chemical process, pharmaceutical packaging, mining, alternative energy, water treatment, environmental monitoring, food processing and much more. For additional information contact Fluid Metering Inc, Syossey, USA. Call toll free 1-800-223-3388 or 1-516-922-6050, Fax 1-516-624-8261, e-mail: pumps@fmipump.com or visit our website at www. fmipump.com which now features “Live Help”, an online direct connection to FMI’s application experts.

Process Industry Informer March-April 2013

AxFlow introduces the new Wemco WSP Heavy Duty Self Priming Pump When pumping solids laden liquids you canâ&#x20AC;&#x2122;t afford to take any chances on your choice of centrifugal pump. The new Wemco WSP self priming pump is a heavy duty pump that works equally well with clean water as well as liquids containing large solids. It comes with a buzz-saw wear plate that allows replacement of wear parts without a complete pump overhaul.

Elastomer

Easy open fill

suction flap

port cover

Mechanical seal

Heavy duty bearings

Shimless impeller

Shaft 17-4 PH

clearance

ST Steel

ÂŽ fluidity.nonstop is a registered trademark of the AxFlow Group

adjustment

Hand nut

Lip seals

release

with isolation

suction

barrier

inspection cover Self cleaning Buzz-saw wear

PR Valve

Solids handling impeller

plate

Scan to see all our fluid handling solutions, or visit www.axflow.co.uk

Process Industry Informer March-April 2013

AxFlow Ltd., Tel: 0208 579 2111, Fax: 0208 5797326, e-mail: info@axflow.co.uk

FLUIDS & LIQUIDS HANDLING inc. pumps & valves PISTON PUMP IS PERFECT FOR THICK, VISCOUS INGREDIENTS The chilled prepared food market is one of the largest and most important sectors in food retailing where consumers are offered a huge choice of convenience foods, such as; pizzas, pasta, curry sauces, soups and desserts. As a result of this, manufacturers are often required to provide solutions which overcome the difficult processing challenges of handling a huge variety of ingredients, whilst maintaining everincreasing quality control standards. For example, transferring high viscosity ingredients such as tomato puree, pulps, creams and syrups, presents unique pumping problems. CSF piston pumps from liquids handling specialists PUMP ENGINEERING are ideally suited to the challenges of transferring thick, viscous ingredients from tanks, drums and IBC’s. Most importantly, CSF pumps are available as quick-strip

versions, so they can be easily dismantled for cleaning, without the need for tools. The pumps are available as a long version for drum emptying where the piston is below the liquid level to enable the pump to handle liquids with a very high viscosity. The positive head and bottom entry positioning of the pump combine to ensure improved flowrate and increased efficiency. Short versions are also available for bottom discharge vessels or wall-mounting where required. CSF pumps are air-operated and depending on the model, will deliver pressures up to 20 bar, while flowrates reach up to 100 lit / min. CSF pumps can also be fitted with a special bag-in drum inlet, a feature which prevents the plastic drum lining used in some containers, from being sucked into the pump.

For non-flowable creams, pastes, gels and waxes, the pumps can be fitted with a follower plate and single or two post ram which will empty any parallel sided vessel. Materials of construction are AISI 304 or 316 polished stainless steel, with a choice of PTFE or nitrile seals. For more information contact Pump Engineering Ltd, Littlehampton, West Sussex Tel: 01903 730900 Fax: 01903 730234 E-mail: sales@pumpeng.co.uk Web: www.pumpeng.co.uk

MAINTENANCE

ANALYSERS

Parsum in-line particle sizer proves its PAT credentials at Ghent University The Parsum in-line particle sizing probe from Malvern Instruments is proving its value as a PAT instrument in granulation research being conducted at Ghent University in Belgium. Professor Thomas De Beer’s Process Analytical Technology (PAT) group at the university are successfully using the instrument to continuously monitor granulation processes and to develop effective automated strategies for process control. Professor De Beer said, “In our research we look at all aspects of PAT. We focus not only on assessing different technologies and instrumentation for monitoring, but on applying the resulting data to process control. Using Parsum we have tracked the evolution of particle size in real time during fluidized bed granulations. The data provide detailed information during Design of Experiment (DoE) studies and enable us to develop models for real-time batch evaluation. These models help drive effective automated process control and reduce batch release times, both of which are important goals for pharmaceutical processors.” For further details of Prof De Beer’s work visit http://bit.ly/ProfTDBeer To find out more about the Parsum probe go to http://www.malvern.com/velocimetry Malvern and Malvern Instruments are registered trademarks of Malvern Instruments Ltd. For more information contact Malvern Instruments Ltd, Malvern, Worcs. Tel: +44 (0) 1684 892456 Fax: +44 (0) 1684 892789 E-mail: salesinfo@malvern.com Web: www.malvern.com

SMS RELAY WITH ENHANCED FEATURES The GSM-PRO relay module from Contaclip provides a remote control & maintenance solution that can signal changes of inputs and outputs through text messages and email. The email function allows for a better overview of messages and makes it easier to collate and sort alarm and status reports. It is possible to configure the unit to work using your own server or alternatively the Contaclip server can handle all the email functions without any extra cost or third party involvement. All 8 inputs can be configured as digital or analogue (0-10VDC) and the unit has an operating voltage of between 10...30Vdc so is also suited for mobile applications. It is also possible to link 4 of the inputs directly to the 4 change over relay outputs to give some simple logic function. GSM-PRO now has a built-in hours counter for the digital inputs as well as a full event data log that can be easily downloaded or sent automatically by email. Programming of the GSM-PRO could not be easier. The software is free to download and the unit can be remotely programmed from anywhere in the world providing you have an internet connection. This negates the need for site visits to update any user settings or firmware. For more information contact OEM Automatic Ltd, Whetstone, Leics. Tel: 0116 284 9900 Fax: 0116 284 1721 E-mail: anne.massey@uk.oem.se Web: www.oem.co.uk

enclosures

LAMINATED COPPER BARS Rittal has recognised a rise in the popularity of laminated copper bars in the OEM and panel builder market and produced a technical guide, which shows how to calculate fault rating capacities of their laminated copper bar. When engineers design systems using the laminated copper bar consideration must be given to the installation in regard to fault rating and the mounting. One advantage of the laminated bar is its flexibility and the ability to be connected direct to circuit breakers, control gear and busbar systems. The laminated insulation offers protection against indirect contact to live copper conductors. Securing the mounting of the bar can be achieved using Rittal’s universal supports. The supports, both single and multi-stacked, are made from fibreglass- reinforced, thermoplastic polyester, which has the strength and flexibility to be securely mounted on support rails. For more information contact Rittal Ltd, Hellaby, Rotherham. Tel: 01709 704000 E-mail: information@rittal.co.uk Web: www.rittal.co.uk

Camlock Systems launches products for cabinet and enclosure industry Camlock Systems has introduced an extension of its popular wing knob, T handle and L handle ranges. The new products, designated Series 08 are fitted with a lock cylinder that is compatible with all 92 Series key combinations, including the popular 92369 key number. Camlock Systems has manufactured its new products in response to demand from the cabinet and enclosure industry. All products have passed salt spray water and other environmental tests and are perfectly suitable for applications that are sited in damp environments. The wing knob and T handle are IP65 rated and fitted with a rubber gasket. A stainless steel cap and spring loaded shutter protect the keyway. The new products are available in black polyamide, die-cast zinc alloy with a chrome plated or black powder coated finish. For more information contact Camlock Systems Ltd, Eastbourne, East Sussex. Tel: +44 (0) 1323 410 996 Fax: +44 (0) 1323 411 512 Web: www.camlock.com

Process Industry Informer March-April 2013

The basis of safe pipe expansion joints By Franz Hingott, TÜV SÜD Chemie Service GmbH, Materials Technology

Offering resistance and durability, pipe expansion joints made of high-performance plastics have become firmly established in plants and systems of the chemical industry. However, their service life depends on a number of influencing factors. Exact specifications of the minimum requirements and suitable testing methods are imperative for dependable service-life predictions. Drawing on decades of experience in this field, TÜV SÜD Chemie Service describes the basis of today’s practice solutions. To accommodate thermally induced changes in length and circumference and vibrations in piping systems, expansion joints made of polytetrafluoroethylene (PTFE) are used in chemical plants. This high-performance plastic, more commonly known under its brand name Teflon, is suitable for many acids and lyes and offers nonstick characteristics, temperature resistance and high mechanical strength. However, in the past manufacturing-related defects in PTFE expansion joints have led to incidents in chemical plants. The damage resulting from these incidents not only caused significant costs but also posed potential hazards for people and the environment. To avoid these problems, the individuals in charge of operation and maintenance had to address two questions: Firstly, what minimum requirements do PTFE expansion joints have to fulfil to ensure safe operation? And secondly, how to reliably predict the service life of components under defined service conditions?

Specification guideline for the chemical industry defines minimum requirements The research group “AK-Chemie PTFE-Kompensatoren” (Chemistry Research Group PTFE Expansion Joints) was set up in 2000. In addition to Infraserv, today’s Interessensgemeinschaft Regelwerke Technik (IGR) e. V., the German Community of Interests for Industrial Practice, represented by TÜV SÜD’s experts, the research group comprised representatives from Bayer, BASF, Infracor and Dyneon. As the data available at this time was inadequate and there were no standardised specifications, the first task of the research group was to develop guidelines for PTFE expansion joints. To do so, they examined the expansion joints available on the market for existing deficiencies and defects. Basically, even expansion joints from different vendors have a similar design. The PTFE bellows is made up of several convolutions with root rings in the base of each convolution increasing compression strength. The Figure 1: Expansion joint with higher the number inflated convolution caused by of convolutions, the greater the range of overpressure movement provided by the bellows. Low numbers of convolutions, by contrast, increase compression strength. PTFE bellows are available in two versions, black and white. The black colour comes from soot particles introduced during production to prevent electrostatic charging. This type of expansion joint is frequently used in plants of the chemical industry with explosion hazard. White expansion joints without soot are not electrically conductive. For installation in piping systems, these expansion joints are provided with loosetype flanges. The experts examined PTFE expansion joints with three convolutions in various sizes. The research group identified three main sources of defects: fluctuations in bellows thickness, i.e. mostly failures to reach the minimum thickness; notches in the material; and inhomogeneous

dispersion of carbon black. To avoid these defects in the future, three manufacturing companies were included in the research group and contributed their experience regarding the design and manufacturing of PTFE expansion joints. After specification of the sources of defects, the experts defined the safety-related minimum requirements. On top of this, they developed recommendations for standardising the lengths of PTFE expansion joints which up to that date had varied from manufacturer to manufacturer. In May 2004 the research group introduced the specification guideline “PTFE expansion joints, technical delivery conditions, dimensions” drawn up jointly by all members of the group. This specification guideline was adopted in the collection of specification guidelines of the chemical industry and is used as the basis for the manufacturing, testing and delivery of PTFE expansion joints with metal back-up rings. The standard introduced binding dimensions for pipe expansion joints with three, four and five convolutions and loose-type flanges. In addition, it lists and describes all non-conformities in PTFE bellows that impair their function and are therefore unacceptable, and includes a detailed documented procedure on how to control the quality of manufactured expansion joints.

Not every test method is suitable Overall, the expansion joints manufactured in accordance with the specification guideline met the expectations of the experts. However, some expansion joints failed to withstand long-term service under extreme conditions. Deformations were identified on some, while others ruptured during service operation. Given this, the research group met again in 2008 to investigate the causes of those incidents considered unacceptable by plant operators. The research group aimed to investigate which operating conditions limited the safe use of the expansion joints and what test methods are the most suitable for dependable long-term predictions of service life.

Creep-rupture internal pressure tests proved a suitable test method for service-life prediction. Today, this method has become firmly established for predicting long-term performance of piping systems. The test examines how components perform over time at a defined temperature and pressure. As early as 1956, for example, the experts started to investigate the creep-rupture performance of polyethylene pipes in the long-term test rig of TÜV SÜD Chemie Service, previously Hoechst AG. The experts also had access to the results of long-term measurements carried out on pipes made of various fluoropolymers. TÜV SÜD’s experts based their service-life predictions for PTFE expansion joints on the assumption that these joints behave similarly to pipes. The tests performed on the long-term test rig had proved that sound long-term prediction can be made through extrapolation. The experts agreed that at least ten measurements had to be carried out over a period of one year to determine the maximum permissible internal pressure over a 50-year period. The internal-pressure creep-rupture tests were carried out at a temperature of 150°C in accordance with ISO 9080 on PTFE expansion joints with a size of DN 80. The start of the creep-rupture tests was determined with the help of the pressureincrease method. In this method the internal pressure is continuously increased at a constant temperature until the PTFE expansion joint ruptures. Based on the results of this test method, the test points for determining the creep-rupture curve are determined.

Conclusion

Figure 2: Expansion joints with defects (1) Incipient cracking on the inside top of the convolution (2) Indentations caused by back-up rings and bulging with notches (3) Uneven convolutions with some wrinkling at the top of the convolutions (4) Plastic deformations with stress whitening zones (5) Sharp-edged transitions including notches

At that time, statements on creep-rupture performance had primarily been derived from manufacturers’ information about the burst tests carried out by them. However, as testing conditions differed largely between the individual manufacturers, comparison of the results obtained in these tests proved impossible. In addition, the investigations revealed that burst tests are unsuitable on principle for delivering valid information about the creep-rupture behaviour of PTFE expansion joints, as they provide identical results for both flawless expansion joints and expansion joints with pre-defined defects. This was in conflict with the findings gained in practice, which proved that pipe expansion joints with pre-existing defects failed much earlier.

Process Industry Informer March-April 2013

Test rig for long-term tests

Internal-pressure creep-rupture tests and pressure-increase tests permit reliable determination of the long-term performance of PTFE expansion joints. Based on these results, the experts can make reliable predictions of the service life of pipe expansion joints under realistic service conditions. This also offers the advantages of minimising the efforts and costs involved in servicing and maintenance. One of the prerequisites is that the PTFE expansion joints used comply with the requirements defined in the specification guidelines.

The experts at TÜV SÜD Chemie Service support companies in determining the longterm performance of piping systems and components made of high-strength plastics. To fulfil their task the experts can make use of an in-house testing laboratory with test stations, heating ovens and pressure equipment, which is suitable for testing a wide variety of different components and materials.

TÜV SÜD Chemie Service GmbH Industriepark Höchst 65926 Frankfurt am Main, Germany Can be contacted on: Tel: +49 (0)69 305 5488 Fax: +49 (0)69 302 469 E-mail: franz.hingott@tuev-sued.de Web: www.tuev-sued.de/chemieservice

A reliab plant, is a co There can’t be many manufacturing companies in the western world that don’t recognise the importance of safety; legislation and reputation underpinning natural concern for employee welfare. Yet it is more rare for organisations to be similarly committed to reliability, and fewer still that recognise the close relationship between reliability and safety. Giving reliability the same credence as safety, will not only do wonders for business performance, it will also help achieve safety goals. Figure 1 Reliability is somewhere on the radar of most organisations but for many, it is far from being a core business value. Nowadays however, more senior executives have started to recognise the benefits to be gained from focusing on reliability and the increased capacity and lower costs that come with it, rather than just cost. In the current economic environment this may seem counterintuitive because ‘we need to keep costs down to remain competitive’. But this ignores the superior gains that can be made by focusing on asset productivity. Eliminating the defects causing losses in plant capacity can both maximise the capabilities of assets and reduce costs. The better performing organisations are the ones asking themselves which processes, practices and culture are required to maximise the capability of their assets through defect elimination. The removal of unplanned failures increases plant capacity and it reduces costs because there is less time spent on repair and maintenance. Energy costs fall because you’re not continually cycling the plant up and down. At the same time, quality improves and secondary failures also disappear. Andrew Fraser, MD of change management consultancy, Reliable Manufacturing, says this leads some to describe reliability as ‘magic’: “When they start their plant back up after a failure, organisations often find something else has gone wrong; a side effect of the primary failure. But if you remove the primary problem there’s a domino effect and all the other associated problems disappear ‘like magic’ “

Recent research by Exxon Mobil shows that maintenance staff are five times more likely to get injured during a reactive task than during one which has been planned. Similarly, DuPont (one of the first companies to establish the link between safety and reliability) discovered that of all injuries it had experienced, the most likely was to a maintenance technician with less than two years experience, carrying out a reactive maintenance task. Reliable Manufacturing defines reactive maintenance as any work not scheduled at least seven days in advance. “The fewer interruptions for reactive maintenance, the lower the injury rate. Having a weekly scheduled maintenance plan, which gives employees clear visibility of everything that needs to be done in the upcoming week, is fundamental,” says Moore. He quotes the example of an Australian chemical company, which implemented a more reliable work environment over an eight-year period by increasing the proportion of preventive and predictive maintenance work (PM /PdM); figure 2. As it did so, there was a clear correlation with the decrease in the number of injuries. “The company increased its PM/PdM work from 5,200 orders to 13,250 As a result the total injuries per year more than halved from almost 350 to 160.” Plants that implement a higher percentage of PM/PdM work also lower costs and increase overall equipment effectiveness in the process.

Fraser also believes that organisations are increasingly recognising the value of reliability in achieving safety goals, and he claims reliability will eventually become a core value for many organisations. “I still remember the feeling of guilt I experienced at the end of one particular site meeting in my first production role 25 years ago, when I realised that I wasn’t putting safety as high on the agenda as the site manager seemed to indicate we should be. But the guilt eased after a few days when it dawned on me my boss never asked me about safety unless there was an incident or an investigation. So in day-to-day operations, he wasn’t transmitting the importance of safety to me. It wasn’t until it became a measurable part of our personal objectives that we began to give real attention to safety performance and where improvements could be made. Subsequently when several managers were overlooked for promotion because of their poor safety record, then we knew it had become a core value in the organisation. Reliability is on a similar journey.”

Principal consultant, Ron Moore presents strong evidence to suggest that plants, which are more reliable, are also safer. Data collected from a large US paper manufacturing company across some fifteen plants worldwide, over a five-year period (figure.1), shows the plants’ asset utilisation (blue) against injury rate (red). As asset utilisation goes up, the injury rate comes down. The correlation between the two is 80%; remarkably high for industrial data. Most accidents occur in reactive situations. When a plant is running well, with high asset utilisation, there are fewer failures to react to. A key facet of a reliable plant is less reactive maintenance.

Figure 2 Another benefit comes in the form of reduced environmental incidents. In the case of this UK chemical plant (figure 3), environmental incidents were eliminated as their reliability strategy yielded a 20% improvement in asset utilisation.

Process Industry Informer March-April 2013

ble plant is a safe ost-effective plant simultaneously and harmoniously - they must be ‘reliable’; they must do many things really well, and be tenacious about all their practices. In fact in Fraser’s experience, it is very difficult for companies to have a really good safety record without being reliable. In one instance, pursuing a policy of ‘safety at all costs’ meant the UK chemical plant concerned paid the ultimate price - it went out of business. “Although it had an excellent safety record, it also had extremely poor reliability and asset utilisation; it was down at 60% when it should have been at 80% to 90%. Management was spending so much time and money auditing people for safety practices and procedures, there was little left to dedicate to the performance of the plant, and that ultimately led to its demise. So you can do it but it takes an extraordinary amount of management resource and cost, which is to the detriment of the business.” The business case for establishing reliability as a core value is certainly a compelling one and Fraser insists that business leaders need to get reliability to the top of the agenda. “It must be given the same level of importance as safety,” he says. But whilst reliability should be led from the top, Fraser says (like safety) everyone must share in the responsibility.

Figure 3 However, it is a mistake to think that reliability revolves around maintenance; it begins long before this. To achieve reliability you have to begin by getting the processes right and eliminating existing defects. This model (figure 4) demonstrates where companies should concentrate their efforts - as indicated by the red blocks, most defects occur in design; installation/start-up, and operation. For new organisations, or those with new plant or equipment, the focus should be on incorporating reliability practices into the initial design, buy and store phases. For the majority of course, plant and equipment are already in place and it isn’t possible to have a significant impact on the first three functions. In that case, the immediate focus should instead be on installation, start up and operations.

“The objective is to instil a culture of reliability. It must become part of the day-today running of the business and KPIs introduced, so people are assessed against it. All companies have a safety policy, which governs everything they do with safety, such as: ‘no task is so urgent that it can’t be done safely’; management must provide a safe working environment; or everyone is responsible for preventing injuries. We advocate that companies should be thinking along the same lines for reliability - to eliminate injuries and failures: so, ‘no task is so urgent that it can’t be done safely and reliably’; management must provide a safe and reliable working environment’; or ‘everyone is empowered to stop unsafe and unreliable behaviour’.” Fraser explains that this isn’t just about managers lowering costs and improving the safety reputation, it’s a cultural change, a shift in attitude towards operating the plant; making sure each department is operating reliably and therefore safely. “When I was working with one of the oil major’s in Aberdeen, I was stopped on the stairs by somebody who said, ‘it’s part of our safety policy here to hold the handrail when using the stairs’. That wasn’t a manager but an employee and he used the words ‘our policy’ because it had become part of the fabric of the organisation. This should also be happening with reliability, and in some cases it already does.” By putting reliability at the top of the agenda, organisations will reduce the need for reactive maintenance, so cutting the number of injuries and creating a safer work environment. The implications of a reliable and safe site are huge: increased asset utilisation and production capability; improved customer satisfaction; and ultimately, revenue growth. Reliability is not just the safe option, it is the driving force behind a successful organisation.

Figure 4 “It is not sufficient to concentrate on maintenance,” says Fraser. “It’s like blaming your garage for the poor reliability of your car - they didn’t design and build it, nor do they operate it on a daily basis. The garage just fixes the defects.” This strategic focus on reliability can in turn, help companies achieve their safety goals, as well as reduce costs across their organisation. Colin McLean, former General Manager of BP Grangemouth says, “A safe site is a reliable site, is a cost efficient site”. Of course companies can achieve individual targets without establishing reliability, such as attaining improvement in safety by solely focusing on safe work practices; in costs just by focusing on budget; and in carbon footprint reduction by tackling just environmental issues. However, if companies want all these things to happen -

Process Industry Informer March-April 2013

Reliable Manufacturing Warrington,Cheshire Can be contacted on Tel: +44 (0)1925 261033 E-mail: info@reliable-manufacturing.com Web: www.reliable-manufacturing.com

health & safetY

ARI-SAFE-FN ANSI SETS NEW STANDARDS OF SAFETY AND RELIABILITY The new ARI-SAFE-FN ANSI full nozzle safety relief valve expands the range and diversity of Safety Relief valves manufactured by ARI-Armaturen. The product is accredited with a host of safety standards and approvals allowing engineers to specify with absolute confidence - VdTUV approved, certified according to ASME-Code with UV-stamp and manufactured according to API 526 (American Petroleum Institute). Commenting on the company’s latest product development, Nick Davies, UK Sales Director, said, “The ARI-SAFE-FN ANSI is part of our ARI-SAFE range of safety valves which already offers around 35,000 variations. Safety has always been an important feature of all ARI products and we are very proud of the latest addition to our range which is manufactured to the exacting API 526 standard. Introduced by the Petroleum Industry many years ago, API 526 has become an internationally recognized design standard which allows globally operating companies to use one unique design code with set standards for dimensions, pressure-temperature rating, maximum set pressure and body materials. Full nozzles are usually incorporated into safety valves designed for process and highpressure applications and the accurately centred nozzle (nozzle thread close to seat) in the ARI-SAFE-FN ANSI assures precise repeatability of the set pressure. Optimal guiding of the plug on the seat (two-piece stem) provides high reliability the valve is also extremely durable due to protection against crevice corrosion (nozzle thread close to the seat) and corrosion-resistant bellows seal made of Inconel 625.” A number of unique features also make the ARI-SAFE-FN ANSI easy to handle and easy to service; - Reversible plug (sealing surfaces can be used on both sides) - Straightforward replacement of the plug sealing plate - Identical nozzle ring for each orifice size - Broad spectrum of applications due to the standardised O-ring soft sealing plug - Multifunctional conversion in a few simple steps due to modular system Suitable for a broad spectrum of applications due to the standardized O-ring soft sealing plug, the ARI-SAFE-FN ANSI will deliver reliable, safe performance and a long service life. For more information contact ARI-Armaturen UK Ltd, Tewkesbury, Glos. Tel: 01684 275752 E-mail: ndavies@ari-armaturen.com Web: www.ari-armaturen.com

STATIC GROUNDING EQUIPMENT FOR HAZARDOUS AREAS A common feature of powder processing equipment operating in hazardous locations is the potential for static electricity to accumulate on multiple parts of the plant equipment. Isolated components of fluid bed dryers, hoppers, micronizers, hoses and powder conveying systems can accumulate voltages capable of discharging electrostatic sparks into potentially combustible atmospheres with minimum ignition energies well below the energy of a static spark. For users requiring ground status indicators and process interlocks, the installation of multiple grounding systems to monitor each component individually is likely to be both cost and space prohibitive. The Earth-Rite® MULTIPOINT is a discrete static grounding system, with process interlock capability, that can monitor and ground up to eight pieces of potentially isolated equipment, all at the same time, eliminating the need to install multiple grounding systems. The ground status of each object is displayed by an array of green and red LEDs mounted in a hazloc approved enclosure. If the MULTIPOINT detects that an object is not grounded it can be configured to shut down the transfer process to stop the electrification of equipment. To learn more about the Earth-Rite® MULTIPOINT or the dangers of static electricity in hazardous areas please contact Newson Gale. For more information contact Newson Gale Ltd, Colwick, Nottingham Tel: 0115 940 7500 Fax: 0115 940 7501 E-mail: groundit@newson-gale.co.uk Web: www.newson-gale.com

Vortex FP control panels monitor gas detectors in Zone 1 hazardous areas Compact model now available for tight spaces where other flameproof panels may not fit Crowcon’s new Vortex FP Compact control panel increases the flexibility of its flameproof product range. Like the existing Vortex FP, the FP Compact is specifically designed to monitor toxic and flammable gas detectors or fire detectors where there is a need for the control system to be installed in Atex Zone 1 and 2 hazardous areas. Its more compact size, however, means it is particularly suited to confined spaces such as analyser shelters in refineries, offshore rigs or FPSO (floating production, storage and offloading) installations. All day-to-day operations on either model can be performed without having to open the panel’s enclosure: gas levels, alarms and faults are viewed at a glance through a window and all system functions are accessed either via buttons or a ‘Crowmag’ magnetic key (supplied). This means the whole system can be checked at a glance without a ‘hot work’ permit being required, which in turn means adjacent areas can remain online, saving time and money. The standard Vortex FP contains up to 24 relays and can monitor up to 12 gas/ fire detectors, while the FP Compact contains up to 16 relays and can also monitor up to 12 detectors. Rated IP66 for dust and water ingress, both models meet all the latest gas detection legislation and EMC standards and is validated to the IEC 61508 (SIL 1) functional safety standard. The control panel is also highly configurable: it can be factory-set according to end-user requirements or altered at any time by a PC using the software provided. Adjustments can also be made in-situ without the need for additional equipment. All relays are monitored continuously, ensuring the integrity of the entire control system. Modbus capability also allows two-wire linkage between the panel and the control room, saving on a potentially large number of costly cable linkages. In areas where explosive or toxic gases are a real and imminent danger, both the Vortex FP and the Vortex FP Compact allow workers to perform their jobs more efficiently without compromising their safety. For more information contact Crowcon Detection Instruments Ltd, Abingdon, Oxon. Tel: +44 (0)1235 557700 Fax: +44 (0)1235 557718 E-mail: sales@crowcon.com Web: www.crowcon.com

LOK LINK ADAPTOR CONNECTS MODULAR SAFETY INTERLOCKS TO ENHANCE MACHINE SAFETY Fortress Interlocks has introduced a new LOK Link adaptor that connects its modular mGard interlocks directly to its new amGard Pro range of LOK and Stop safety gate switch interlocks. The ability to link the two enhances Fortress’ mechanical mGard range by adding a safety switch and direct solenoid control option to the mechanical module. This means there are several possible configurations that LOK Link provides that will enhance safety in a variety of heavy duty, industrial applications. LOK Link can connect stainless steel mGard heads to explosion proof locks, facilitate electrical indication of bolt position, connect a head for small radius doors and join mechanical interlocks with monitored exchange boxes and solenoid controlled exchange boxes and bolt locks. Trapped key interlocking is a proven method of safeguarding operators and machinery. By trapping and releasing keys in a pre-determined order, safe working environments can be achieved and only then will access be granted. Fortress’ mGard range of robust mechanical trapped key products is a completely modular system where individual modules can simply be added or removed depending on the application. The new amGard Pro range builds on the modular, robust design of the existing amGard range but with added features that delivers new control functionality. amGard Pro is designed for heavy duty environments and the LOK Link adaptor provides customers with new configurations to suit their applications. For more information about LOK Link, contact Fortress Interlocks Ltd, Wolverhampton Tel: +44 (0)1902 349 000 Fax: +44 (0)1902 349 090 E-mail: sales@fortressinterlocks.com Web: www.fortressinterlocks.com

Process Industry Informer March-April 2013

ASSESSING

When evaluating the risk of a data or system security breach, it’s essential that one addresses the consequences in a comprehensive way. One of the most significant threats is the devaluation of the business itself and the impact on the company’s reputation. The data breach or technical compromise is actually only the mechanism through which the threat is realised. Here, Peter Bassill - Managing Director of penetration testing and information security specialist Hedgehog Security explains the issues at hand. No-one is exempt from the risk posed by data loss. There have been numerous local authorities who have suffered very publically over the last couple of years. The UK Government recently confessed that UK utilities have suffered multiple attacks this year. In the private sector Sony, AT&T and e-mail marketing provider Epsilon have all been the victims of data breaches. There is another risk however, and it’s one that could have a niggling but compelling cost for all businesses. Governments globally are beginning to legislate to encourage firms to adopt higher levels of security. This creates a level of red tape that has a price tag associated with it, both in terms of the internal cost of achieving compliance and the price of securing external consultants, software, hardware and services to become compliant.

Who cares and who should The people that should be concerned are the people at the top of the business. If you are the CEO of a business you could be liable for any data breach if you haven’t taken adequate measures to avoid it. Should the Information Commissioner choose to bring criminal charges under the Data Protection Act, you could face very serious consequences. The irony is that in most areas of industry, the board takes extensive precautions to ensure that the company is in safe hands and that should anything go wrong, they are covered. For instance, on a construction site the health and safety manual you are talked through on entry is biblical in length and contains far more than Ten Commandments. Ironically, your induction also often includes the provision of a wireless network password that you could use to hack the company’s valuable data.

SECuRITY RISKS

The lesson is that information security is something to be taken seriously at a high level, just as we take the other areas of our businesses seriously.

Penetration testing The most common way to estimate the level of risk you face, and produce a plan of action for countering that risk is to engage the services of a penetration testing specialist. In its simplest form, penetration testing is a series of simulated attacks on the company, done to evaluate its level of security and establish how it can be improved. They can range from physical security breaches to Spear-PHISHING campaigns delivered via e-mail. For example my company’s comprehensive penetration testing services are fully integrated into our ISO27001 and ISO9001 security and quality management systems. We believe this provides the customer with confidence in the quality and confidentiality of the process.

VCISO Although penetration testing is the most common method of managing data security risk, it isn’t the only way. Large businesses will often appoint a Chief Information Security Officer (CISO) who will provide the knowledge and experience needed to manage the threat in an organised and effective manner. The catch is that the typical price tag that comes with this kind of appointment is in excess of £120,000 per year. As a result we have launched a more affordable Virtual CISO, or vCISO, programme, managed by senior level people experienced in the CISO role. If your organisation is large enough to require a security leadership role, but not quite ready to dedicate an internal resource to the task, Hedgehog can help achieve your objective, by working as a member of your senior management team leading security programs and initiatives. We believe we are the only business in the UK to offer this service. The Virtual CISO program often means one of our Chief Information Security Officers is on-site once or twice a week to ensure consistent progress. In times of need, they also tailor their involvement and time to ensure appropriate coverage is maintained.

Mitigation But perhaps the most important thing that UK Plc can do to protect itself against the threat that data breaches represent, is change its attitude towards them. A security breach isn’t just another piece of data on a system. Many companies seem to fail entirely to recognise the intrinsic value of an individual’s name, telephone number, address and password - as well as any other details they hold. Companies must come to recognise, from the top down, that data isn’t just a series of bytes on a PC - it’s one of the core foundations of the business and should be protected.

Process Industry Informer March-April 2013

Why data breach could be the biggest risk your company faces in 2013

Most companies are quite happy to take out appropriate insurances - because they understand the value in the product. Few understand the value in good data management; until there has been a breach and it’s too late to take any nonremedial positive action. Once a business has resolved to take action on its data management policies there is genuinely no time like the present. However, that doesn’t necessarily mean that you have to start with a huge investment. There’s no question that every business needs an information security programme in 2013 but you can start small and improve later. The key is to take the first step.

Social engineering One of the most important things to understand about data security is that it isn’t just an IT issue. However, if you create a phrase by putting any word in front of the word information, most people will simply read ‘IT’ or ‘technology’. The reality is that 75% of company security is about people and most security breaches aren’t the result of an information technology process being lax. They are the result of human error caused by socially engineered attacks. These attacks could be as simple as breaching a building by talking your way past the cleaners. It could be as complex as a highly targeted con-job on the CEO. The key is to deliberately catch the target doing something stupid and take advantage of their actions. Again this doesn’t have to be costly, even if you are a large company with many thousands of staff. You could look at mass delivery methods, like e-mail, posters, computer based training and so on, all of which could be incorporated into your normal procedures. Podcasts, infographics, cartoons and videos can all work and the more creative they are, the better. One of the most successful programmes I’ve ever worked on was focussed on the CEO’s regular monthly e-mail address. All we did was add an occasional note to it focussed on security. Because the audience was already engaged, they paid attention to the message and acted on it. There’s no question that, whether the business is large or small, multiple small touches are more effective than a heavy handed approach. Once you have dealt with the social element of data security, IT actually only makes up the last ten per cent of the issues you might encounter. Your IT system can focus on finding anomalies in behaviour that might be indicative of a potential attack and, in so doing, can dovetail neatly with your other security measures.

Hedgehog Security Stoke-on-Trent, Staffordshire Can be contacted on: Tel: 01782 467900 Web: www.hedgehogsecurity.co.uk

health & safetY

PROCESS ENGINEERING & PROJECT SOLUTIONS

Alarm Annunciation

PROCESS CARE SOLUTION™

The

signalling of a process error through illumination of a lamp or LED is a traditional method of visualising process failures. Nowadays this is reported through DCS, HMI or other central monitoring of critical and none critical alarms. However, this should not dilute the importance of the annunciator as still the most effective manner of displaying plant wide condition.

The SEHSE

HSE guidelines to EEMUA 191 suggest that alarms captured by a DCS require a separate alarm system for the critical events alongside the process control. In some instances though, re-transmission of alarms is an important factor for the end user. To this end, manufacturers offer various communication protocols to pass this data to a common infrastructure such as automated substation protocol under IEC61850. RTK offer a device that not only transmits this but can accept the same protocol to initiate the alarm from the DCS as an intelligent lamp box, fully KEMA certified. For more information contact RTK Instruments Ltd, Knaresborough, North Yorkshire. Tel: +44 (0) 1423 580500 Fax: +44 (0) 1423 580501 E-mail: enquiry@rtkinstruments.com Web: www.rtkinstruments.com

heat transfer & energy

NEW POWER & ENERGY LOGGER FROM THE TEST TOOLS SHOP The Hioki PW336020 Power & Energy logger is the latest featured product from the Test Tools Shop it’s the first true power and energy logger from Hioki that enables the user to produce simple load profiles. You can now look at your energy consumption over a specific time frame days/weeks/months and compare the load profiles to show the energy saving that has been achieved. Load profiles for different electrical phases can be monitored to check that the load across each circuit of your electrical supply is well balanced, reducing the risk of overload and thus loss of production, services or serious electrical damage to your facility. Review this and other great products from the Test Tools Shop... Check them all out at www.testtoolsshop.com For more information contact GMC Instrumentation Ltd, Cannock, Staffs. Tel: 01543 469511 E-mail: sales@gmciuk.com Web: www.gmciuk.com

Production optimization, performance losses, failure analysis, equipment reliability, risk analysis and reduction, environmental impact... Process Care Solution™, provides a preventive or curative outsourced technical support for everyday problems in production plants. This service of INEVO Technologies relies on a team of experimented doctors and engineers specialised in process engineering and project management. Well versed with industrial equipment and their operations, they are independent from suppliers and OEMs. With non-intrusive measurement equipments (ultrasonic flow, temperature, energy, thickness...), access to vast databases of information, operational excellence methodology, calculations and sizing methods, Process Care Solution™ provides: audits, diagnostics, qualification, validation and training. With short and shared time assignments, possibility of service contracts and the guarantee of a reliable technical and economic expertise, Process Care Solution™ meets a real challenge: giving any companies access to reactive specialists with cutting edge technical skills. For more information contact INEVO Technologies, Solaize, France Tel: +33 (0)4 78 08 37 79 E-mail: infos@inevo.fr Web: www.inevo.fr

flat springs for safety critical applications

BURR AND STRESS FREE FLAT SPRINGS FOR SAFETY CRITICAL APPLICATIONS Precision Micro, Europe’s largest advanced chemical etching company, is reporting a significant upturn in demand for flat springs as a result of the increasing popularity of specialist Martensitic stainless chrome steels, such as Sandvik 7c27mo2, for this application. As the fatigue properties of flapper valve steels continue to improve, focus is turning to the method of spring manufacture. Flatness, recoil and fatigue strength are enormously important in this stringent application; material properties that must not be compromised during spring production. Conventionally, flat springs have been stamped or laser cut but both methods have limitations. Blanking creates deformation, stressing the material and compromising flatness. Laser cutting is a thermal process that causes heat stress and leaves rough edges that could be initiation points for fatigue fracture if not removed completely. Both of these manufacturing techniques generate burrs that need to be removed by tumbling... a process that can in itself mar the material surface finish and add additional process cost. Despite these steels having excellent corrosion resistance, Precision Micro claims it overcomes all these potential problems with its standard chemical machining process. The process produces perfectly flat springs and imposes no stress on the material. The burr-free parts have an exceptional edge finish with no lips, pits or surface imperfections that could become initiation points for fatigue fracture. In addition, the company is also able to offer 100% automated optical inspection (AOI) that ensures components are within agreed dimensional limits and identifies any surface imperfections in the material. This investment has been made as a result of long established customer ‘partnerships’ with leading automotive manufacturers, where flat springs are prevalent in safety critical applications, such ABS braking systems, suspensions systems and fuel injection. Flat springs are expected to flex millions of times over many years and with market led process innovations, Precision Micro is helping spring manufacturers achieve that objective. For more information contact Precision Micro Ltd, Erdington, Birmingham Tel: +44 121 380 0100 Fax: +44 121 749 4157 E-mail: info@precisionmicro.com Web: www.precisionmicro.com

Can’t find what you are

looking for?

Log onto www.piimag.com and search our easy to use Product Finder Process Industry Informer March-April 2013

instrumentation

Explosive thinking MARECHAL’s DXN Self-ejecting is designed to enhance the safety of electrical installations in hazardous areas This new and unique ejection system for zones 1/2 (gas), and zones 21/22 (dust) on the market, is certified according to the ATEX 94/9/CE directive and IECEx standards, and complies with all current safety and security regulations for the protection of equipment and personnel. MARECHAL ELECTRIC has developed the explosionproof DXN DECONTACTOR™ range of compact and watertight connectors as part of its mission to provide safe electrical installations for use in hazardous areas. Rated for operation up to 63A, DXN units combine a new mechanical self-ejecting mechanism with MARECHAL’s unique patented DECONTACTOR™ integrated load-break switch. This unique solution is currently used on lifeboats that operate from offshore oil rigs. It can also be used for applications such as mobile containers, cranes, electrical boats, truck hookups or any portable equipment. Connecting the DXN self-ejecting socket-outlet by direct insertion ensures users are provided with the same features as standard DXN ranges. The new DXN decontactors are available in three different versions: standard plugs and connectors, self-ejecting plugs and self-ejecting coupler sockets.

whilst connected. Whether connected or disconnected, both types of self-ejecting DXN decontactors can be operated by any authorised person, under any circumstances and often without the need for a Hot Work Permit. Mounted on top of the selfejecting explosion-proof connector, a “shark’s fin” latch is used to lift the ‘hook’ from the base and disconnect the plug from the socket. The force required to operate this system is comparable to the force required to disconnect a plug from the socket of a standard DXN connection manually. This operation immediately releases the plug every time tension is detected on the cable. The shark’s fin hook, which is mounted on the base of the plug, is connected by a tension cord to the power cable. Pulling on this cord activates the shark’s fin hook to release the plug. Both systems are rated as standard ranges for operation at a maximum up to 750-V.

Permanent safety

For more information call Marechal Electric, Chester, Cheshire on Tel: 01244 851926 E-mail: contact@marechal.com or visit Web: www.marechal.com/en

In terms of unique features, the two new self-ejecting systems have been designed to protect equipment from accidental or forcible disconnection and full load. The systems also protect equipment from being moved

Key Facts: Designed for hazardous areas Automatic IP66/IP67 water- and dust-tight sealing Integrated load-break switch Robust and compact design High-performance GR housing

Free competence guide to optimising chemical industrial processes The chemical industry is characterised by a wide range of processes and conditions are often harsh. From raw material storage to preparation, from chemical synthesis to end products, METTLER TOLEDO in-line measurement solutions play an ever increasing role in helping you to remain competitive. Download the latest competence guide to optimising chemical industry processes. Topics discussed in this new guide include: • Greater process integrity and reduced maintenance via innovative Intelligent Sensor Management (ISM) technology • Securing product quality with less reagents and additives • Faster cycle times in phase separation and filtration • Highly efficient gas scrubbing To download this free chemical guide visit: www.mt.com/uk-chemical-brochure For more information on solutions for the chemical industry call 0116 234 5095 or visit our dedicated web page at www.mt.com/pro-chemical Note: ON-LINE LINK Tracking link for on-line: Click here to download the free chemical brochure http://uk.mt.com/gb/en/home/supportive_content/ brochures/product-organizations/pro/chemical-brochure. html?crel=UK_PRO_eAdv_261 For more information contact Mettler-Toledo Ltd, Beaumont Leys, Leicester Tel: 0116 235 7070 E-mail: enquire.mtuk@mt.com Web: www.mt.com

INDUSTRIAL, INTRINSICALLY SAFE AND FLAMEPROOF PRESSURE TRANSMITTERS High accuracy pressure and differential pressure transmitters for the realtime monitoring of operations in a range of arduous environments Pressure & Differential Pressure Transmitters Exd & Exia certified hazardous areas Industrial & Weatherproof applications Various ranges from -1 to 1000 Bar

T: +44 (0)1752 339866 W: www.pyropress.com

Process Industry Informer March-April 2013

Stainless Steel construction 33

instrumentation

CAL range offers cost-effective, reliable temperature control

exida Certied

When Moore Industries—the #1 company in Alarm Trips—needs SIL 2 or 3 Functional Safety approval, we looked to the company that is the leader in Industrial Safety Certifications—exida. Our STA Safety Trip Alarm is your answer to back up your PLC or DCS “soft” alarms with 40 years of field proven “hard” alarm experience. • exida certified to Safety Instrumented Systems to IEC 61508:2010 for systematic integrity up to SIL 3 and for random integrity up to SIL 2. This means that an STA is approved for single use in Safety Instrumented Systems (SIS) up to SIL 2 and in redundant architectures (1oo2, 2oo3, etc.) up to SIL 3.

Get our NEW IEC 61508 White Paper To view our STA demo and download our IEC 61508 White Paper, go to:

www.miinet.com/safetyseries

West Control Solutions is providing a range of exceptionally durable temperature controllers that deliver long service even in the most demanding applications. The CAL range of controllers has been designed as an easy-to-use, low-cost option for regulating temperature in a variety of applications, including plastics, packaging, drying and laboratory equipment. Efficiency is enhanced by the CALGrafix software, which reduces the installation time required and allows quick and simple controller configuration. The CAL range, which includes the 3300, 9300 and 9400 controllers, offers a simple menu for programming and full P.I.D. operation for efficient performance, while the unique dAC function minimises overshoot problems associated with conventional P.I.D. Controller. The IP66 smoked plastic fascia and rubberi;sed buttons with positive feedback means the CAL controllers are robust enough for arduous industrial applications and have aesthetics to complement equipment in a laboratory environment. CALGrafix software adds value to the CAL range of temperature controllers, offering a cost-effective tool for process monitoring and controller configuration. CALGrafix enables a series of powerful features, including data logging and process data archiving, chart recording, virtual instrument display and on-screen alarm display. All of these features can be accessed via a Windows® based PC bringing critical data relating to issues such as quality control within easy reach. For more information please contact: West Control Solutions, Brighton, East Sussex Tel: +44 (0) 1273 810116 Fax: 01273 609990 E-mail: chloe.garrett@West-CS.co.uk Web: www.West-CS.co.uk

EMERSON INTRODUCES THE FISHER® FIELDVUE™ DVC6200 SIS DIGITAL VALVE CONTROLLER FOR SAFETY INSTRUMENTED SYSTEMS Intelligent automatic partial stroke valve testing provides improved safety and reliability Emerson’s new FIELDVUE™ DVC6200 SIS digital valve controller responds to safety demands, and features partial stroke and position monitoring capabilities for the final control element in a safety instrumented system (SIS). Intelligent automatic partial stroke valve testing provides improved safety and reliability versus traditional pneumatic and jammer partial stroke methods. Meeting plant safety and reliability targets is easier using the DVC6200 SIS, which combines the field-proven linkage-less, non-contact feedback design of the DVC6200 and DVC2000 platforms with the safety demand and automatic partial stroke testing capability of the DVC6000 SIS. The DVC6200 SIS has been evaluated to the latest version of IEC 61508 (2010) and is certified as a SIL 3 capable device for both 4 or 20mA and 0 or 24Vdc power settings. An integral position transmitter is available with the DVC6200 SIS, and is capable of reading valve position even upon loss of power to the digital valve controller. The position monitoring safety function has been evaluated independently from the digital valve controller safety function and is SIL 2 capable. Partial stroke valve testing can be used in service to safely increase the period of time between proof-testing the final control element. Additionally, the DVC6200 SIS confirms solenoid operation and captures useful diagnostic data during a trip event. When integrated with Emerson’s DeltaV™ SIS logic solver, the native interface provides users increased availability, while at the same time removing complexity from their safety systems. DeltaV SIS provides out of the box tools that allow direct access to the DVC6200 SIS diagnostics and partial stroke data, and the ability to set-up and run the partial stroke tests automatically. Visit www.FIELDVUE.com for more information or contact your Emerson sales office and ask to see the DVC6200 SIS product bulletin.

Process Industry Informer March-April 2013

Thermowells

- a lesson in performance under pressure Thermowells must be properly designed and specified to withstand the pressure and stresses of their environment. Andrew Dunbabin, Product Manager, High Temperature Products for ABB Limited’s Measurement Products business, argues that users should be aware of all the relevant standards, in order to guard against potentially disastrous failures. A thermowell is the pressure-tight receptacle designed to protect sensitive temperature measurement instrumentation from harsh process conditions. The danger is that a hollow tube sticking into a process pipe or vessel could present a point of weakness if not properly specified. Any failure could result in damaged plant, or even injury and prosecution. So it’s vital that thermowells are manufactured and specified correctly to withstand the pressure and mechanical stresses that it may be exposed to, as well as any corrosive or erosive media they are likely to meet in a given process environment. The first concern is obviously pressure. There is currently no thermowell equivalent to the legally binding pressure vessel regulations, but international pressure vessel and piping standards, such as ASME VIII and its European counterpart, PD 5500, set out clear standards for pressureretaining parts. Although these standards are not enshrined in law, it would be hard to justify any deviation from them, especially following an incident. End users specifying thermowells from reputable manufacturers can generally be confident that the correct standards have been met. But if in any doubt, it can be useful for them to know their own way around the relevant standards so that they can ask suppliers the right questions.

Pressure fittings Thermowells are generally fixed to vessels and pipes using a flange. ASME VIII refers to ANSI B16.5 when it comes to defining the standard for flanged fittings. It is ANSI B16.5 that gives us the familiar flange rating system. ANSI B16.5 in turn relies on other standards to specify the types of material that may be used, such as ASTM A182 for austenitic steels and ASTM A105 for carbon steels. These materials standards are complex, but one of the main points to note is that, unlike thermowell stems, flanges must not be machined from bar stock. Instead, the parts must be manufactured from plate or from forged material that is hot worked into shape before being machined.This ensures that the flow lines of the metal follow the shape of the flange closely and so make it as strong as possible. Material traceability starts with the mill that made the steel. A materials certificate describes the chemical and mechanical properties of any material supplied by a mill, and any manufacturer with good engineering practices and a third-party verified quality system in place should be able to trace any material back to the mill certificate.

PD 5500 is the equivalent European standard. Although it is not legally binding as yet, it will become law when it completes its journey through the lengthy European ratification process and is adopted as a European Directive. It follows the ASME codes closely in its underlying principles, although the requirements for dimensions and markings differ.

harmonic frequency of the stem, the standard also provides a method for calculating the induced frequency of the vortices.

Welding standards

The standard recommends designing in a safety margin so that the induced frequency is no more than 80% of the harmonic frequency of the thermowell. However, many plant engineers prefer to take a more cautious approach and work to a margin of 25 or 30%, especially if the consequences of any failure are likely to be disastrous.

Of course, materials standards are only part of the story. Thermowells manufactured from more than one part will be welded, in which case ASME VIII calls on the welding standard, ASME IX. The situation is slightly more complicated in the European system, where there are a number of different standards that apply to welding. Once again they make largely the same demands as the American equivalent, ASME IX, but it’s a good idea to seek advice from a reputable supplier as to which particular European standard applies in a specific case. Whether the user is working within the US or European system, there are two distinct aspects to the welding standards. First there is the qualification of the person carrying out the work. The standards require that the quality of the individual’s workmanship will have been regularly verified by a Welding Specialist appointed by the trade’s governing body, which is The Welding Institute in the UK. Next there is the welding procedure. Choosing the right procedure for a particular service is a highly skilled job and a competent manufacturer should be able to indicate which welding procedure they used.

Mechanical stress Pressure is not the only physical challenge for thermowells. In pipelines, they will also experience mechanical stresses on their stem as fluid flows past them. It’s easy enough to calculate the static forces that are exerted by the mass of fluid impacting on the stem, but at higher flow rates the stem will also shed vortices, known as Von Karmen vortices. These can present a real danger if the frequency of the shedding approaches the resonant frequency of the stem. ASME PTC 19.3 is the accepted standard for analysing the harmonic frequency of thermowells. Given the calculated

Any flange manufactured and supplied under the ASME codes must have the flange size and rating stamped on it. Some manufacturers may also add marks indicating the cast number and the order against which it was supplied.

Process Industry Informer March-April 2013

Some applications are more at risk of vortex-induced failure than others. Where the fluid flow rate is high and the damping effect of the fluid is low (mainly gases), it’s a good idea to check by running the calculation based on ASME PTC 19.3. If the calculation shows that a particular thermowell could be at risk, there are several possible solutions. Geometry plays a key role, so a shorter or thicker thermowell may be more suitable. Some operators may suppose that the required length is fixed by the diameter of the pipe, but the thermowell does not have to reach the very centre. Temperature measurements should still be representative as long as the measuring element reaches the middle third of the pipe, so there is some flexibility. Velocity collars can also change the resonant frequency of the thermowell. These devices form a tight fit where the stem meets the pipe wall, effectively shortening the unsupported length of the stem. The downside of this approach is that velocity collars can be expensive. Again, a reputable supplier should be able to carry out the necessary calculations to ensure that a thermowell is safe to use. All they’ll need from the user is information on the fluid, including the operating temperature and pressure, the specific volume and the velocity.

Failure is not an option They may seem like standard pieces of kit, but thermowells routinely face some of the toughest conditions encountered in industry. In many applications, particularly in the oil and gas industries, the consequences of failure would be disastrous, so it’s worth checking with your supplier that all the relevant standards have been met.

ABB Measurement Products, St Neots, Cambridgeshire Can be contacted on E-mail: moreinstrumentation@gb.abb.com ref ‘thermowells’ or Tel: 0870 600 6122.

A change of position

Kevin Lacey of Brammer and Nigel Dawson of Festo examine developments in the use of positioning drives in the automation market, and what the future holds in this area. In every area of handling system design, the need for optimised speed, accuracy and repeatability is now accompanied by a corresponding requirement to drive out cost at every opportunity by minimising upfront component costs and on going running costs, particularly surrounding maintenance. A further influence is the need for greater flexibility and complexity in movement, but with the ability for simple control and rapid change of settings. Traditional robots working across several axes have each section operating ‘in series’, with each motor effectively having to carry the next one. Not only does this slow down operating speeds due to the additional inertia of the motor on each section, but the energy usage implications created by having to move so much weight for each cycle are clear. It is no surprise that this approach to robot design is now increasingly being eschewed in favour of more efficient and flexible set-ups. The process has been aided by an increased willingness among component manufacturers to move away from complex proprietary systems to a more modular approach through which customers can effectively select, design and install a complete system themselves based on the specific requirements of the application. Common to all of the new handling systems is a move completely away from ‘in series’ motor operation to systems which enable optimum usage of motor power by having them working in combination. While aesthetics are a consideration, generally more important is to design a system where the requirement for physical movement of the motor is minimal. The most common points of failure on systems of this kind are generally in the area of bearings and moving cabling, so reducing overall component movement will be integral to increasing servicing and maintenance intervals.

A number of options exist... A number of options exist depending on customer requirements. For simpler, two-axis operations, H-shaped systems allow a large and flexible working area, working on a parallel kinematic system with two stationary motors putting their power into a continuous belt. Modern control systems enable rapid movement in any direction, even diagonally. T-shaped systems operate on a similar principle but in a cantilever design. Both H and T systems can be mounted vertically or horizontally. Where even greater freedom and flexibility is required in the

handling process, tripod-based systems enable completely free movement within a three-dimensional space. These systems generally have ver y rigid kinematics, with drives securely connected to each other and motors again completely stationary. Between them, these three system types can now cater for virtually all small picking system requirements. Although less of a factor in smaller handling systems due to the lighter loads involved, energy consumption is set to become more and more of a consideration in the future. Currently, specifiers seeking greater power will generally opt for pneumatically driven systems, choosing electric where greater precision and control is demanded, although greater energy efficiency, as well as considerations such as flexibility, safety and productivity are also likely to generate a move towards the use of electric systems.

A challenging decision... Another area where specifiers and system designers face a challenging decision is in the area of decentralisation. Traditionally, motors are located in the machine, with drives housed in a control cabinet. However, recent years have seen an increased demand for motors with drives built onto them with the twin aims of reducing the amount of cabling and reducing overall machine footprint by needing a smaller control cabinet. Nevertheless, all drives generate a certain amount of heat during operation, and if for operational or safety reasons, the drive has to be housed in a dustproof or waterproof enclosure, there is simply nowhere for any excess heat to dissipate. The implication is that the system cannot then run at full capacity, meaning a component will have to be over specified to do the same job. Furthermore, the drive can weigh at least half and even up to the same amount as the motor, contributing further to the mass that needs to be moved, with the potential to further slow down operation while consuming more energy. For these reasons, decentralisation has yet to become the norm, although there has been some uptake on bus systems, where a single cable connects all remote nodes, whether they are drives, remote I/O or pneumatic valves. Whether centralised or decentralised and pneumatically or electrically driven, however, further developments in handling systems will continue to be introduced as customers demand greater control, flexibility and ease of operation. Brammer UK Ltd, Wythenshawe, Manchester Can be contacted on: Tel: 0161 653 8600 Web: www.brammeruk.com Festo UK, Brackmills, Northampton Can be contacted on: Tel: 0800 626 222 Web: www.festo.co.uk

Process Industry Informer March-April 2013

instrumentation POWER PLANT CONDUCTIVITY MEASUREMENT IN WATER TREATMENT AND CYCLE CHEMISTRY Conductivity measurement throughout a power plant treatment system has typically required a variety of sensors to span the range. With METTLER TOLEDO new sensor technology this is no longer necessary and the measurements can be made using a single conductivity sensor. Download the latest application note: Power plant conductivity measurement in water treatment and cycle chemistry. Topics discussed include: • Make up water measurements • Sensor simplification • Cycle chemistry measurements The UniCond conductivity sensor with integrated Intelligent Sensor Management (ISM®) has a built-in measuring circuit and calibration memory to achieve highest accuracy. It provides a robust digital output signal. The reliability is further enhanced by an especially wide electrode spacing to prevent particle fouling between electrodes. See how this breakthrough in conductivity measurement technology can help you meet water treatment challenge by downloading this free application note at: www.mt.com/uk-powerplantcond-an For more information on solutions for the Power industry contact Mettler Toledo Ltd, Beaumont Leys, Leics. Tel: 0116 234 5095 E-mail: enquire.mtuk@mt.com Web: www.mt.com/pro_power

calibration Cost-effective solution for biomass storage inventory measurement The application of the latest noncontact scanning technology to a new range of level measurement systems has resulted in a breakthrough in providing an accurate and cost-effective solution which is particularly relevant to general biomass, renewable energy applications. The revolutionary 3D Volume Scanner System available from level and flow specialists ALLISON ENGINEERING provides important benefits to inventory measurement applications, such as in wood pellet boilers where accounting for large quantities of biomass fuel materials has traditionally been largely guesswork. This new system eliminates the problems associated with conventional ‘point-level’ devices which only measure distance to a single point. Whilst this may be adequate for liquid applications it is not suitable for biomass solids, where the product is uneven. Also, in general biomass storage, the materials have a tendency towards product build-up which can result in dangerous hot-spots which prevents operators from scheduling timely delivery. Allison, for large-scale firing, the accuracy of the 3D Volume Scanner information promotes more efficient OFGEM reporting which helps power stations to claim their Renewable Obligations Certificates (ROC’s). Allison Engineering’s new 3D Volume Scanner System is designed to take multiple measurements of the product profile to build a three dimensional map of the bay, silo, vessel or stockpile. Based on the volumetric measurement and also the product density, operators are able to identify both the total inventory and also the product profile. With this information, which has until now has been unavailable, operators can identify stock levels and plan for timely delivery of replacement fuel. End of week or month stock discrepancies, which can also create considerable friction between finance and operations departments, can be better understood with more accurate and realistic inventory measurement and 3D imaging.: For more information contact Allison Engineering, Basildon, Essex.Tel: 01268 526161 E-mail: generalsales@allison.co.uk Web: www.allison.co.uk/bulk-solids

New Fluke current loop calibrator delivers the power of hart communications in a compact test tool Fluke has introduced the Fluke® 709H Precision HART Loop Calibrator, an easy-to-use tool with a user-friendly interface and HART capabilities that reduces the time it takes to measure or source, voltage or current, and power up a loop. With its best-in-class accuracy at 0.01% of reading, the 709H is ideal for process technicians who need a precise loop calibrator and powerful HART communicator in one compact, rugged, reliable tool. The Fluke 709H supports a select set of HART universal and common practice commands. In the communicator mode, technicians can read basic device information, perform diagnostic tests, and trim the calibration on most HART-enabled transmitters. In the past, this could only be done with a dedicated communicator, a high-end multifunction calibrator, or a laptop computer with a HART modem. The 709H also features a built-in, selectable 250-ohm resistor to tune the loop for HART communications. 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: www.fluke.co.uk

food grade lubricants

New detectability makes foodlube® safest ever Leading UK food-grade lubricants manufacturer ROCOL has introduced innovative caps and actuators on aerosol spray cans in the FOODLUBE range to help reduce the risk of foreign object contamination during food and drink processing. Building on its long-standing NSF registration for FOODLUBE and its corporate ISO 21469 certification, both of which offer crucial safety assurances about lubricant formulation, the company has now become the first in the UK to add DETEX™ metal detectable plastic actuators and caps on all aerosol cans. This means that, unlike traditional aerosol packaging, all caps and actuators on FOODLUBE packs can be identified using standard metal detection equipment should they become loose in food and drink processing areas. The patent-pending DETEX caps and actuators are themselves manufactured from safe materials deemed acceptable by the US Food and Drug Administration for use in food processing plants. ROCOL marketing manager Joanne Ferguson says: “The addition of DETEX caps and actuators represents another important step in helping food

and drink processors avoid costly downtime, product recalls and the risk of reputational damage. “We are continuously looking at new ways to help address safety risks, and this includes utilising new technology like DETEX wherever possible. Our corporate strength as part of the global ITW Group gives us privileged access to developments of this kind.” FOODLUBE products are available for a wide range of applications across processing plants in the food, drink and clean industries. Individual lubricants are all NSF H1 registered, which means they have been independently assessed and deemed safe for processing equipment used to produce food and drink for human consumption. For more information about the FOODLUBE range contact ROCOL, Swillington, Leeds, West Yorkshire Tel: 0113 232 2600 Fax: 0113 232 2740 E-mail: enquiries@rocol.com Web: www.rocol.com

Process Industry Informer March-April 2013

pROCESS CONTROL Rockwell Automation enhances HMI operator experience and data integration with latest FactoryTalk View software FactoryTalk View 7.0 HMI software improves processsystem capabilities, information integration and usability Manufacturers, particularly those in process industries, can gain increased functionality and an enhanced operator experience with the latest version of the FactoryTalk View human-machine interface (HMI) software from Rockwell Automation. FactoryTalk View Site Edition (SE) and Machine Edition (ME) 7.0 applications, releasing in early 2013, offer more efficient alarm management, simplified installation, improved user experience, and integrated data sharing in a wide range of production environments. “To stay competitive, our customers need scalable HMI solutions that are easier to install, enable operator productivity, and are more tightly integrated to company control and information systems,” said Tony Carrara, product manager for FactoryTalk View SE software, Rockwell Automation. “To meet all these needs, we are leveraging our deep experience to evolve our visualisation software.” FactoryTalk View SE 7.0 software will support larger numbers of HMI clients and servers in a single system, increasing the size of systems that can support the FactoryTalk View SE alarming subsystem, FactoryTalk Alarms and Events. The FactoryTalk Alarms and Events alarming subsystem has been enhanced to align with ISA’s Alarming Standard 18.2., and will now support the shelving state. The subsystem now also allows users to configure remote-alarming commands on display faceplates, saving crucial time when an operator needs to react to device alarm situations. The newest version includes an improved installation process and design environment. The new installation process in FactoryTalk View SE and ME software saves time with a streamlined work flow that automates installation of FactoryTalk For more information contact Rockwell Automation Ltd, Milton Keynes, Bucks. Tel: 0870 242 5004 Fax: 01908 839696 E-mail: ukmarketing@ra.rockwell.com Web: www.ra.rockwell.com

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EMERSON UNVEILS INDUSTRY’S FIRST SUITE OF WIRELESS PREENGINEERED ESSENTIAL ASSET MONITORING SOLUTIONS Integrated application solutions monitor more key assets 24/7 to avoid shutdowns, slowdowns and reduce maintenance, energy costs Emerson Process Management has announced the availability of Essential Asset Monitoring solutions, the industry’s first family of integrated wireless application solutions for equipment monitoring. The pre-engineered monitoring and analysis solutions embed process and equipment knowledge into a wide range of applications and use existing wired and new wireless instruments to form a network for continuous automated expert monitoring. Integrated solutions are available for pumps, blowers, compressors, heat exchangers, fired heaters, corrosion, and cooling towers. The new 24/7 online monitoring solutions reduce monitoring costs through preengineering savings and wireless efficiency. Whereas wired continuous monitoring is traditionally afforded for only the most expensive and critical assets, the lower costs of Essential Asset Monitoring solutions enable expanded asset oversight. “Equipment failures are a common cause of outages and incidents,” commented Tom Snead, President, Global Projects,

Emerson Process Management. “Predictive monitoring by Essential Asset Monitoring solutions delivers diagnostics as well as equipment and process health alerts that enable timely corrective actions to keep the facility online, increasing production availability and savings on maintenance and energy costs.” Snead continued, “Our research has shown that unit or site-wide Essential Asset Monitoring application solutions can help owner-operators increase production capacity by 1.2%, save 14% of maintenance costs, and 2% of energy costs.” The pre-engineered solutions are scalable. Users simply choose the number and type of applications that monitor threats specific to their facility. Their resulting solution will include a wireless field network communicating data from monitoring instruments to AMS Suite operator graphics and maintenance screens, and to host systems and data applications. For more information on Essential Asset Monitoring, go to www.EmersonProcess.com/EAM

HONEYWELL INCREASES INTEGRATION AND ASSET LIFE WITH EXPERION PMD RELEASE 800 Latest release offers increased integration and easy upgrade for process, machinery and drives automation Honeywell (NYSE:HON) has upgraded Experion® PMD, boosting the range and functionality of its comprehensive automation solution for controlling processes, machinery and drives through a single system. The new release of Experion’s integrated Process, Machinery and Drive control, (PMD) widens the scope of the solution further, integrating Experion Alarm Management, Experion Integrated Historian, OneWireless™ and Digital Video Manager solutions for the first time. Release 800 also adds a new Field Controller Express (FCE) controller with over 60 percent more controller point capacity, integrated Profibus and TotalPlant Alcont UPLINE/IOLINE highway interface, native peer-to-peer connectivity with Experion MX and the Experion PKS controller family through parameter connection and a single point of data entry. “With Experion PMD the result is better quality, more efficient production, and reduced maintenance and project lead times,” said Brad Garnett, business director, Pulp, Paper & Continuous Web Solutions at Honeywell Process Solutions. “The updates in Release 800 make it a truly all-encompassing automation solution for pulp and paper manufacturers, as well as others in the chemicals, metals, pharmaceuticals and food and beverage industries.” PMD controllers can be used on all control levels for implementing advanced controls, fast machine controls and process controls. A single, consistent set of engineering tools across these levels means lower capital costs and enables cost effective execution of production line and plant- wide control. Benefits include reduced database maintenance, easier training, increased access to diagnostic information, single alarm and event logging, and faster control responses. For more information about Honeywell industrial automation solutions, visit https://www.honeywellprocess.com.

Process Industry Informer March-April 2013

pROCESS CONTROL NEW VIDEO FROM MOORE INDUSTRIES HIGHLIGHTS DISTRIBUTED I/O SOLUTIONS Moore Industries has produced a new video detailing the advantages of using distributed I/O products such as the NCS NET Concentrator System® in plant settings. Available through the Moore Industries website at http://www.miinet.com, the video shows how a distributed I/O network provides a universal and modular way to connect a wide range of signal input and control output possibilities. Hosted by journalist and industry expert Peter Welander, the NCS NET Concentrator System video shows the benefits of using a distributed I/O network to send information between instrumentation devices in their and control elements in a control room or on a factory floor. Connecting field devices to the NCS NET Concentrator System or a similar device saves time and expenses associated with the installation and repair of wiring. The modular nature of distributed I/O networks makes it easy to add expand operations or integrate legacy process sensors. In addition, peer-to-peer systems are redundant, meaning that a break in a wire pair will not affect signal transmission.

The NCS NET Concentrator System solves several challenges that engineers deal with when establishing communications between field instruments and control devices. Its universal design can handle a range of signal input and control output possibilities. It is also capable of establishing peer-to-host or peer-to-peer connections, with the ability to send signals through wireless, Ethernet or fiber optic networks in peer-to-peer communications. More information about the NCS NET Concentrator System and other Distributed I/O products are available at the Moore Industries website at http:// www.miinet.com/ProductInformation/SelectionGuides/ ProcessControlandDistributedIONetworks.aspx. Other videos from Moore Industries can be found at the company’s YouTube page at http://www.youtube.com/MooreIndustries. For more information, contact Moore IndustriesInternational, Inc North Hills, California, U.S.A. Tel: (818) 894-7111 Fax: (818) 891-2816 E-mail: info@miinet.com Web: www.miinet.com

Siemens industry partners with Elite Controls to offer one-stop-shop solution Siemens Industry has announced that its solution partner agreement with Livingston-based Elite Controls now offers customers across all industrial environments an enhanced control systems service that also extends to instrumentation solutions. With over 20 years experience in providing software and control system integration, Elite Controls has a well deserved reputation for providing innovative solutions for customers in the oil and gas, food and beverage and power sectors. By teaming up with Siemens, Elite Controls now intends to extend its current area of expertise to include specialist instrumentation solutions as part of an integrated approach. The partnership means that Elite Controls now offers a ‘one-stop-shop’ for all control and instrumentation projects to include the full range of Siemens’ instrumentation product portfolio. Martin Johnson, sales manager for Elite Controls, says: “We already have extensive control systems experience and the addition of Siemens technology for instrumentation solutions as part of an integrated offering to the marketplace is an

exciting development for the company. We are delighted to have entered into this agreement with Siemens Industry which we believe (L-R) Martin Johnson, will be mutually beneficial Elite Controls and Ronnie for both companies, as well Snedden from Siemens as our customers.” Industry celebrate their new Dale Snow for Siemens partnership agreement. Industry comments: “Elite Controls has extensive expertise regarding control systems, software integration and process instrumentation. This partnership ensures customers requiring software, control system and instrumentation assistance can benefit from a single point of contact and follow-up expert service support. This formal agreement with Elite Controls will further strengthen our offering to the marketplace.” For more information contact Elite Controls UK Ltd, Bolton, Lancs. Tel: 01204 598855 Web: www. elitecontrolsuk.com or visit www.industry.siemens.co.uk

WEIGHING ULTRA COMPACT WEIGH MODULE FOR FAST IN-PROCESS TABLET TESTING METTLER TOLEDO’s ultra compact weigh module is ideal for use in weighing applications where installation space is extremely limited. Fast and easy to integrate into machines, its 25mm width minimises the space needed for an in-process quality control device. In-process weight control of 100% of the output of a tablet pressing machine is a real challenge. These machines run at very high speed, producing tens of thousands of tablets per hour. Quality control of each tablet is only possible if distances between individual process steps are short. Plus the mechanical pressing process generates noise, vibrations and dust, adding further complications. The WMC weigh module is designed to cope with these challenges. It has a weighing capacity of 20g and a readability of 0.00001g. The weigh module can be allocated

in rows to weigh lots of tablets in parallel. Its very small width reduces the distance between weigh modules and helps to keep overall dimensions of the test device to a minimum. The short weighing time per tablet, as little as 0.3 seconds, enables the check weighing process to keep the pace of the tablet press. The filter algorithms ensure the measuring of correct and repeatable results in spite of vibrations from the machine. The robust stainless steel design with built in overload protection guarantees high precision weighing performance in an industrial environment. It is equipped with a fast RS232 interface for high speed data processing. The module has options to communicate with PLC systems via DeviceNet™, Profibus®, ControlNet™ or EtherNet/IP™. For more information contact Mettler Toledo Ltd, Beaumont Leys, Leics.Tel: 0116 235 7070 E-mail: enquire.mtuk@mt.com Web: www.mt.com/WMC

Process Industry Informer March-April 2013

Yokogawa releases enhanced version of stardom™ network-based control system Upgrading of DNP3 SCADA protocol functionality for upstream oil & gas and other applications 119YOK - Stardom Yokogawa Electric Corporation has released an enhanced version of the STARDOM™ network-based control system. With this release, the integrity of the data transferred between supervisory control and data acquisition (SCADA) systems and programmable logic controllers (PLCs) is ensured in challenging upstream oil & gas and other applications.The STARDOM system has been enhanced to make better use of the functions supported by the DNP3 protocol. Product features With this enhancement, the FCN and FCN-RTU controllers now support a dual connection to DNP3 clients, enabling the same data to be sent to master and backup SCADA systems (the DNP3 clients) at the same time. When the same essential data is stored on master and backup SCADA servers in separate locations, the system can switch over to the backup SCADA server in the event of a disaster or some other eventuality that could cause the master SCADA server to go offline. This disaster recovery system ensures the uninterrupted monitoring and control of oil & gas fields, water supply facilities, and other types of infrastructure. About STARDOM STARDOM is an open network control system consisting of components with control, operation, and monitoring functionality, and is highly acclaimed as it combines the reliability of a DCS with the versatility and economy of a PLC. The autonomous controllers at the core of STARDOM have the same control and monitoring functions found in a PLC as well as the information distribution functions of a PC. They are widely used as intelligent remote terminal units (RTU) in distributed applications such as natural gas and oil wells and pipelines. When used in combination, FCN and FCN-RTU autonomous controllers and Yokogawa’s FAST/TOOLS SCADA software give increased flexibility in distributed applications. Major target markets • Widely distributed installations such as those used in oil & gas, water supply, and wastewater treatment applications • Small- to medium-sized plants for the processing of oil, chemicals, iron & steel, nonferrous metals, pulp & paper, food, pharmaceuticals etc. • Small- to medium-sized power plants that employ wind, steam, or water turbines Applications Monitoring, operation, control, data collection, and data storage for geographically distributed facilities. Further Details: Louise Mungrue. Yokogawa UK Ltd, High Wycombe, Bucks. 0HH Tel: 01628 535640 E-mail: louise.mungrue@ uk.yokogawa.com Web: www.yokogawa.com/uk

Demand Project Qu to Ease Maintenance Reduce Cost of Owne

Once a control system project is completed, its ownership transfers to the customer and their production & engineering staff. From that point on

ownership kick in. This long period of responsibility for the machine control system is often not fully considered during the procurement process. Tw

ownership experience for customers and suppliers alike and both actions will maximise the quality of project engineering - allocated sufficient b A project is deemed successful by both customer and supplier when each of its various component disciplines is met:

- budget - deadline - functionality and - engineering quality. Too often projects are compromised on budget and timescale, so jeopardising the engineering quality and resulting in an undesirable ownership experience. The procurement process is nearly always classified as “successful” when the lowest price for whatever being bought is obtained for what appears to be the same level of goods and services provided. It is no secret that a lower cost will mean reduced deliverables, though the compromises that will be made by the chosen supplier to provide the cheapest price often reside in the engineering discipline and are not obvious. The quality of engineering and project management is not so easy to determine at the procurement stage and it is this engineering input that determines the life-long ownership experience. Of the four important success criteria one is invariably met - functionality. Deadline comes next in the list of must-haves, then budget and finally engineering quality.

Why are they prioritised that way? It might be a “natural” phenomenon. Three of the four disciplines conclude when the project is handed over. Even when budgets are squeezed: (1) Functionality cannot suffer - the machine must perform its primary functions - and because this is easily measureable everyone understands and agrees. (2) Deadlines have to be met - because shutdowns are planned and downtime is expensive - again, measureable, understood and agreed. Then (3) Budgets often flex - one party or other will generally end up overspending on their originally projected costs, The last important discipline is engineering quality and its impact lives-on long after the handover stage. It is the least understood by procurement professionals, it is the most difficult to measure and the easiest one to unwittingly compromise. A low cost price inevitably means that less time can be afforded to a project and when time is tight corners are unwillingly cut in order to achieve a deadline. No one wants this. Understanding the engineering and management content of a project is therefore crucial to optimise the ownership experience and discern supplier proposals.

What can customers expect from a well engineered and managed project? Both customer and supplier have key roles to play. The involvement of customer-focused engineering professionals in the assessment process is strongly advocated. Today’s control systems are highly technical and complex in nature. The procurement process begins with a visit from a supplier sales and applications engineer. This should be someone with extensive experience in the field of control and automation engineering. He must be familiar with the subject machine, its process and the control methods employed (both when the machine was built and with current best practice techniques and equipment). The supplier company’s track record of providing solutions for a specific application or ones closely comparable is a good indicator of the company’s ability to deliver. Testimonials and site visits are an excellent way to satisfy these queries. The supplier’s independence from component manufacturers will ensure that whatever solution they propose will be the most appropriate equipment for one’s application. This can be a particularly complex area and depth of experience will simplify the decisions enormously. Look for a fundamental understanding of the machine process. It is probably the most difficult skill to acquire but the most important in delivering a successful project. This refers again to track record. The supplier’s proposed technical solution should stand up to customer scrutiny. There is usually little room for variance here if the subject machine is to be controlled in a prescribed way. So, the suppliers understanding of the process will be critical, as will their suggested key equipment manufacturer. The real differentiator in solutions usually boils down to the engineering content, the project structure and management. These, as discussed above, directly influence the system ownership. Here are the key engineering activities to expect in an industrial automation project with some brief associated comments. 1. Planning A project plan detailing key design stages and review milestones indicates good engineering discipline. 2. Survey The degree of detail required for a useful machine survey cannot be overstated. 3. Specification This document is arguably the most critical document of a project. Laying down the full scope of supply, the

Process Industry Informer March-April 2013

uality e and ership

n, ease of maintenance and cost of

wo simple measures can optimise the

budget & realistic timescales. control philosophy and functionality. 4. Electrical Design (Hardware) Electrical design has always been very important for longevity of any control system. Electrical design engineers must have not only a comprehensive command of high level electrical engineering methods but also in-depth knowledge to design legally compliant safety systems, cabling techniques and component specification. 5. Software design (SCADA, PLC, Drives, sensors) Well-written, structured and well-documented software is one of the most important elements in the onward system maintenance and support activities. Expediency when diagnosing and resolving downtime causes can save significant amounts of loss of production time and accordingly, money. 6. Procurement It is important to understand that there is a high skill level required in the procurement of specialist control equipment. Supply chain relationships that exist between the system integrator and their suppliers can mean longer warranty periods, improved prices and elevated support levels from product specialists. 7. Panel Build The development of electronic components means better, faster performance characteristics, which in turn means higher dynamic electromagnetic interference. EMC regulations require high resistance is a prerequisite for both emissions and tolerance. 8. Test The testing phase (prior to shipment) of a control system makes a significant impact on the system commissioning time. Thoroughly testing the control panel at this stage will identify most sub-standard components and verify the quality of the control panel construction. More extensive testing should include the energising of higher power controllers and the calibration of motors, transducers and sensors. Communications networks can be set up and tested so that once on-site, the fundamental system elements are pre-qualified operationally. 9. Shipping Shipping, carriage and packing is an activity that is too often taken for granted. Todayâ&#x20AC;&#x2122;s control systems comprise many components that include sensitive, micro-electronic control equipment that uses integrated circuit technology. Rough handling and transport of control panels can significantly reduce the longevity of a control system due to shock loads being experienced by miniature elements embedded in the main system components. We advocate careful handling and

transport methods are employed at each stage of the shipping activity. 10. Installation (Optional) Installation is rightly seen as a major part of a control system project. An efficient installation activity reduces the downtime burden, potentially reducing loss of production significantly. Planning, management and good documentation are key elements to this activity. The quality of the installation work also has a significant bearing on the ease with which future maintenance and support services are provided and the speed at which failures are found and resolved. 11. Commissioning Commissioning very often feels like a frustrating delay getting into production rather than the task that is guaranteeing production reliability. Pressure is always imposed to hasten through this activity in the race to get production from the machine, often meaning that full process and material trials are left incomplete and deferred to a later date. In the event this works out being an inefficient approach. A comprehensive commissioning plan, agreed prior to the commissioning exercise commencing will set out the actions and parameters determined and agreed by parties that, once met, are proof of compliance with the project specification requirements. 12. Documentation Maintenance and support of any new machine or control system relies heavily on the depth and quality of the system documentation. It is rare to find many simple components in a modern control system. Manufacturers are constantly striving to develop their components with the aim to maintain a market leading position. This means that the availability and knowledge of control components are relatively short lived. Self-sufficiency is therefore highly desirable in the machine maintenance discipline, for both efficiency and cost reasons. No engineer can effectively support and fault find on a control system without up-to-date and comprehensive documentation. These activities rely on the professional development of control circuits using market leading design tools (CAD etc.) and custom software that is generated according to recognised industrial standards and with a good documentation regime. 13. Sign-off Obtaining the customer sign-off is a critical and sensitive

Process Industry Informer March-April 2013

stage for both parties. A commissioning plan helps this process greatly. Having a pre-determined schedule that is developed up-front is the professional way to address this activity. 14. Training Training is a vital ingredient in the machine ownership period. Without controlled, educational exposure to the sometimes-wide range of components with resident software, the ready uptake of ownership by the maintenance team is difficult to achieve. A confident engineer works much more effectively than one with limited knowledge and significant reliance on external agencies. Training is essential. These are the key management activities to expect: 15. Regular engineering stage reviews Engineering complex control systems is a highly skilled capability. An engineer must be multi-faceted, with an expert command of electrical engineering, software development, machine safety, personnel safety, explosive area design methods to name a few. Most with serious legal compliance obligations on behalf of the customer. Given the range and degree of expertise required regular reviews of the various elements is an essential part of the design process. Attainment to plan is also of significant commercial importance because deadlines need to be met. 16. Progress correspondence and/or progress meetings with clients Projects inevitably produce variations as they progress. No matter how deep an initial machine survey is something new always comes to light. Some part of a process has not been identified or some product that has not been processed in living memory will need trialling. It is with these on-going developments in mind that regular dialogue between project manager and client becomes necessary. Projects such as these rely heavily on a strong customer-supplier relationship. For this reason close dialogue and regular development and progress updates prove essential. Optima Control Solutions Ltd., Blackburn., Lancashire Can be contacted on Tel: 01254 272829 E-mail: info@optimacs .com Web: www.optimacs.com

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