May 2015 issue of Process Industry Informer by Process Industry Informer

www.processindustryinformer.com

MAY 2015 Volume 11 No. 3

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

Is there a bias? see on page 12

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

CONTENTS. 4-5 News & Events 6, 8, 9-10 Applications 11 Mixing & Blending 11 Weighing 13 Women in Engineering 13 Network & Communication 15 Air Compressors 15 Data Loggers 19-20 Health & Safety 22 Bearings 36-38 Fluids & Liquids Handling (incl. Pumps & Valves) 40 Chillers

WOMEN IN ENGINEERING

COMPRESSED AIR SYSTEMS

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

40 Lift Trucks 40, 41, 43-46 Process Measurement 48 Condition Monitoring 48 Calibration 48 Enclosures 52 Test Measurement 55 Products & Suppliers Directory

MOTOR AND MACHINE PROTECTION

PROTECTING CRITICAL INFRASTRUCTURE FROM THREATS

THE BENEFITS OF CALIBRATION

LOOKING BELOW THE SURFACE

FLEXIBLE CONNECTIVITY SOLUTIONS

LATEST CERAMIC PRESSURE TRANSMITTERS

USING HEAT WISELY IN FOOD WASTE AD

BENEFITS OF USING WIRELESSHART INSTRUMENTS

MAKE ESOS EASY

23 BPMA News

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NEWS & EVENTS AMBITIOUS VALVE MANUFACTURER BIFOLD CONTINUES TO GROW DEVELOPING 48HR DESPATCH FOR EFFICIENT & QUICK DELIVERY

PUMPING CORROSIVE AND ABRASIVE LIQUIDS AT ACHEMA

Bifold’s 48hr Despatch

Bifold has recently moved to larger premises in Chadderton and so have been able to develop many different initiatives due to their expansion within the factory. The initiative that has the biggest impact for customers is that Bifold now has the capability to deliver products, configured and built to order within 48 hours. Bifold’s modular approach to product design and extremely efficient build and test processes have afforded increasing levels of flexibility as to the number of valve types that can be assembled and tested with short lead times. Along with the preferred range that is advertised, Bifold is also able to accommodate reasonable requests for alternative, configurable valve options that the customer may require and are more than willing to cater to individual customer requests. Whilst this 48hr service is applicable to single valves and small batch quantities, Bifold are also able to, within reason, accommodate specific demands for large quantities. Bifold are dedicated to maintaining the excellence of their products and their new facility confirms their commitment to shortening lead times and meeting customer demands. They would like to take the opportunity to thank all their customers for their continued support.

For more information contact Bifold Fluidpower Ltd, Chadderton, Greater Manchester Tel. +44 (0) 161 345 4777 Email: gbancroft@bifold.co.uk Web: www.bifold.co.uk

DEMAG V-TYPE CRANE TRIUMPHS IN RED DOT AWARDS

Wanner International will display its full range of Hydra-Cell diaphragm pumps at Achema 2015 on Stand L53 Hall 8 with the theme: “HydraCell seal-less pump technology… Its different”. The unique and advantageous differences will be highlighted in product displays, working demonstrations and cutaway pump models. Compact in size, Hydra-Cell pumps have a seal-less design that eliminates leaks, hazards and the expense associated with replacing dynamic rotary seals and packing. They can operate with a closed or blocked suction line and run dry indefinitely without damage, eliminating downtime and associated repair costs. API 674 configurations of Hydra-Cell pumps are also available as are versions with ATEX Cat 2 Zone 1 & Cat 3 Zone compliance. The Hydra-Cell metering and dosing range will also be featured, with focus on the electronic and mechanical adjustment control options now available. Exceeding the performance requirements of API 675 in terms of repeatability, linearity and steady state accuracy, the Hydra-Cell with multiple diaphragms in a single pump head configuration generates virtually pulse-less flow, removing the need for pulsation dampeners in most applications. The unique, high efficiency multi-diaphragm design is claimed to handle abrasives with less wear than gear, screw or plunger pumps. Low energy requirement and minimal maintenance needs also contribute to the claim that Hydra-Cell pumps have the lowest total cost of ownership in many applications. For more information contact: Wanner International, Fleet, Hants. Tel +44 (0)1252 816847 Email: NHerrington@wannerint.com Web: www.hydra-cell.eu

- Award success at prestigious product design competition - International recognition for the unique crane girder design - Second award for the V-type design The Demag V-type crane has won the Red Dot Award: Product Design 2015, which is a major worldwide award scheme for product innovation. The international judging panel, comprising designers, design professors and trade journalists from 25 nations, made the award in the machinery product category, in recognition of the innovative crane girder design. The Red Dot accolade follows on from the success of the patent pending V-type crane design at the prestigious iF Design Award at the beginning of February. Andreas Hambrock, Head of the Universal Cranes business line of Terex Material Handling, stated: “We are proud that the Demag V-type crane has now impressed two international judging panels. With its dynamic and translucent V-profile, our unique crane girder fulfils all the requirements of high class design.” In total, around 5,000 products from 56 countries were submitted for the Red Dot Award: Product Design, in this its 60th year. As the winning product, the Demag V-type crane will be shown from 29 June to 26 July 2015 at a special exhibition in the Red Dot Design Museum in Essen, Germany, and will be part of the museum’s permanent exhibition in the following months. As a result, the V-type girder concept offers significantly greater efficiency in load transport and higher handling rates. For more information contact Demag Cranes & Components Ltd, Tel: 01295 676100 Email: bnb-help@terex.com / Web: www.demagcranes.co.uk

PROCESS INDUSTRY INFORMER May 2015

NEWS & EVENTS FLUKE OFFERS FREE iPAD® FOR REALTIME SHARING OF THERMAL IMAGING DATA While stocks last and before 30th June 2015, Fluke UK is offering a free iPad® to purchasers of one from a range of Fluke Thermal Imaging cameras. Using Fluke’s latest Connect app or SmartView® Mobile app downloaded to the iPad, customers can generate reports and communicate results directly to their client or colleagues from the jobsite. This saves time and money, allows safer working and uses the latest innovations to become more productive. While stocks last, customers who buy a Fluke Ti105-iPad-mini, Ti110iPad-mini or Ti125-iPad-mini Thermal Imaging camera iPad special bundle will receive a free iPad® mini, and customers who buy a Fluke Ti200-iPad-Air, Ti300-iPad-Air or a Ti400-iPad-Air will receive a free iPad Air®. More than twenty Fluke tools feature Fluke Connect™ to connect wirelessly with the Connect app, including digital multimeters, thermal imagers, insulation testers, process meters, and specific voltage, current and temperature meters. For more information contact Fluke (UK) Ltd, Norwich, Norfolk Tel: 0207 942 0700 E-mail: industrial@uk.fluke.nl Web: www.fluke.co.uk.

NOV HIGHLIGHTS EXPANDED MONO™ TECHNOLOGIES IN WASTEWATER AT SHANGHAI EXHIBITION Shanghai New International Expo Center Visitors to IE expo 2015 were able to see innovative MonoTM products and services from NOV, which have reinforced its leading position in wastewater treatment. Exhibiting in the Environmental Hall, NOV showcased its MonoTM product offerings for sludge dewatering applications, as well as complete transfer solutions. The three-stage MonoTM Compact C range progressing cavity (PC) pumps on show are designed for filter frame press supply and high-pressure holding applications. Their compact design minimizes process footprint and they can handle operating pressures up to 16 bar. Also displayed were new MonoTM high-pressure dosing pumps, which offer a reliable, cost-effective alternative to the more expensive traditional gear pumps. They feature a modular, easy-to-maintain design, and provide an efficient, reliable and low maintenance solution for applications which require low-flow, accurate dosing. The core part of the InviziQ™ Pressure Sewer System was also displayed. InviziQ™ is gaining popularity as a superior replacement for conventional gravity-fed domestic sewer systems. It does not rely on gravity to operate, and provides reliable sewage handling in remote areas irrespective of slope requirements, environmental concerns or difficult terrain.

For more information contact Mono Pumps Ltd, Tel: +44 (0)161 339 9000 Email: Shuo.ding2@nov.com. Web: www.mono-pumps.com/zh/ie_ expo_2015

CROWCON’S PORTABLE GAS DETECTORS GET MED APPROVAL FOR CONFINED SPACE WORK IN SHIPS Crowcon – a world leader in portable and fixed gas detection instruments – announces that its portable gas detectors are now approved by the Marine Equipment Directive (MED) for use in confined spaces aboard ships. The atmosphere in any confined space in a ship is potentially dangerous: it may be deficient in oxygen and/or contain flammable or toxic gases or vapours. According to the Marine Accident Investigation Branch (MAIB), accidents in confined spaces continue to be one of the most common causes of work-related fatalities on board ships due to: • Complacency leading to lapses of procedure • Lack of knowledge • Potentially dangerous spaces not being identified • Would-be rescuers acting on instinct and emotion rather than knowledge and training Avoiding confined spaces is always the best option. If access is needed for maintenance, inspections or other essential tasks, however, all necessary precautions must be taken. The MAIB says ship owners and operators should: “Implement measures aimed at improving and identifying all dangerous and potentially dangerous spaces and increasing compliance with safe working practices.” To this end, the International Maritime Organisation (IMO) recommends all vessels to carry a minimum of two portable gas detectors, configured for LEL (Lower Explosion Limit) and O2. Other detectors may be required depending on the cargo being carried. Any EU-registered vessels are also required to only carry gas detection equipment that conforms to Council Directive 96/98/EC on Marine Equipment, otherwise known as the Marine Equipment Directive (MED). The ideal confined space gas detector for ships should be: • Compact and lightweight • Easy to use with one-button operation • Have a bright display • Have powerful audible and visual signals to warn when pre-set gas levels are reached • Tough and waterproof, with impact-resistant casings and a high degree of ingress protection Personnel working in cramped, confined spaces, perhaps in the dark, should be faced with nothing more daunting than a clear display, simple, one-button operation and loud/ bright alarms. Crowcon’s Gasman, Tetra and Tetra 3 portable gas detectors meet all these requirements and are now fully compliant with the MED. For more information contact Crowcon Detection Instruments Ltd, Abingdon, Oxon. Tel: +44 1235 557700 Email: fiona.macrae@crowcon.com Web: www.crowcon.com

PROCESS INDUSTRY INFORMER May 2015

APPLICATIONS DRIVESURETM ELIMINATES MOTOR/ GEARBOX AND DRIVE DEVELOPMENT AT M-SOLV • Four peristaltic DriveSureTM units fitted to the MSV 700G spray deposition system • Eliminated the risks associated with the separate specification of pump motor, gearbox and drives • Key pump attributes include precise flow rate, accuracy and pulse suppression

M-Solv, an Oxfordshire-based equipment provider for large area electronics systems, is benefiting from DriveSureTM, the fully integrated panel mount pump drive solution for OEMs from Watson-Marlow Fluid Technology Group (WMFTG). Four DriveSureTM peristaltic units are mounted to a spray deposition system for thin film batteries that will aid R&D at a leading university. The use of DriveSureTM removed any risks for M-Solv associated with the separate specification of pump motor, gearbox and drives. Such risks include the incorrect matching of drive output torque to the design torque requirement of the pumphead throughout the pump operating range. Furthermore, the units proved easy to fit, set up and control via analogue signals. Spray application “We recently encountered a new application involving a spray deposition system for thin film batteries,” explains the company’s Strategic Technologist, Dr. Taku Sato. “The spraying takes place in a ‘glove box’ – a sealed container filled with gases such as nitrogen for the processing of sensitive materials.” To facilitate the spraying, M-Solv opted to use DriveSureTM from WMFTG, an integrated range of brushless DC drives and combined speed control board for pumps in panel-mount OEM peristaltic applications. DriveSureTM can be integrated with Watson-Marlow 100, 300 or 500 series pumpheads and is designed for applications delivering flows up to 6100 ml/min with a 50:1 turndown speed achievable. “We had used DriveSureTM units previously in an inkjet application – controlling fluid flow for an ink delivery system – and it proved very successful,” says Dr. Sato. “As a result, we returned to Watson-Marlow for pumps for the spray deposition system.” How it works In the new application at M-Solv, four DriveSureTM units (one for each spray head) are deployed in a pneumatic spray deposition system. Each DriveSureTM pump is mounted in line with its spray head and connected to a reservoir containing the fluid to be applied. The substrate, in this case a thin film battery, is then moved beneath the spray head to receive the fluid at a flow rate of between 1 and 50 ml/min. “Key attributes of DriveSureTM that lend themselves to this particular system are flow rate, accuracy and pulse suppression,” states Dr. Sato. The system, which has been delivered, will be used at a leading university for R&D purposes, although according to Dr. Sato, it has the potential to be scaledup commercially if industry demand should materialise. The equipment manufactured by M-Solv is typically destined for niche large area markets that include photovoltaic (solar panels), flat panel displays and smart windows. The company has enjoyed strong organic growth over the past two years and today employs around 45 people at its headquarters in Kidlington and a satellite facility in Hong Kong. Most of the company’s output is supplied to OEMs in Asia for assembly into final end use products. For more information contact Watson-Marlow Fluid Technology Group Tel: 01326 370370 E-mail: info@wmftg.com Web: www.wmftg.co.uk

INSTANT (COFFEE) BENEFITS WITH CABLE DRIVEN TUBULAR DRAG CONVEYOR Maintaining the quality and consistency of ingredients while in transit through a factory environment is vital to ensure that the end product is in mint condition for packaging and distribution, which is why a leading hot beverages supplier turned to a conveying system from Spiroflow. The company, which packs instant, roast and ground coffee for most of the major high street chains, required a conveyor which streamlined the transportation process and ensured the minimum degradation of product. After taking advantage of Spiroflow’s state-of-the-art testing facility at Clitheroe to trial the equipment prior to purchase, the customer then installed a Cableflow® Cable Driven Tubular Drag Conveyor in a z-shaped unit fed through a bulk bag. To meet requirements the system also incorporated a horizontal plane, rather than a vertical one, to maximise floor space at the plant. Whether transporting powders, granules or whole coffee beans, Cableflow® conveyors are designed for gentle handling and can safely transfer delicate bulk products from single or multiple in-feed points to single or multiple discharge points without any discernible damage. Manufactured in carbon or stainless steel depending on the customer’s requirements, Cableflow® Cable Driven Tubular Drag Conveyors have been developed from Spiroflow’s Aero Mechanical range, which drags the ingredients along the inside of a tube to facilitate an efficient, dust-tight operation.

Spiroflow’s After Sales Manager, Jeannette Carter, said: “Our customer wanted gentle, time-saving conveying equipment that would maximise production. The Cableflow® conveyor has been designed with gentle handling in mind and has helped reduce manual handling and degradation of the product during the process.” Because the tubular drag conveyors are derived from Spiroflow’s AeroMechanical Conveyors, they also enjoy the option to have the patented DART (Dynamic Automatic Rope Tensioner) rope tensioning system for maximum rope life and minimum maintenance. This is a key advantage over competitors’ cable driven conveyors. Flexibility and totally secure handling are required from conveying equipment if coffee materials have to travel dust-free over long distances and complex routes within an operating plant. Spiroflow, world-leading manufacturer of ATEX approved conveying and bulk handling systems, is renowned for solutions that meet the most rigorous standards in hygiene and containment. Spiroflow’s Cableflow® system can handle hot, cold, wet, dry, hygroscopic or temperature sensitive materials and is the only mechanical conveyor that can operate in three planes, enabling complex circuits, eliminating transfer points and using only a single drive. When it comes to the challenges of transporting coffee - whether in powder form, granule or bean - Spiroflow aims to provide the beverages sector the best solution for maintaining product integrity. In addition to Tubular Cable and Chain Drag Conveyors, Spiroflow is also a manufacturer of Bulk Bag Fillers, Flexible Screw Conveyors, Aero Mechanical Conveyors, Bin Activators, Vacuum Conveyors, Bulk Bag Dischargers, Ingredients Handling and Weighing Systems. The company’s technical and engineering expertise has led to it developing an international reputation for an unrivalled range of products with state-of-the-art control systems. For more information on Spiroflow’s products and services visit www.spiroflow.com or call +44 (0)1200 422525.

PROCESS INDUSTRY INFORMER May 2015

APPLICATIONS NEW PROCESS FLOWMETER SELECTION PACK HELPS ENGINEERS CHOOSE THE BEST INSTRUMENT

New information pack from ABB helps users to make the right choice of flowmeter for improved process efficiency A new information pack is now available from ABB to help simplify the selection of flowmeters for process applications. Featuring a White Paper, application guide, webinar presentation and video, the pack explains the key differences between volumetric and mass flow methods and how to choose the right method for industrial process applications. Understanding how to correctly select the right flow variable can lead to significant improvements in process performance and cost effectiveness. Though both technologies will deliver almost identical results under certain conditions, the deviations that can occur where a process is subject to pressure and temperature changes makes it crucial to make the right choice from the outset. Originally produced for the launch of ABB’s latest generation of CoriolisMaster flowmeters, the information pack explains the fundamentals of mass and volume flow and which technique is best suited for particular types of applications. Titled Mass or volume? A weight off the bottom-line, the White Paper covers coriolis, thermal and multivariable DP mass flowmeter technologies, explaining how each one works and their respective advantages and drawbacks. These differences are further explained in the Understanding mass flow video. The application guide, A new generation of mass flowmeters, explains the importance of capacity, accuracy and physical size when choosing a flowmeter and how each criteria can be met by opting for a coriolis flowmeter. The information pack is an invaluable tool for anyone looking to optimise the efficiency and accuracy of their process flow measurements. To obtain a copy, please call 0870 600 6122 or E-mail moreinstrumentation@gb.abb.com Web: www.abb.com/measurement

VALVES MEET TOUGH DEMANDS IN DEEP WATER OILFIELDS Badger Meter control valves, available in the UK through Pump Engineering Ltd, are continuing to make an important contribution in applications such as oil extraction in ultradeep oil wells thanks to their ability to overcome the difficult challenges associated with these applications. For example, withstanding extreme pressures, wide flow ranges and ultra-low temperatures. As a consequence of increasing global demand and escalating fuel prices, oil and gas production has increased significantly at much greater depths. While market forces have driven the need for production companies to ‘push back the boundaries’ and extract oil and gas from greater depths, technological advances have been required to meet the challenges to enable safe and efficient deep sea oil extraction. As oil and gas production moves to deeper water, flowline pressures rise and seawater temperatures fall and this can result in the formation of hydrates. If these ice-like hydrates are left unchecked they can deposit on the inner wall of flowlines and agglomerate, until they completely block the flow line. To eliminate the potential problem of hydrates forming in flowlines at these depths and pressures, chemical additives, such as methanol or mono ethylene glycol, are injected into the well-stream. These additives act as anti-freeze and are effective in preventing hydrates from forming and therefore play a key role in helping to keep flowlines open. The Badger Meter Company, represented in the UK by Pump Engineering, was challenged to manufacture one inch valves which could handle ethylene glycol at flows up to 2 (two) lit/min at 700 bar. These valves were successfully deployed in deep water oilfields in the Eastern Gulf of Mexico where pressures are relatively high and temperatures relatively low and therefore the risk of hydrates forming is high. Additive and injection applications are ideal for these valves as they are suited to both low pressure and high pressure duties. The Badger range includes models ranging in size from ¼” up to 2”, capable of operating in temperatures from -270º up to +800ºC, with CV’s from 0.000018 to 2.5 and range ability from 50:1 to 15:1. They can be supplied as standard in 316 stainless steel or Stellite trims although alternative materials such as Monel, Hastelloy B& C, titanium and zirconium, can also be specified. Further details are available from: Pump Engineering Ltd, Littlehampton, West Sussex Tel: +44 (0) 1903 730900 E-mail: sales@pumpeng.co.uk Web: www.pumpeng.co.uk

GREENBANK TECHNOLOGY LTD CHOOSE AXIUM’S PURE-SCREEN FILTERS Greenbank Technology Ltd, specialists in design, manufacture and supply of Thermal Process equipment to many diverse industries worldwide, has incorporated Axium Process’ Pure-Screen wedge-wire filters in their innovative Torrent One Can Washer System. The filters, which are designed for hygienic applications and manufactured in 316L stainless steel, are suitable for back flushing, CIP and SIP operations. They are used as part of a rigorous pre-rinse process to remove any possibility of foreign bodies or debris that is larger than 100 micron from entering the rinse water. Axium’s Pure-Screen filter range, which is renowned for its rugged construction and versatility, is available with a range of interchangeable stainless steel wedgewire elements from 10 micron up to 6000 micron. Manufactured as 90°, in-line and straight-through options with end connections to suit customer requirements, the Pure-Screen filter range has been designed for applications where the highest quality has been specified and where product consistency is essential. The company’s specialist fabrication capabilities are available for customers requiring filters to their own specification and include a Compact, Duplex, Stand Alone and High Capacity 6 inch body design. For more information contact: Axium Process Ltd, Hendy, Swansea Tel: +44 (0) 1792 883 882, Fax: +44 (0) 1792 886 049 Email: info@axiumprocess.com | Web: www.axiumprocess.com

PROCESS INDUSTRY INFORMER May 2015

APPLICATIONS VERSATILE VERDERFLEX PERISTALTIC PUMPS MAKE RECYCLED CARS GREEN & CLEANER DID YOU KNOW THAT 95% OF CAR MATERIALS CAN BE USED AGAIN / RECYCLED?

At the end of its’ life, a car yields on average, 140 kilos of shredder waste: 26 kg of metals, 69 kg of plastics, 11 kg of minerals and 24 kg of fibres. In Tiel, Netherlands, a Post Shredder Treatment plant (PST) was built in 2011, for the recycling of cars. The PST plant is one of the two plants in Europe that are able to recycle to approximately 95% of the waste materials. Aiming for 100% recycling, continuous research and development is conducted in the company. In 2015 their goal is to recycle 95 percent of end-of-life vehicles. The last valuable material recovered is from shredder waste in the plant, which is crucial in order to fully achieve the legal objective. Today ARN has already reached this goal by separating about 40 percent of all shredder waste from cars. 56 percent of the remaining shredder waste is incinerated with energy recovery: just 4 percent at the most ends up in the landfill. The separation process is accomplished by a large number of different techniques. 179 different machines are used to screen the waste, cut it in the hammer crusher and centrifuge the waste particles to enable separation of the Verderflex Dura 45 hose pumps circulate copper parts shredder waste. Sink-or-swim tanks are also used to separate in a settling tank materials with different specific gravity from one another. Huge mega magnets are used to separate the larger metallic parts. Most techniques consist of innovative technical airflows in cyclones of different nature (eg, swirling, air blowing under or above or sideways), feeding or just by draining fluids. Also settling and circulation of fluid streams (for re-use of the process materials such as calcium carbonate) are recurring techniques. Separation through fluid streams Calcium carbonate In the last stage of separation, several materials are separated in fluid stream baths, using a difference in specific gravity. Calcium carbonate,powdered limestone, is circulated in a settling tank. Since this material is heavy, it will settle after 30 minutes. In order to keep the calcium carbonate from sticking to the bottom, a Verderflex Dura 45 hose pump is used to keep the fluid stream moving. Since requiring a single hose change. Separation of copper parts in a settling tank Verderflex rapide tube pump doses ecodish Copper parts are circulated by a stirrer in a settling tank. The copper parts are pumped into another tank by a specific movement of the stirrer. Due to the high gravity of copper, the copper parts settle at the bottom of the tank and every 2 weeks the tank has to be cleaned out manually. For this application, ANR purchased 3 Verderflex Dura45 pumps, and used them as circulation pumps. This prevents copper parts from settling at the bottom of the tank and are pumped into another section of the separation process. Separation larger plastic particles (>130 mm) Plastic waste is separated by circulating water. The plastic floats and is pumped out by a Verderhus screw channel pump. After many trial pumpings, the Verderhus, with its half open screw impeller,pumps plastic into the plastic containers. This works extremely well without clogging the pump. Extra lubrication for the plastics Verderflex Rapide tube pump doses a small amount of ecodish every hour to the circulating water. Ecodish is an organic lubricant, which lubricates the plastic even more to make it float away faster and smoother. Throughout this plant Verder Ltd is responsible for supplying 7 pumps, helping the World become a greener place! Customer prospective Since the opening of the plant, ARN have developed a number of manufactured products from the recycled materials. As a result, BlueRoots was developed; this product is suitable for manufacture of street name plates and street furniture. A new promising product is sheet material, suitable for sheets being used in construction. Emile Bregita (Head of Technical Department, ARN says “We are very satisfied with all the Verder pumps used in our plant. Without exception, the pumps run continuously without problem. We almost forget that they are there! We are so satisfied with the pumps that we have recommended Verder to colleague companies who Verderhus screw channel pump, pumps plastic experience problems with their waste process flows!” waste without clogging For more information contact Verderflex Ltd, Castleford, West Yorkshire Tel: +44(0) 1924 221020 E-mail: info@verderflex.com / Web: www.verderflex.com

EUROPE’S LARGEST MOTORS & DRIVES PACKAGE POWER TATA STEEL REVERSING ROUGHER Two of Europe’s largest synchronous motors, with the highest power-rated medium voltage (MV) drives ever used in a reversing roughing mill, have been commissioned by ABB at Tata Steel’s Port Talbot hot strip mill in South Wales. The replacement motors and drives were the focus of a major £25 million reversing roughing upgrade – part of the rolling process which transforms a 23 cm thick slab of red-hot steel into sheet, less than 3.5 cm thick, before further reducing it to produce hot rolled strip. The reversing rougher is a heavy torque application demanding two ABB 12.5 megawatt salient pole synchronous motors, with two ABB MV drives rated at 36 mega volt-amperes, 3.1 kilovolts, to power the slab between a set of rollers. The new synchronous motors give the response demanded while the ACS6000 MV drives with its motor control platform using direct torque control, provides unrivalled speed and torque control. Over a four week period, starting in August 2014, the plant completely closed for what was to be the most intense upgrade in 25 years. The old motors and spindles were removed and the foundation for the new equipment prepared. The pre-assembled new motors were then lifted into position at the same time that the new spindle system was being installed. The two motors were connected with the spindle system and all the pre-installed and commissioned services and control equipment was connected ready to run the new motors. “It’s fantastic to see the installation progress to schedule and really justifies the approach we took on this project with 90 percent of equipment pre-installed before shut down,” says Steve Winkley, Tata Steel’s project manager for the roughing mill project. “We are really happy with ABB, in terms of the equipment and the company; both performed absolutely brilliantly.”

For more information contact ABB Limited, Zurich, Switzerland. Tel:: +41 58 586 7312 E-mail: emmanuel.chabut@ch.abb.com

PROCESS INDUSTRY INFORMER May 2015

APPLICATIONS REVERSE OSMOSIS SLASHES ANNUAL FUEL COSTS AT WESTONS CIDER BY £44,000 – AND NETS JOINT INDUSTRY AWARD FOR WESTONS AND SPIRAX SARCO Westons Cider has cut its annual fuel costs by £44,000 per annum and has significantly reduced water consumption following the installation of a Spirax Sarco Reverse Osmosis (RO) water treatment system. The savings achieved led to Westons Cider and Spirax Sarco being named joint winners of Food Processing magazine’s Energy Management award in 2014. The Spirax Sarco RO system reduces fuel and energy consumption by cutting the amount of boiler blowdown and water needed. Regular boiler blowdown prevents total dissolved solids (TDS) from accumulating in the boiler, where they can cause problems such as carryover and deposits. The RO system from Spirax Sarco treats water before it reaches the boiler feedtank and removes more than 98% of TDS to produce high-quality, lowconductivity water. This has cut blowdown from 3% to less than 1%, resulting in the saving of fuel, water and boiler treatment chemicals. The RO-treated water is so clean that it has removed the build-up of deposits from the boiler, reducing the number of man hours needed to maintain the boiler, especially ahead of its annual insurance inspection. Westons Cider’s engineering manager, Jason Roberts, comments: “Before the RO system was installed, it would take our engineer approximately three days to strip down the boiler ready for its annual insurance inspection, do any work needed, then put it back together again and get it steaming. Following the installation of the RO system, it now takes a little over a day.” For more information contact Spirax Sarco, Cheltenham Glos. Tel: 01242 521361 E-mail: ukenquiries@spiraxsarco.com Web: www.SpiraxSarco.com/uk

MORGAN SINDALL PROVIDING CAPENHURST WITH CORE PROCESS DESIGN FOR LCF SUPPORTING SAFE MANAGEMENT OF URANIC MATERIALS

HPC KAESER ROTARY BLOWERS RISE TO THE CONVEYING CHALLENGE AT FINE LADY BAKERIES

Fine Lady Bakeries, part of the Heygate Group specialise in supplying own label bakery products to leading supermarkets, wholesalers, as well as supplying bread to the sandwich making industry. Blowers are an essential component within the baking process, used as part of the process to pneumatically convey large volumes of flours and powders to various points for the initial mixing process. Braby Ltd, a leading aluminium silo manufacturer, in conjunction with blower specialists HPC KAESER, were the preferred choice to design and install the silos and conveying systems for phase 1 of the Fine Lady Bakery in Manchester. Through their collaboration on other projects over several years, Braby Ltd were confident in HPC Kaeser’s ability to provide the best solution with high quality, reliable and energy-efficient blowers for their new Manchester bakery. As a result, for Phase 1, HPC Kaeser’s supplied a total of 5 blowers, comprising of; 4 x DB 236 / 30 kW machines, for flour transfer to process and 1 x DB 166C / 30 kW machine for the tanker unloading station. Phase 2 was completed three years later, effectively doubling capacity, and consisted of 4 x DB166C / 30 kW for transfer duties, 1 x DB166C / 30kW for a second tanker discharge station, and a BB 89C / 11 kW for minor ingredients transfer. The result is a successful, easy-to-maintain and energy-efficient installation with the added benefit of ultra-quiet operation. Since the blowers were installed in late 2010 and 2013, Fine Lady Bakeries have been delighted with the performance of the blower packages supplied by HPC Kaeser. Fine Lady Bakeries Engineering Manager, Clive Cope comments, “We were confident that the blowers would provide the reliability for our conveying requirements and we are not disappointed. They provide trouble-free operation, are easy to maintain and operate at very low noise levels”. Clive added, “Energy efficiency is increasingly important to us and we appreciate that the HPC Kaeser blowers meet our energy saving requirements”. For more information contact HPC Compressed Air Systems, E-mail: mark.sharman@hpcplc.co.uk Tel: +44 (0) 1444241671. Web: www.hpccompressors.co.uk

Morgan Sindall, with its design and engineering business, Morgan Sindall Professional Services, has won the Core Process Reference Design contract for the Legacy Cylinder Facility (LCF) at Capenhurst Nuclear Services (CNS). The LCF will house a process facility for the responsible management of legacy nuclear materials. The Core Process is focused on the best way to transfer existing materials into suitable vessels, in preparation for future deconversion and long-term storage. Morgan Sindall will create a blueprint for the equipment and processes that fulfill the requirements of the LCF. Specifically, it will design the plant for the transfer of uranium hexafluoride into new cylinders, safely sampling, categorising and filtering the contents. Richard Webster, managing director at Morgan Sindall Professional Services, believes the company’s valued contribution to this project as well as Morgan Sindall’s unified approach to design and delivery were the principal reasons for being awarded the LCF Core Process contract: “As a multi-disciplinary business providing engineering and construction expertise, we can ensure the project phases are intrinsically coordinated,” he said. “This is especially useful in complex projects typical of nuclear facilities. We are pleased to be building a strong relationship with CNS and further raising our profile in the nuclear sector.” David Slater, Managing Director of CNS, says that Morgan Sindall understands the company’s key objectives: “The team has demonstrated technical expertise and will support us in adapting and responding to the changing demands of the nuclear industry, helping us to ensure the work carried out is done in a responsible manner. Ultimately our goal is to deliver this project safely, on time and budget and Morgan Sindall will play a key role in helping us achieve that target.” The Core Process Reference Design phase is due for completion in May 2016 and the facility is due to open by 2020. For more information contact Clare White, Morgan Sindall Professional Services Tel: 01789 204288 | E-mail: info@construction.morgansindall.com | Web:www.professionalservices.morgansindall.com

PROCESS INDUSTRY INFORMER May 2015

MIXING & BLENDING

WEIGHING

NEW MINI CYCLOMIX FOR BLENDING DPI FORMULATIONS

INCREASE RELIABILITY AND EFFICIENCY OF YOUR WEIGHING PROCESS

To support R&D work for the blending of DPI (dry-powder inhaler) formulations, Hosokawa Micron has developed the Mini Cyclomix lab mixer. Based on the proven Cyclomix high shear blending technology the Mini Cyclomix incorporates many key features that add real benefits for use in the development of pharmaceutical powders. Blending formulations for dry-powder inhalers (DPIs) is a delicate matter. Delivering a fully homogeneous blend, without deterioration of the particles is a prerequisite. To disperse the actives in the lactose, the cohesive forces between the fine particles need to be broken, requiring a certain amount of mechanical energy. If too much energy is applied however, adhesive forces between the carrier and the actives will be too high, limiting the separation during inhalation. Finding the right balance for the required mixing energy is a critical issue and calls for a very efficient mixer. Exchangeable product bowls: The unit is highly versatile with exchangeable product bowls of 100 ml, 1 ltr or 2 ltr. Easily connected to the drive unit by a bayonet ring without any special tools. It is also possible to extend the range of bowls in the future. Offline filling and discharging: Because the product bowls are detachable, they can be filled and discharged in a separate location such as a dispensary or a glovebox. The bowl can be taken to the drive unit as a contained bowl. Simple, efficient operation: Integrated touch panel operation and featuring straightforward recipe management, data logging and data export. The large surface area, in relation to the product volume, makes the Cyclomix a very efficient mixer compared with other high shear blenders, resulting in a homogeneous blend with a minimum input of mechanical energy.

Even small inefficiencies can add up to big costs. Why settle for inefficient operations when you can improve overall productivity with innovative POWERCELL® technology from METTLER TOLEDO. Modern weigh modules with POWERCELL® technology help predict and diagnose issues before they even happen to avoid downtime and production problems - keeping your equipment running until repair is possible. METTLER TOLEDO’s accuracy white paper and batchcontrol checklist can help increase yield, reduce risks and enhance the efficiency of your weighing process. Stand-alone batch controller advantages also include: • Minimum raw material wastage and risk through track and trace • Legislative compliance • Consistent results • Lower costs

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

Download the batching checklist and accuracy white paper today: www.mt.com/uk-SWB605-WP www.mt.com/uk-batch-checklist

PROCESS INDUSTRY INFORMER May 2015

FEATURE

WOMEN IN ENGINEERING

By Eur Ing Dawn Bonfield CEng, FICE, FIMMM, FWES – President Women’s Engineering Society (WES)

If you work in engineering and read a lot of the engineering press you would be right in thinking that you have heard more talk about the lack of women in engineering over the last couple of years than ever before. And depending on the sector you work in, you may also have noticed more young women entering the profession, and those that do are invariably competent and do very well. This is because they have made it there often against the odds, and have had to be very determined to overcome a number of barriers to get there. But why do we want more women in engineering, and why is it so difficult to attract them? To understand this we need to take a look back at the history of women in engineering, and the corresponding history of the Women’s Engineering Society which was established in 1919. During the First World War women were encouraged into these technical roles in their thousands to make the bombs and munitions, aircraft wings, and an array of other engineering equipment that the war effort required. And they did this with great success - there is evidence to show that women were especially suited to the ‘re-engineering’ of production processes to improve efficiency, and were used as consultants to make improvements to these processes even after the war finished. But the end of the war brought an act called the Restoration of Pre-War Practices which prevented these women from continuing in these technical roles, and so the die was cast and we reverted to an industry which remained the domain of men. Come the Second World War a very similar situation occurred, but again after the war women were no longer encouraged to remain in these roles, and the ones that we know to have been successful at this time are all extraordinary women who went against the grain. So in general terms engineering has continued to attract either only the most determined women, or those who have something that we call ‘engineering capital’ - a parent or close relative who works as an engineer, which has meant that the number of women in engineering has remained at less than 10% for decades (the lowest in Europe). But then came the ENGINEERING SKILLS SHORTAGE that we hear a lot about these days, where according to Engineering UK we will need to double the number of graduates and technicians over the next 10 years to keep up with the predicted growth in the sector. This has focused the mind somewhat and it has become obvious that we are not going to do this unless we appeal to more than half of the population (ie. the male half), and start to encourage more girls to consider engineering. But the skills gap is not the only reason we need more women. Evidence is growing in engineering as well as other sectors that shows the benefits of diverse teams of workers: productivity increases, profit increases, the working environment improves, and staff feel happier at work and are more likely to stay. And with the use of automation and advanced processes, engineering is not the heavy, physically demanding industry that it used to be, so there is no good reason for not encouraging women into the industry these days. So with all of these positive reasons to attract more women to engineering, why is it so difficult to convince girls that engineering is a suitable career for them, and why do we find that when we do convince them they often don’t stay? The reasons why girls don’t choose engineering are numerous, but not complicated. One reason is that girls, their teachers and their parents don’t know enough about what engineers really do - or when they think they do they equate engineering with a dirty job, or one which involves fixing car engines or boilers. In addition we have the problem of unconscious bias that we have across many careers which stereotypes different sexes to different careers. It is a problem that affects boys taking English A level as much as it does for girls taking physics. We also have the issue of good physics and maths teachers being thin on the ground and teaching in a way that doesn’t appeal to girls. We know traditionally that girls like to learn more about the context of a problem and not the problem in isolation from the context. We use the example of the lightbulb, where if you ask a girl to wire up a circuit to get a

light bulb to come on then she is more likely to do it if she knows that the light is a signal to a deaf person that somebody is ringing the doorbell, whereas the boy isn’t as concerned with the context or the reason. Another issue is that we don’t do enough to stress the importance of creativity in engineering, and the need for the diverse range of skills that girls often bring with them such as communication, organisation and innovation. But we’re not failing completely and we do encourage some girls to see the benefits of a career in engineering, and thankfully we are finding more and more girls entering the industry, so the next problem is how to look after them and get them to stay. Being in a minority in any situation can often be difficult, and whilst it might be easy to see your female colleagues as ‘one of the lads’, unless the organisational culture is one of inclusiveness it is often the case that this culture will not attract and retain women employees. Unconscious biases need addressing, and a supportive environment where women feel valued and able to be themselves at work and not subject to continual ‘harmless banter’ is essential, and this is equally true for any other minority group. If your organisation is struggling to attract women to apply for your opportunities, it is worth thinking about where you advertise and the type of language you use in your job adverts. We have a lot of evidence that points to the fact that women see themselves as ‘who they are’ and not ‘what they do’, so your job adverts need to reflect this if you truly want a diverse workforce, and it might be that different ads for attracting different genders are required. Maternity leave is an inevitability with many women employees too, but this needs to be seen as an opportunity and not a threat. And more and more often in the future we will see men taking paternity breaks too, so we need systems in place that support and progress these employees whilst away from the workplace, and reintegrate them to a meaningful career afterwards, not penalising them. Lots of good practices exist around career breaks, and if you have ever calculated the cost of losing a valued employee because of a maternity break, then you will know that it is well worth the small investment in supporting that employee back to a valued role in the organisation after their break.

And don’t forget that 23 June is National Women in Engineering Day, so this is an ideal opportunity to look at your own practices for attracting, developing and retaining your female engineers – or working with schools to encourage your future workforce. www.nwed.org.uk If you would like more information about the WES please log onto www.wes. org.uk

PROCESS INDUSTRY INFORMER May 2015

WOMEN IN ENGINEERING

NETWORK & COMMUNICATIONS

VEOLIA WATER TECHNOLOGIES WOULD LIKE TO ENCOURAGE MORE WOMEN TO FOLLOW A CAREER IN ENGINEERING

HARTING M12 WITH CONDUIT STILL BETTER PROTECTED

After 30 years’ of WISE (Women Into Science and Engineering), engineering classes at universities around the UK now have a growing number of female students. With role models like Professor Helen Atkinson, Professor Wendy Hall and Judith Hackitt, they are proving to be exceptionally good engineers, who are in demand in all sectors of industry. High Wycombe based Veolia has been working with schools having recently supported an engineering conference for girls at Wycombe High School, Bucks helping Year 10 form students to understand how business works. “Veolia is strongly committed to promoting engineering careers and we would love to see more girls applying to us”, says Justine Jefferies, HR Business Partner & Employee Development Advisor. “We can offer student sponsorship, modern apprenticeships and part-time degrees.” Megan Chapman, a mechanical engineer apprentice in the UK, working within the Quality Control team at ELGA LabWater, part of Veolia, feels that working with local schools and promoting the opportunities with the engineering sector is ensuring our next generation of engineers. Visit www.veoliawatertechnologies.co.uk for more information.

HARTING has introduced a new version of its established M12 connector with a conduitmaking it ideally suited to tough applications in industrial scenarios. The new “M12 with conduit” solution offers IP protection class 65/67, and can be readily applied in temperatures ranging from -40°C to +85°C. In addition, the standard housing now accommodates plastic tubing of a nominal 10 mm width, providing customers with the option of adding further protection by simply fitting a plastic tube. The connector and the associated cable are joined with a reliable crimping method, and can be supplied either in 4-pole (d-coding) or 5-pole (a-coding) configurations, both as plug or socket. In order to achieve the corresponding protection classes and provide strain relief, seals for various cable diameters from 4.5 to 8.8 mm are included in the package. For more information contact HARTING Limited, Tel: +44 (0) 1604 827500 Fax: +44 (0) 1604 706777 Email: gb@harting.com Web: www.harting.co.uk

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PROCESS INDUSTRY INFORMER May 2015

FEATURE

COMPRESSED AIR SYSTEMS WHY IT PAYS TO CONSIDER THE BIGGER PICTURE REGARDLESS OF ESOS

By Phillip McArragher - Technical Manager of Burgess Hill based HPC Compressed Air Systems Compressed air has long been essential for a wide range of manufacturing, process and automation technologies and in some situations its importance is underlined by the fact that users regard it as the ‘fifth utility’. Over time the complexity and efficiency of compressed air systems has dramatically increased and today this is even more important as a result of the Energy Savings Opportunities Scheme (ESOS). ESOS is the UK governments’ response to the EU’s efficiency directive and is essentially a mandatory energy assessment audit applicable to all UK companies with a minimum of 250 employees, or an annual turnover in excess of £42m. It is estimated that generating compressed air accounts for 12% of all industrial energy usage across Europe and whilst the ESOS initiative is a positive step towards a better understanding of energy usage, it does not oblige companies to carry out improvements. However, the commercial reality is that the focus on energy efficiency will only intensify. Therefore, why would any forward-thinking company not wish to implement changes that could result in significant cost-savings, especially over the longer term, giving them a competitive edge, regardless of whether ESOS is applicable to them or not?

IMPROVING USER AWARENESS - LOOKING AT THE BIGGER PICTURE

As the range of compressed air applications grows, so does the demand for increased air quality along with the requirement for optimum reliability and efficiency. However, many ‘systems’ still operate as they did 20 or 30 years ago where, due to a lack of user awareness, they are often referred to as just ‘the compressor’. Therefore the bigger picture of the system as a whole is ignored. To gain the most from optimising compressed air system efficiency though requires an integrated, system approach. Philip McArragher, Technical Manager for HPC Compressed Air Systems, recommends that when considering compressed air installations, only a comprehensive and inclusive approach will result in cost-effective air production. The role of the air treatment equipment, system controller, air distribution network and even the user, should not be under-estimated, they all have a significant effect on system reliability, efficiency and performance.

GREATER COST-AWARENESS IS REQUIRED

When talking about energy costs, users are usually able to quote the price per Kilowatt Hour but hesitate when asked how much their plant’s cooling water costs per cubic metre. Ask them how much a cubic metre of compressed air costs and the vast majority will be at a complete loss. This is due in part to most purchasing decisions being more concerned with the initial investment cost of the system, instead of accurately considering the long-term operating costs. Even with a perfectly optimised system, energy costs for compressed air production can amount to approximately 71% of total operating costs, whereas the initial purchase investment (excl. installation) accounts for approximately just 15% and for servicing an additional 14%. The larger the compressor the larger the operating cost element becomes.

ACCURATE COST ANALYSIS IS THE FIRST STEP

The once common excuse that it’s not possible to ascertain accurate data costeffectively regarding actual compressed air costs to assess potential energy-savings is no longer valid. System providers like HPC have long since offered convenient analysis procedures and equipment. At moderate cost, key data such as pressure, pressure losses, air consumption values and air leakages can be gathered, analysed and documented within a couple of days. Furthermore, with constantly rising energy costs and the potential for increased legislation in the future, HPC along with most other leading system manufacturers, remain committed to producing quality compressed air with minimum energy consumption.

ENERGY SAVING POTENTIAL EMPHASISED BY ‘SAVE II’ AND ESOS

HPC welcomed the results both from an EU study on energy savings in compressed air systems as part of the EU ‘Save II’ project and the ‘Efficient Compressed Air’ campaign (2002 to 2004). These studies, along with the more recent demands of ESOS are making users more aware of the need to comply and to optimise the efficiency of their compressed air system. Of the 80 billion kilowatt hours required to produce compressed air in Europe since the beginning of the decade, more than 32% could have been saved through improvements in efficiency, amounting to an annual saving of E 2.5 billion (about £ 1.7 billion) based on average European energy prices. Another fundamental finding of the EU study was that such potential savings could not be realised simply by improving individual components within a system, they

could only be achieved through an integrated system optimisation approach, as most non-optimised systems show weaknesses in all areas.

DECEPTIVE CONTENTIONS

When the EU study was published, some manufacturers promoted individual products such as workshop compressors, variable speed compressors, or solitary air treatment components that would supposedly provide energy savings of up to 40%. However, significant reductions in energy consumption cannot be achieved simply by adding single components to an existing compressed air system. This would simply be repeating the errors of the past. The seminars and compressed air audits of the ‘Efficient Compressed Air’ project also confirmed that system optimisation is only possible through an integrated approach.

THE GOLDEN RULES - CHECK EVERYTHING FIRST

A detailed overall picture of the existing system is essential when considering new investment in a compressed air equipment. The following steps are recommended: · Check air consumption, air quality and time dependent operation for all air consuming equipment. · Note location, material type and sizing of the main air supply lines. · Produce a schematic diagram of the air production and treatment systems. · Use data-loggers, perform a detailed compressed air analysis over a period of at least ten days to include the following data; total air consumption, compressor partial load volumes, pressure measurement upstream and downstream of air treatment equipment and in areas with supply bottlenecks. · Assess all leakage losses of compressed air. Evaluation of this data provides the key information required to calculate actual compressed air costs.

AIM FOR CENTRALISED SYSTEMS

To achieve maximum energy efficiency, as many items of compressed air equipment as possible should operate at the same pressure. De-centralised compressor systems, network areas operating at a different pressure, or air quality and the use of small oilfree compressors for the purposes of particular processes, should only be considered in exceptional circumstances. In the long-term, such solutions invariably drive up energy costs and unnecessarily restrict flexibility with regards to possible future plans for expanding production or system modernisation. Problems with compressed air quality usually occur due to moisture and insufficient compressed air drying. These can be identified via pressure dew point measurement and attention should only be turned to the compressor and associated equipment after this measurement has been taken. Until recently, the predominant principle for compressor system design was to opt for the lowest possible purchase cost. This strategy usually resulted in poorly dimensioned compressed air installations comprising completely incompatible system components. Anyone trying to solve these problems simply by installing a master control system will usually find out quite quickly that no ‘off-the-shelf’ solution will work effectively or properly. Compressed air dryers must be precisely tailored to match compressor outputs and the individual compressors should be correctly sized for compatibility with one another. Only then will a master control system be able to select the correct compressor combination at the appropriate moment.

OUTSTANDING SAVINGS - PROVEN BY EXAMPLE

A really efficient compressed air supply can only be achieved through a comprehensive design strategy that meets all specific compressed air requirements and which involves every system element and companies such as HPC with long established Authorised Distributors across the UK are perfectly placed to provide the key requirements of: · The monitoring and analysis of existing compressed air installations. · Guidance and formulation of energy saving proposals to satisfy ESOS requirements. · The specifying and supply of new equipment or services to achieve energy savings.

IN SUMMARY

This underlines the importance to consider the bigger picture, particularly in relation to reducing energy consumption, regardless of end-users having any obligation to comply with the requirements of ESOS.

PROCESS INDUSTRY INFORMER May 2015

AIR COMPRESSORS NEW BOGE WHITE PAPER EXPLAINS HOW TO REDUCE COMPRESSOR ENERGY USAGE BOGE Compressors has released a new white paper that explains how to reduce energy use in compressed air generation whilst maintaining the performance of a compressed air supply. With up to 30 percent of a site’s total electricity usage often used to produce compressed air, this free white paper offers guidance on how to tackle high and costly usage by boosting energy efficiency. The white paper covers a variety of topics that contribute to effectively maximising energy efficiency when generating compressed air and optimising compressor performance. This includes detecting leaks, enabling businesses to identify energy losses with the intention of implementing change to prevent unnecessary costs, and heat recovery, for the purpose of reusing energy for applications such as water and space heating. It also provides an explanation of the best methods for achieving energy savings when operating two or more compressors, which is accomplished via a modern electronic central controller, and outlines the role of energy surveys in generating energy savings. “This white paper is a valuable tool to businesses that are interested in improving the efficiency of their compressors and compressed air systems in a cost-effective manner,” said Mark Whitmore, General Manager at BOGE. “The benefits of enhanced energy efficiency extend further than simply reducing emissions; businesses also have the opportunity to make significant energy cost savings.” For more information contact: BOGE Compressors Ltd. E-mail: m.heeley@boge.com Tel: +44 14 84-719921 Fax: +44 (0) 1484 712516 Web: www.boge.co.uk

PROCESS INDUSTRY INFORMER May 2015

DATA LOGGERS METPOINT® BDL PORTABLE:

A MOBILE DATA LOGGER FOR SUSTAINABLE ANALYSES BEKO TECHNOLOGIES have extended the METPOINT BDL graphic-display recorders series with a mobile variant for data logging in compressed-air and compressed-gas applications. The new METPOINT BDL portable will complete the stationary standard and compact versions of the successful measurement equipment series. The METPOINT BDL portable data logger is designed for the measured value acquisition via a multitude of different transducers. With this, it is suitable for use as a hand-held device where measured values need to be recorded and logged by mobile devices – also beyond compressed-air applications. The different sensors are easily configurable and connectable and are automatically identified by the device, depending on the sensor type. The electronic detection system measures the connected input signals and acquires the information that is necessary for the respective application. The information is indicated and stored in the METPOINT BDL portable. The process can thus be archived in the long term or also transmitted to other systems. All the measured values, measuring curves, and limit value exceedances are displayed on the touch screen. Screenshots can be generated and curve courses can be relocated and zoomed with a simple finger movement. With this user friendliness, the mobile METPOINT BDL portable is in no way inferior to the stationary variants. Especially for the use as a mobile dew point measuring device in compressed-air systems, BEKO TECHNOLOGIES also offers the new mobile METPOINT BDL portable as a complete set with a pressure dew point transmitter, measuring chamber, and connecting cable. During the pressure dew point measurement, diverse sensors can be used for different compressed-air qualities. For more information please contact BEKO Technologies Limited, Tel: 01527 575778. E-mail: info@beko-technologies.co.uk Website: www.beko-technologies.co.uk

FEATURE

LOOKING BELOW THE SURFACE: THE INCREASING IMPORTANCE OF A PLANNED APPROACH TO PLANT ASSET MANAGEMENT

Mike Priddle, Managing Director at NHE, leaders in the design, manufacture and installation of industrial process plant, discusses why taking a proactive, planned approach to plant maintenance is a strategy more companies are embracing to benefit from improved plant reliability and performance, with a measurable return on assets (ROA). In human nature, we prefer to think of ourselves as proactive rather than reactive. To be reactive implies that there has been no initiative about the action, and in terms of manufacturing plants, it is letting the equipment set the agenda. With regards to plant maintenance, we find that many companies are still reacting to the condition of their plant rather than being a step ahead. In an environment where most businesses are facing increasing cost, product quality and competitive pressures there is an ongoing need for UK manufacturing operations to improve productivity and reliability. As a result, it is ever more important for companies to be ahead of the game by proactively managing the service and maintenance of plant and equipment. Not only this, there are additional pressures surrounding corporate goals to reduce costs and maximise ROA. The advantages of preventative maintenance are clear-cut; by being ahead of the game plant managers will see an overall improvement in their plant’s operating performance, a reduction in total cost of ownership (TCO) and a reduction in unscheduled downtime.

SO WHAT ARE THE KEY TYPES OF PLANT RISKS AND FAILURE MODES THAT CAN OCCUR IN MANUFACTURING PLANTS USING CHEMICAL PROCESSES FOR SURFACE FINISHING?

There are three key types of plant and equipment associated with surface finishing; automated lines; manual lines and fume extraction systems. Typical automated or manual process lines include; cleaning lines; chemical etching lines; electroless plating lines; electrolytic plating lines; hard anodising lines; chromic anodising lines; TSA (Tartaric Sulphuric Anodising) lines and conversion coating lines such as alocrom and phosphating. Fume extraction would then be used to control pollution, emission and biological monitoring in order to fulfil specific requirements, and these tend to be bespoke. For each type of plant outlined, there are a number of general risks and failures modes that can apply: Process tank failure: if process tank integrity fails then the risk of aggressive chemistry flooding would present a major health & safety and environmental risk. For example, chloride stress corrosion cracking (CLSCC) is one of the most common reasons why austenitic stainless steel pipework and vessels deteriorate in the chemical processing and petrochemical industries.1 Thank failure can result from a combination of causes such as residual stress from fabrication and welding, a rough surface finish leading to a long period of slow localised

corrosion and short periods of rapid crack growth when the temperature hits a certain level during cleaning cycles. Fire: Failure can also originate from equipment overheating through failure of the heating and cooling elements. This also presents a fire risk which is incredibly dangerous in facilities where chemistry is involved, often resulting in critical damage to the plant and the building in which it is housed. Chemical: The chemicals themselves present their own risk. Any process that involves chemical handling can lead to leakage and spillage from failed pipework, valves or pumps which can damage parts of the plant and/ or adjacent equipment that is not already protected from chemical ingress. Additionally, chemical spills from poorly maintained plant and equipment can pose a significant health & safety risks to operators in the area. Wear and tear: This is one of the most common failure modes in any type of machinery, especially when there are moving parts involved. For example, we tend to see excessive wear and breakage in components such as lifting belts and wheels in transporter lines due to a lack of servicing and maintenance whilst in air extraction systems, a lack of cleanliness can often cause premature wear and failure of the drive belts and bearings in extractor fans. Air/fume extraction: Faulty or poorly maintained fume extraction equipment can also lead to a serious threat of legionella, again implicating the health & safety of employees. These risks can often turn to reality through the failure of gauges, monitoring sensors, heating and cooling devices in process plant. Regular, planned maintenance and servicing can eliminate costly unplanned downtime resulting from the failure of these plant critical components.

INDUSTRY DRIVE TOWARD PREVENTATIVE MAINTENANCE

External factors are putting many companies under pressure to maximise production capacity and improve product quality while trying to cut their overhead costs at the same time. Over time, this has put more pressure on maintenance departments to maintain the reliability of critical or more complex process plant and equipment. Recognising that these challenges are often compounded by increasingly stringent health & safety and environmental regulatory compliance, forward thinking manufacturing companies are developing a more proactive approach to plant asset maintenance. Reactive maintenance is often known as ‘firefighting’, and is sometimes as risky as the original denotation of the word. This break-fix approach is not an ideal

PROCESS INDUSTRY INFORMER May 2015

strategy and its use is often driven by economic pressures; however, this is a false economy. A typical scenario would be to operate the machinery until a failure occurs. It is only at this stage when the appropriate repairs are made, and this tactic can incur extreme costs through critical machine failure and lost production output resulting from unplanned downtime. In today’s manufacturing environment, competition, environmental and health & safety implications make this route challenging with the increasing preference being towards taking a preventative maintenance approach.

REGULATIONS

Generally speaking, where there is risk there is an accompanying regulation and plant and equipment maintenance is no exception. Maintenance on plant and equipment is carried out to prevent problems arising, to correct faults, and to ensure equipment is working effectively.2 While production and profitability are high on the agenda for responsible companies, health and safety is equally important. The Health and Safety Executive’s (HSE) Control of Substances Hazardous to Health (COSHH) regulations play a key role in this area, and in particular the Provision and Use of Work Equipment Regulations 1998 (PUWER)3. Ultimately preventative maintenance protects operators and employees from risk of injury e.g. lifting gear falling and chemistry spills, leaks and fires. The condition of plant and equipment is also affected by the Industrial Emissions Directive (IED)4 which influences the environmental responsibility of companies. The IED is the successor of the IPPC Directive and in essence, it is about minimising pollution from various industrial sources throughout the European Union. These regulations link back to the operation of air and fume extraction equipment. For example, if there are any faults in the mechanical parts, dangerous fumes and gases could leak into the atmosphere. With regards to the water treatment in plants using a surface finishing process, the Environment Agency drives the ‘Consent to Discharge’ regulations under the Water Resources Act 1991 (as amended by the Environment Act 1995)5 for companies that wish to discharge effluent into inland freshwaters, coastal water or estuaries and ground waters or land. Should a company be using water treatment systems, these will need to be heavily regulated to ensure that the water levels are safe. For example, referring back to the chemical risks involved of surface finishing, if the equipment is damaged or worn this could have contamination implications.

MAINTAINING PLANT HEALTH AND FITNESS

The primary goal of preventative maintenance is to prevent the failure of critical, more complex or higher capacity equipment before it occurs. It is a strategy designed around time based, usage or condition based activity to preserve and enhance equipment reliability, replacing worn components before they fail, and which includes: critical process equipment checks, partial or complete overhauls at specified periods, oil changes, filter changes and lubrication. In addition, engineers record equipment deterioration so that they know to replace or repair worn parts before they cause systems failure. It is the most cost effective way of extending the life cycle of existing machinery and is a small fraction of the cost of production disruption and associated customer dissatisfaction. Other key benefits of implementing a preventative maintenance strategy include the fact that businesses will avoid unplanned plant shutdown and disruption to productivity, thereby improving Overall Equipment Effectiveness (OEE). Early inspection also helps identification of wear and tear to allow for replacement before breakage or failure as well as complying with various insurance requirements.

SO WHAT PROCESS PLANT FUNCTIONAL AREAS WOULD TYPICALLY BE TESTED?

For mechanical operations, strict testing would be carried out to assess the general wear and tear on all moving parts, such as; lid assembly; carriage/ transporters; extractor fans. Similar tests are carried out on the tank structure. Then for electrical, control and automation, it is important for tests to be carried out on gauges, monitoring sensors and control devices to ensure that they are all operating accurately. Current feeds will also be tested to ensure that they are maintaining the correct safe levels, and cabling and trunking needs to also be inspected to make sure it is all intact. However, a lack of sufficient in-house maintenance resources coupled with the lack of necessary skills and experience can often be a barrier to improving service and maintenance activity for industrial process plant. Acquiring the necessary regulatory knowledge, mechanical, electronic and IT skills may need regular investments in employee training or, alternatively, the outsourcing of service and maintenance contract to a specialist company. There are different levels of service and maintenance outsourcing support available in the market. As the market leader in the supply of metal surface treatment process plant, NHE offers a holistic approach in the form of a tiered structure suited to different requirements. A premium plus programme would be tailored towards manufacturers with critical operations, when downtime is not an option. This includes all aspects of service and maintenance including guaranteed emergency breakdown support, consignment stock for critical spares and remote, condition-based diagnostics where applicable. The premium level is suited to manufacturers that require the additional security of emergency cover. This maintenance programme has been designed to ensure the minimal possible downtime and includes recommended spares lists and the option of consignment stock for critical spares. There is also a basic level of maintenance support available to companies, which is designed to provide an annual plant service and ensure correct operation and calibration, while at the same time checking the plant for wear and tear. Prior to an external evaluation, there are also a range of checks that plant managers can carry out themselves to maintain the general upkeep of their facilities through inspection of condition and cleanliness of equipment. Additionally they should be following operation and maintenance instructions which are provided with the plant itself. All critical plant assets should be regularly serviced and maintained to improve manufacturing performance and avoid unplanned downtime and unnecessary maintenance activity and costs. A wide range of industries are already benefiting from taking a proactive approach to the maintenance and servicing of plant due to the OEE benefits and reduction in costly unplanned downtime as well as adhering to the increasingly stringent regulatory compliance requirements that put pressure on manufacturers. The truth is, most manufacturing facilities would benefit from a well-executed, planned maintenance programme and, where they are operating critical, complex or high capacity process plant, they could find this strategy is enhanced by outsourcing critical service and maintenance activity to a specialist supplier. For typically less than a few per cent of the capital cost of process plant investment, the business case for preventative maintenance services should be easy to make. 1 http://www.hse.gov.uk/research/rrpdf/rr902.pdf 2 http://www.hse.gov.uk/Toolbox/machinery/plant.htm 3 http://www.hse.gov.uk/work-equipment-machinery/puwer.htm 4 http://ec.europa.eu/environment/industry/stationary/ied/legislation.htm 5ttp://www.clfabrication.co.uk/lib/downloads/Application%20for%20Consent%20to%20 Discharge%20Guidance%20Notes.pdf

FEATURE

USING HEAT WISELY IN FOOD WASTE AD PLANTS By Matt Hale, International Sales Manager, HRS Heat Exchangers If you are planning or operating an anaerobic digestion (AD) biogas plant to handle food waste, it makes sense to maximise the efficiency of the process at all stages. However, not utilising the heat naturally generated as part of the process could be costing you thousands of pounds a year, particularly if you are adding heat elsewhere. Optimal AD plant performance can be achieved by fine-tuning the feedstock mixture and retention times to maximise biogas production, as well as regularly servicing the CHP engine to maintain electricity generation. But some aspects are overlooked, such as the waste heat from the radiator attached to the gas engine. Many operators simply use it for cooling, which is potentially wasting a resource worth thousands of pounds each year. This is potentially wasting a resource worth thousands Fig. 1. Dry solid content improvement of pounds each year. If you are makes digestate easier and more cost generating heat separately for effective a different part of the process, such as drying or concentrating digestate (the organic biofertiliser output from the AD process), then you are also paying for heat which you may be able to get for free. With biogas combustion heat tariffs under the Non-Domestic RHI between 2.2 and 7.5 p/kWth and heat from an LPG-fuelled boiler currently costing somewhere around 6.6 p/kWth, the price of heat is self-evident. With a typical gas engine producing half its output as usable heat, the heat produced by a 300 kWe engine could be worth as much as ÂŁ124,000 a year under the RHI before tariff degression is considered.

UNDER-UTILISED HEAT STREAMS

One solution is to capture and transfer this wasted heat with heat exchangers. These are an established way of capturing the heat generated in one part of a process, and transferring it for use in another. However, despite their widespread use in industries such as food manufacturing and the chemical sector, they are underutilised in the AD industry. There are four main areas of the Fig. 2. Heat exchange systems help food AD process where heat, which is waste AD plants recover and utilise 40% available and may otherwise be of heat produced wasted, can be utilised in plants treating food waste: feedstock preheating, digester heating, pasteurisation and evaporation. Which ones are most suitable or useful will depend on your exact situation, but even if it isnâ&#x20AC;&#x2122;t feasible to use the heat as part of your AD process, surplus heat can still be used for other purposes such as drying processes, heating nearby offices or workshops, or hot water for washing down equipment. Using surplus heat in this way is also free, without the need to buy additional fuel, and all of these applications can be fulfilled using a suitable heat

exchanger, often with benefits over other technologies such as the tank heating systems often used for pasteurisation. A well designed system could recover and utilise 40% of the heat produced by the plant.

Fig. 3. AD plant uses HRS exchanger technology (centre) for heat efficiency

HEAT EXCHANGERS RESOLVE EFFICIENCY CHALLENGES

Using heat exchangers in the pasteurisation system is more efficient than using tanks with heating jackets as they have a much lower heat requirement; up to half of that of some systems. This is because tank systems have lower heat transfer efficiency and usually dump the hot water after use, rather than reclaiming it. Using heat exchangers means that effective pasteurisation of digestate, for example to comply with PAS 110, is possible using surplus heat rather than the installation of an additional heat source such as biomass boiler which could add hundreds of thousands of pounds to your project. Using a well-designed heat exchanger system can provide you with a continuous pasteurisation process which uses less Using heat wisely in food waste AD plants energy than alternative systems, while allowing additional thermal regeneration, or recovery, levels of up to 60 per cent. This saved heat can then be used elsewhere in the process, such as an evaporation plant, helping you to maximise your RHI eligibility. Heat can also be used to separate water from digestate by evaporation. This technique can reduce the overall quantity of digestate leaving the plant by as much as 80%, greatly reducing the transport costs associated with the removal of digestate. A well designed system will include measures to retain the valuable nutrients in the digestate while the evaporated water can be condensed and reused. For example, the captured water can be added back to the feedstock as it enters the digester, making the entire process almost self-sufficient in terms of water use and eliminating liquid discharges from the plant. After evaporation, the treated digestate dry solid content can be as much as 20% (often a fourfold improvement), making it much easier to transport and handle. Tariff digression, increasing competition and environmental concerns mean that efficiency is directly linked to the operational sustainability of a plant. Incorporating cost-effective heat exchanger systems into the process from the beginning, or retrofitting them to an existing plant, is one of the easiest ways to ensure future financial feasibility and save hundreds of thousands of pounds each year.

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HEALTH & SAFETY FORTRESS INTERLOCKS AND TROAX MESH DOORS UP TO THE IMPACT CHALLENGE! A dramatic impact test on the Fortress Interlocks amGardpro interlock fitted to a Troax St30 mesh door has been captured on video see: http://youtu.be/HpO9i7BLVfY In the test, the mesh door and interlock were subjected to a powerful impact of 1600 joule. The door was slightly deformed by the impact but no parts came loose and it was held firmly in place by the interlock. The interlock was also fully functional after the test. “This test really demonstrates how robust our interlocks are,” says Fortress’ Managing Director Rob Lewis. Our locks really are ‘fit and forget’ for a huge range of industrial applications in the toughest environments.” Fortress and Troax recently combined forces to create a new perimeter guarding system to protect workers from dangerous machinery. By utilising a unique new bracket which fits Fortress interlocks to Troax perimeter guarding panels and gates, it enables the safeguarding of virtually any machinery installation. Very easy to install for both end users and OEMs, the brackets are 100% compatible with Fortress’ modular amGardpro and tGard ranges of modular interlocks and Troax’s modular mesh panels. This means that whatever configuration of interlocks or mesh panels is specified first, the brackets will always fit. Both the amGardpro and tGard interlocks combine solenoid or non-solenoid safety switches with full control functionality in one device, allowing their use across a vast array of industrial applications. For more information contact Fortress Interlocks Ltd, Tel: +44 (0)1902 349000, Fax: +44 (0)1902 349090 E-mail: sales@fortressinterlocks.com Web: www.fortressinterlocks.com

CASELLA UNVEILS NEW HAND ARM VIBRATION METER Casella’s new Hand Arm Vibration Meter has been developed to monitor those susceptible to hand arm vibration syndrome (HAVS). This serious condition affects one in ten people working with hand-held, vibrating power tools¹, such as hammer drills, chainsaws and concrete breakers. Encompassing a number of conditions including Raynaud’s Disease and White Finger, without proper workplace precautions and monitoring in place HAVS can cause irreversible and painful damage to the blood vessels, nerves and joints in the arm, hands and fingers. For the estimated two million people at risk² from hand arm vibration syndrome the innovative meter available from Casella will go a long way in evaluating risk and accurately assessing vibration levels. With just three operational buttons this instrument is much easier and quicker to use than other available meters. It tracks the length of time the operator is exposed to the vibration and is able to calculate and simply display total exposure, in accordance with current legislation. “All of our measuring and monitoring solutions, whether for noise, dust or vibration, are developed to help prevent occupational disease. We keep usability and reliability at front of mind to ensure the process is as easy as possible and that occupational health is given the same priority as workplace safety.” Says Andrea Bowen Technical Product Manager at Casella. For more information contact Casella, Kempston, Bedford. Tel: 01234 844100 Web: www.casellasolutions.com

V-SHAPE Vario GFD with HydroSpray

Michael Freiherr, product manager

Better spraying – better with Güntner! Your advantages using the HydroSpray-System: – Operation optimized using location-specific climate data – Spraying up to 1,000 hours per year – Easy installation, automatic draining, no interference with transport dimensions

PROCESS INDUSTRY INFORMER May 2015

– Patented sectional spraying offers: • Precise condensing and outlet temperatures • Up to 50 % less water consumption compared with conventional systems

www.guentner.eu/hydrospray

HEALTH & SAFETY SMITH FLOW CONTROL CELEBRATES 30TH ANNIVERSARY Valve interlocking firm has grown from three staff members to 78

Valve safety interlocking specialist Smith Flow Control (SFC) has celebrated 30 years of protecting people and assets at process plants worldwide. SFC was formed in April 1985 by Malcolm Brown, Mike Smith and current managing director Mike D’Anzieri. The company now employs a total of 78 staff, mostly at its headquarters in Witham, Essex, but also in regional offices in Australia, China, India, the Netherlands and the United States. A third of all staff have been with the business for more than 10 years. SFC introduced the coded card linear key concept to interlocking technology, and the concept has achieved widespread adoption on a global scale. The firm’s product range has evolved considerably over the past 30 years to include a full suite of mechanical interlocks for a wide range of applications and valve management products. More recently, new product development has diversified into electronics and RFID technology. “Our product range is constantly evolving and we pride ourselves on delivering customised solutions that our clients need,” explained Adrian Brown, SFC’s R&D manager and son of founder Malcolm. “For the last three decades, SFC has offered a precise and personal service. We appreciate and value the importance of supplying suitable products to our customers, and so adapt our product range to meet individual requirements. The continuous quest for new product development and ongoing product improvement requires a high level of energy and commitment, which can only come from a collective dedication to being the best in the industry.” Managing director Mike D’Anzieri added: “The business continues to grow at a tremendously fast pace. I am incredibly proud of our achievements to date, and I am especially grateful to all the employees for helping to make it happen.” For more information contact Smith Flow Control Ltd, Witham, Essex Tel: +44 (0)1376 517901, Fax: +44 (0)1376 519720 E-mail: enquiries@smithflowcontrol.com Web: www.smithflowcontrol.com

THE NEW EN ISO 14119 STANDARD HAS ARRIVED The new standard “EN ISO 14119:2013 Safety of machinery - Interlocking devices associated with guards - Principles for design and selection” has arrived and will replace EN 1088 as from 30th April 2015, with a one year transition period. In contrast to the previous standard EN 1088, EN ISO 14119 considers additional technologies such as RFID or electromagnetic guard locking, classifies interlocking devices and stipulates more clearly the specifications for installing guards. These stipulations are particularly significant with regard to protection against guard manipulation, also known as defeating of guards. EN ISO 14119 will replace all national standards on this subject and will be valid worldwide. This signifies a huge step forwards: the old standard was purely European, whereas the new standard is published by ISO. Specifications regarding the series connection of safety switches and safety gate systems are new, addressing the long-known subject of fault masking. EN ISO 14119:2013 provides machine builders and users with much wider scope to use a broader range of technologies when interlocking guards, it also places more responsibility on the designer to prevent foreseeable, deliberate bypassing of guards, and it will change the way in which guard interlocking devices are connected across machines. With its safety switches and safety gate systems, Pilz meets the specifications of the new standard and supports design engineers who develop standard-compliant, future-proof.

For more information contact Pilz Automation Technology, Tel: 01536 460766 | Email: sales@pilz.co.uk.

PORTABLE METHANE DETECTOR IDENTIFIES LEAKS FROM A SAFE DISTANCE Crowcon’s ATEX-certified LaserMethane mini (LMm) is rolled-out to cities across Italy Crowcon - a world leader in portable and fixed gas detection instruments – announces that the use of its LaserMethane mini (LMm) portable methanedetection device has been rolled out to all major Italian cities following the successful completion of a trial with a leading Italian gas distribution system operator. The LMm portable, ATEX-rated, remote methane detector allows the gas to be detected at distances of up to 30 metres to provide improved operator safety. The two-year trial of the LMm detector took place across a number of cities throughout Italy, allowing the device to be tested under a range of operating and weather conditions. The trial confirmed that, even in difficult urban situations, the it was able to monitor gas leaks from a remote location. A key application is remote monitoring of methane gas leaks in closed premises or confined spaces. By allowing them to remain at a safe distance from potentially dangerous leaks, it provides additional safety for operators, as well as making the detection process faster and easier and also eliminates the risk of false positive readings because it is sensitive only to methane. Other remote monitoring applications include: the monitoring of above-ground riser pipes and it can be used to check valves, fittings and pipes inside a pressure regulating station, providing readings which are faster and more accurate than the results from traditional methods. The LMm is ATEX-approved for use in explosive environments and can detect methane at a distance of up to 30 meters in standard mode, or 100 meters with a reflector. The latest LMm Gen 2 version includes a separate LED alarm indicator and louder audible notification. For more information contact Crowcon Detection Instruments Ltd, Tel: +44 1235 557700 Email: fiona.macrae@crowcon.com Web: crowcon.com

EMERSON’S CONDITION MONITORING SYSTEM EXPANDS PROTECTION TO MORE FIELD ASSETS TO IMPROVE SAFETY & AVAILABILITY Emerson Process Management has introduced the CSI 3000 Machinery Health Monitor, a compact protection system for a wide range of machinery such as pumps, compressors, centrifuges, blowers and generators. The CSI 3000 delivers protection data in situations where a standard rack-based system simply will not fit or is not a cost-effective approach. Easy assembly and userfriendly, customisable setup means the CSI 3000 has a short path out of the box to improving availability and ensuring the safety of rotating assets. The CSI 3000 measures shaft vibration, bearing vibration, position and speed, and generates key signals. The system provides the user with alarm outputs for each channel and does not require additional signal converters for shaft vibration and displacement measurements. “Emerson offers a complete line of protection monitors – from the rack-mounted CSI 6500 online monitoring system and the basic CSI 9360 Vibration/Position Transmitter, to the CSI 6300 SIS that guards against overspeed conditions,” said Björn Müller, Emerson’s product manager for online sensors. “This is another example of how we are delivering capabilities that bring stability to our user’s operations through services and technologies that reduce downtime and improve availability.” For more information about Emerson’s CSI 3000 and other CSI technologies, please visit: www.EmersonProcess.com/csi

PROCESS INDUSTRY INFORMER May 2015

FEATURE

PROTECTING CRITICAL INFRASTRUCTURE FROM THREATS By Tony Berning, Senior Product Manager, OPSWAT According to research performed by Lloyd’s of London insurer, Aegis London, “in the first half of the 2013 fiscal year, the US Department of Homeland Security’s Industrial Control Systems–ComputerEmergency Readiness Team responded to more than 200 incidents, 53% of which were in the energy and utility sector, and many of them sponsored by states such as China”. Efforts to improve the security of critical infrastructure systems like nuclear power plants and water treatment facilities have accelerated at a rapid rate since the issuance of US Executive Order 13636, “Improving Critical Infrastructure Cybersecurity”, on February 12, 2013. As attacks become more sophisticated and digital control systems increase in complexity and levels of automation, it is increasingly difficult to prevent threats from impacting the operation of critical infrastructure. As a security measure, most critical infrastructure systems are air-gapped, or isolated from external networks. Because of this, portable media is a primary vector for cyber-attack; it is often the only way to transport files to and from secure areas. As key attack vectors for malware, it is extremely important that extra attention is placed on securing the portable media devices that are that are brought in and out of a secure facility. While imperative to the protection of critical infrastructure, securing portable media devices is not easily done, and there are many requirements that can impact the portable media security policies for operators of critical infrastructure. In many cases, there is no single source for an organisation’s portable media security policy, and individual facilities may require unique security policies. This article outlines a secure data workflow which organisations can implement in order to balance their security needs against their operational requirements, as well as how best to approach the crafting of security policies that address the inclusion of portable media while ensuring adherence to EO 13636.

SECURITY BALANCING ACT

When making decisions about security policies for a critical infrastructure facility, the costs of implementing a stricter policy need to be weighed against the potential costs that could result from the failure of a weaker policy. The solution for each organisation will vary based on the requirements necessary to meet their security and business objectives. Increases in digital security rarely come without a corresponding increase in operating costs. These costs include purchasing a security solution, implementing this security solution, and finally managing and maintaining the solution. Initial costs often include the physical infrastructure necessary to deploy the solution, such as servers, kiosks and networks, as well as the consulting services that are often required to implement the solution correctly. Following the solution deployment there will be ongoing costs, which include the monitoring and management of the solution, keeping the solution up-to-date, and educating employees. Employees must be trained on the new security policy and associated procedures, which often results in a temporary reduction in productivity as employees acclimate to the new security processes and procedures. That said, these expenditures must be weighed against the costs of a potential security breach, which can be enormous. Facilities may be forced to suspend operations if the breach is serious enough; the monetary impact of even a temporary shutdown is difficult to calculate given the nature of the industry. There are also the remediation costs, the forensics to assess the damage as well as the removal of any malware that has found its way into the secure network. Coupled with this is the significant productivity loss, as employees’ usual workflow is hampered during the investigation and cleanup effort. Monetary damages aside, there are other costs that may result from a security breach. The impact to an operator’s reputation can be serious, criminal liability and classaction lawsuits may follow if others are negatively impacted. Depending on the breach, the loss of classified or sensitive information is also a possibility, the financial impact of which may be hard to quantify. Finally, by definition, any operator of critical infrastructure provides services to the public, which, if disrupted, will have significant negative impacts (such as power outages) on many individuals and groups outside of the operator itself.

DEFINING ACCEPTABLE MEDIA AND CONTENT

Defining a portable media and content strategy is key to a secure data workflow policy. As with all security programs, development of a program and policy should consider the business and technology requirements and limitations of an organisation. When developing a secure data workflow policy, organisations should first define what types of portable media are acceptable and how they can be used. In secure facilities, the standard policy is to restrict the types of media and files to only those

PROCESS INDUSTRY INFORMER May 2015

necessary for employees to perform their jobs prohibited to eliminate the risk they introduce. Another facility may decide to only allow USBs and CD/DVDs and ban other types of portable media like external hard drives. For example, if an external storage device has multiple partitions or is not a read-only device it could be classified as a high security risk and therefore not adhere to the secure data policy. The same is true for limiting the files that are permitted by an organisation’s security policy. Administrators may choose to limit the file types that are allowed; for example, banning executable file, but allowing document files. Administrators could also filter files based on their properties; for example, limiting files to a specific size or blocking any encrypted files where a password has not been provided.

DESIGNING SECURE DATA WORKFLOWS

The secure data workflow policy within a critical infrastructure facility, especially pertaining to physical media being brought from an insecure environment into a secure network, should attempt the highest level of precaution achievable. The best security policies have multiple layers of protection, to guard against many types of threats, both known and unknown. This defence-in-depth strategy will minimise the risk of any one threat getting past all of the security layers. A secure data workflow should leverage threat protection methods including: - User authentication and source verification: Prevent unauthorised users or sources from bringing in data and facilitate logging for future auditing. - File type analysis and filtering: Prevent risky file types from entering the facility, including files that have spoofed extensions - Multiple anti-malware engine scanning: Detect threats that are known by any of the many commercial anti-malware engines, and leverage many varying heuristic algorithms to detect zero-day attacks. - Document sanitization: Further protect against unknown threats by using sanitization methods to strip potential threats out of documents and images. A common implementation of the above referenced data workflow are kiosks stationed as check points at the entrance to secure facilities. Kiosks provide the bridge for any data entering a secure facility, so that the workflow can be controlled and known and unknown threats can be kept out of the facility. Anyone entering a secure area would be required to use the kiosks to scan all portable media drives before the devices are allowed entry. The kiosks would confirm the user, the source, the file type, look for any malicious partitions and malware, and determine whether the device is secure or if it requires further inspection. An administrator can then also add enforcement of the specific media devices that are allowed into the facility. For example, allowed media devices could be restricted to known, pre-screened portable media that are trusted to be “clean”. Any files allowed through the secure data policy above would need to be copied to the trusted drives before entering the secure facility. This workflow ensures that no portable media enters a secure area without first passing through a full data security analysis. Common architectures for a kiosk-based secure data workflow can include: standalone kiosks, kiosks networked together, and kiosks connected to a centralized scanning server. These solutions can be connected or disconnected from the Internet depending on the facility’s level of security, and the desire for ease of management. The most efficient method of protecting a facility against the threats potentially found on portable media is a difficult one to establish for operators of critical infrastructure. There are many aspects that impact how a secure data workflow is defined and implemented, including the types of portable media expected to be brought into a facility by employees, outside contractors, and visitors. Each should be weighted and quantified to define a strong and robust secure data workflow policy that allows an organization to operate in the most secure and productive way possible. A critical infrastructure facility should err on the side of caution and develop secure data policies that are as restrictive as possible, but flexible enough to evolve with an organization’s shifting security and business needs. An administrator should evaluate various data security policies, measure the benefits and costs of each one, and determine how to successfully implement the security solution. The best policy will be one that takes a facility’s specific business and technology needs into account and is designed accordingly.

BEARINGS SKF LAUNCHES INNOVATIVE NEW BEARING RATING LIFE MODEL The development of an innovative, rolling bearing rating life model leads to a deeper insight into how to improve the field performance of bearing applications. SKF has launched a pioneering new model that will help engineers to calculate a more realistic bearing rating life by considering more influencing factors than before. The new model is a major step forward for the industry, and will play a vital role in enabling OEMs and end users to match bearings to application conditions with even greater certainty, resulting in improved bearing life and reduced operating costs. Developed as part of the SKF EnCompass Field Performance Programme, the new SKF Generalised Bearing Life Model will enable original equipment designers and end users to more closely match bearings to actual application conditions. SKF has developed the model and a corresponding technical paper, which due to its significance to the wider industrial and engineering disciplines has been submitted to the scientific community. The new model builds on the strengths of the current bearing life model, which was developed by SKF over 30 years ago, standardised in ISO 281:2007 and currently used worldwide. The new SKF Generalised Bearing Life Model now successfully separates surface from sub-surface failure modes. Based on explicit tribological models, it factors in new performance parameters, including those for lubrication, contamination, surface strength and mild-wear resistance. By understanding and accounting for more potential failure modes, the model is able to more realistically predict bearing behaviour and life under a wide range of operating conditions in the field. Another benefit of the new model is that it is flexible enough to allow the integration of new knowledge in the tribology and materials sciences as it is developed. As bearing science evolves, so will the model. For more information contact SKF (U.K.) Limited Tel: +44 (0)1582 496433 E-mail: phil.burge@skf.com Web: http://www.skf.com/

PROCESS INDUSTRY INFORMER May 2015

IT MUST BE THAT SPRING HAS SPRUNG… Everything in the garden is happily growing and it seems to have spread to BPMA News!!! It’s been a while but this edition has “taken root” and blossomed into a twelve page issue – not before time I have to say… In this “bumper” issue we bring you news from the EU Council, ring the changes about one of our longest standing members, give advice about saving you money, encourage learning, we keep you in touch with BPMA events throughout the year, not to mention a good number of press releases from our members and also an interesting editorial article. Phew…. Yet again this year’s Pump Industry Awards event was a great success (not only for the winners) and, if you haven’t done so already you can catch up with the winners on page 4. THIS YEAR’S GOLF DAY….. Another successful event was held at Goodwood this year with 56 spirited golfers enjoying a Texas Scramble. Unfortunately, the weather was not with us this year and waterproofs were required for a good part of the day. Nevertheless, everyone agreed the course was excellent as was the service and facilities provided by Goodwood. The day ended with a fantastic meal and presentation of trophies which were awarded as follows: 1st Place – Flowserve 2nd Place – ITT Gould 3rd Place – Grundfos

Next year’s event will take place at The Vale Resort in Glamorgan on Thursday 19 May 2016 Information relating to individual member announcements or advertisements should be made directly to the relevant company.

NEWS

MAY 2015

EUROPEAN PARLIAMENT & EU COUNCIL BACK EUROPEAN COMMISSION TRADE MARK REFORM After two years of inter-institutional discussions, the Commission, the European Parliament and the Council have reached today in so-called “trilogue discussions” provisional political agreement on the trade mark reform package. The agreed measures will make trade mark registration systems all over the EU more accessible and efficient for businesses in terms of lower costs, increased speed, more predictability and greater legal certainty. The reform will improve conditions for businesses to innovate and to benefit from more effective trade mark protection against counterfeits, including non-authentic goods in transit through the EU’s territory. European Commissioner for Internal Market, Industry, Entrepreneurship and SMEs, Elobieta Biezkowska, said in April 2015: “Trade mark intensive industries contribute enormously to economic performance and employment in the European Union. The agreement on the EU trade mark reform package will lead to a modernised and more efficient legal framework. This will promote entrepreneurship and competitiveness, which is good news for Europe. And we will be better equipped to stop the flow of counterfeit products effectively.” The cornerstones of the trade mark reform are: • Significant reductions of the fees for European Union trade marks covering all 28 Member States. The agreed changes will lead to savings of up to 37%, in particular for businesses that seek protection of their registered European Union trade marks beyond an initial period of 10 years; • Streamlined, more efficient and harmonised registration procedures across all trade mark offices in the EU. Faster and less burdensome procedures will be a great improvement for successfully growing companies, mainly SMEs, which roll out their business beyond one Member State and seek trade mark protection in front of multiple national administrations; • Strengthened means to fight against counterfeits in particular of goods in transit through the EU’s territory. This will prevent abuse of the EU as a distribution hub for illegal fake goods to world-wide destinations; • Modernised rules and increased legal certainty by adapting trade mark rules to the modern business environment and clarifying trade mark rights and their limitations. The political agreement on the Trade Mark reform package reached by the three institutions in the so-called “trilogue discussions” still requires to be formally confirmed by the European Parliament and the Council, which is expected in the coming weeks.

ALBANY ENGINEERING One of BPMA’s longest standing members - Albany Engineering Co Ltd located in Lydney, Gloucestershire- for nearly 70 years has become employee owned. Currently employing 70+ people in Lydney and 10 at its other factory in Bradford, West Yorkshire, the company has manufactured rotary gear pumps for over 100 yrs. Today it also produces specialist twin-screw and lobe pumps. Mr Martyn Swaffield, Managing Director since 1967, when he took over the reins from his mother specifically wished to safeguard the future of the company with continued employment for his long serving employees in both Lydney and Bradford. He has formed a trust company The last few months have seen encouraging growth in the number to ensure further decades of employment for local people. 13 current of people participating in our pump technology e-learning employees have worked at Albany Engineering for over 40 years and courses. Currently offering two courses, the “Introduction” course 2 gentlemen have over 50 years’ service. aimed at those with limited knowledge of pumps, providing a Employee ownership is now recognized by governments and customers comprehensive grounding in all aspects associated with pumping around the world as being a stable environment, free from takeover and the “Essentials” course, a challenging course for those threat and with strong work ethic from employee owners. Within British personnel who manage or are involved in, designing, specifying, industry employee owned companies will shortly represent up to 10% selling, sourcing, installing, servicing and maintaining pumping GDP. It is believed that Albany Engineering is the first company in equipment. This course is now recognised to be equivalent to the British pump industry to benefit from the advantages of employee HNC level. ownership. Both courses are independently accredited and quality controlled The occasion was recognised on Thursday 9th April when, after a speech by the National Open College Network (NOCN) and the courses by the new Managing Director Philip Dykes, in which he congratulated are offered in accordance with the UK Qualifications and Credit the new partners on over 1200 years service to Albany between them, Framework and approved by Ofqal. the new employee owners made a presentation to Mr Swaffield and his Entry to both of these courses is by a simple on-line registration and wife Anne of a picture and payment process and offers the learner the opportunity to work at plaque that will be placed their own pace from any computer. in the company reception Our lecture-based courses have also seen an increase in as recognition of this numbers attending our modules here at our premises based in historic occasion together West Bromwich. Five modules are offered covering pumping with a garden seat for Mr fundamentals, pump selection, pump systems, pump testing and Swaffield and his wife Ann. design of hydraulic centrifugal pumps. Courses are held approximately every three months with registration by booking form. Albany will exhibit its Next cheduled Fundamentals and Pumps Selection: 1/2 June 2015 range of pumps at both Visit www.bpma.org.uk/training for further information or contact Intershutz and Achema j.page@bpma.org.uk

TRAINING

during June 2015

TECHNICAL ACTIVITY HIGHLIGHTS AS OF APRIL 2015 A LOT GOING ON – “KEEP IN TOUCH WITH BPMA” CIRCULATORS

Remember the ErP Directive requires that from January 2013, only glandless standalone circulators with an Energy Efficiency Index (EEI) of not more than 0.27 are allowed on the EU market and only glandless circulators integrated into products (eg boilers) with an EEI of not more than 0.23 will be allowed on the EU market from August 2015. A Europump guideline is available and BPMA continues to work with the National Measurements Office (the UK EU Market Surveillance Authority in regard to the ErP Directive) in regard to non- compliant products appearing on the UK market WATER PUMPS Remember as of January 2013, only clean water pumps in scope of the ErP Directive with a Mean Efficiency Index (MEI) of 0.4 (minimum) are allowed on the EU market. Guideline available from BPMA EXTENDED PRODUCT APPROACH The current ErP Directive requirements for clean water pumps identified above will provide the EU with some 3-5 TWh of energy savings. Europump and the EU have agreed that via an Extended Product Approach (EPA) ie pump, motor and VSD (when applied) to be implemented via a review of the ErP Directive in 2016/17 savings of up to 35 TWh will be achievable. BPMA, through Europump is heavily involved in developing this approach and appropriate standards. Details are available from BPMA BOOSTER/MULTIPLE PUMP SETS Investigations are ongoing within Europump to identify an Energy Efficiency Index of assemblies incorporating multiple pumps. WASTEWATER PUMPS The EU has recognised that a possible ErP Directive requirement at the product level would only yield minimal energy savings. Accordingly, the matter to be further considered as part of the ErP review in2016/17 assuming an EPA for wastewater pumps could be established and demonstrate higher energy savings potential. Again, BPMA heavily involved in this process and details available from BPMA ISO 14414 – PUMP SYSTEM ASSESSMENT STANDARD This standard should be followed when carrying out a pump system energy audit and was published on 1 April 2015 DRINKING WATER DIRECTIVE – 99/83/EC In December 2014 the European Commission made an unofficial statement to the industry that the Drinking Water Directive will be revised and Article 10 (Quality assurance of treatment, equipment and materials) might be removed. Secondly, it is highly probable that the European Commission will withdraw standardisation mandate M136 (materials and chemicals in contact with drinking water, mostly handled by TC 164) within a few months, to be replaced with a new mandate. Europump has almost completed its work on a Position paper and also a Guideline to assist members in selling their product on drinking water across all member states, however Draft copies are available from BPMA. WEEE DIRECTIVE Pumps are currently excluded from the WEEE Directive and BPMA are engaged in determining whether or not they will become in scope in August 2018 as part of the revised Directive – noting that a product that is not able to function by itself will not be in scope. Details from BPMA Finding a solution BUILDING INFORMATION MODELLING (BIM) Remember, BPMA through Europump have produced a As a Trade Association, BPMA receive “pump template” for use by pump companies offering via their website both pump enquiries level 2 BIM to contractors – details from BPMA and project tenders from the UK and abroad which we are then able to pass OFFSHORE APPLICATIONS on to our members. Currently offshore activities are excluded from the Machinery, ATEX and Pressure Equipment Directive. These enquiries are sent by email However the European Commission are considering circular to all members headed up ‘Pump Enquiry’ or ‘Project changing the law in this respect and developments are Tender Opportunity’ with the request that the contact details awaited provided are used to get in touch direct with the enquirer if ATEX DIRECTIVE they are able to assist. Remember the new ATEX Directive (2014/34/EU) will be applicable from 20 April 2016. Until then the previous It is appreciated that not all enquiries will be relevant to you, version (94/9/EC) is to be used but always take a moment to read the details—don’t miss an CONSTRUCTION PRODUCTS REGULATION NO. 305/2011 opportunity! Europump position paper available confirming that pumps and pump units “in general” are out of scope of BPMA provide this service to all members completely free of this regulation as they do not fit in to the definition of charge. construction products ROHS 2 Visit www.bpma.org.uk A Europump positon paper is available from BPMA ‘I have had three calls this morning already from companies and EN ISO 20361 “liquid pumps and pump units – noise test can now finally proceed with this ‘An excellent response! code” – grades 2 and 3 of accuracy project—Phillips Consulting SA’ Many thanks—Costain’ ISO/TC115 – Pumps has approved the revision of this standard – details from BPMA

Project Tender Service

This year’s Pump Industry Awards Gala Dinner organised by Touchwave Media and in association with The British Pump Manufacturers Association and sponsored by some of the leading brands in the pump sector was held for the second year running at the Chesford Grange Hotel in Kenilworth on Thursday 19th March. Attended by over 200 pump industry professional who enjoyed the usual “friendly competitive” evening as they anxiously awaited the results, which when announced were met with joyous celebration. As always there was the raffle in aid of the BPMA’s chosen charity WaterAid which raised just under £2000. The evening entertainment was provided by Alfie Moore, policeman turned professional comedian who recounted numerous tales from his life at the front-line of the police force and as was compèred by the charming BBC News anchor Babita Sharma. Folllowing on from the awards programme it was time for the traditional adjournment to the various bars where celebrations and commiseration took place in the usual manner, not to mention that a great deal of networking. For further information about the Pump Industry Awards, & to view the photo gallery of this year’s event please visit the website at www.pumpindustryawards.com. If you are interested in sponsoring, nominating and/or attending the 2016 event please contact Andrew Castle at andrew@touchwavemedia.co.uk.

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! TECHNICAL INNOVATION – PRODUCTS SPONSORED BY: KSB WINNER: THE GRUNDFOS GO REMOTE The Grundfos GO is the most comprehensive platform for mobile pump control available to the market today. It provides simple, handheld support acting as an intuitive assistant and saves time on everything from commissioning, data collection, reporting through to sizing and replacement for a wide range of pumps and applications. The Grundfos GO is always online and ready to use wherever and whenever it is needed. TECHNICAL INNOVATION – PROJECTS SPONSORED BY: PROCESS INDUSTRY INFORMER WINNER: IMPROVING PERFORMANCE OF MINERA COLLAHUASI’S WATER PUMPING SYSTEM, NEPTUNO PUMPS Collahuasi Mining Co., located in Chile at 4.500 meters above sea level, has one of the most aggressive waters in the world, reaching 50.000 (mg/l) of chloride concentration. Neptuno Pumps performed a complete redesign of its pumps through a complete CFD/ FEA analysis together with a full material upgrade, incorporating superior alloys and advanced engineered thermoplastics which improved pump operational availability in a 600%, reaching 18.000 hours of continuous operation, allowing savings of US$650,000 per year. ENVIRONMENTAL CONTRIBUTION OF THE YEAR SPONSORED BY: SPP PUMPS WINNER: PUMP AS TURBINE IN PLACE OF PRESSURE REDUCING VALVE, KSB LTD & KIER KSB’s ‘Pump as Turbine’ was introduced by Kier & KSB into South West Water’s Supply Network, to act in place of a Pressure Reducing Valve, thus capturing energy that would otherwise be wasted and converting it to electricity that can be fed into the grid. This environmentally friendly pump project has enabled South West Water to continue to work towards meeting their target for renewable power generation (30GWh by 2015). MANUFACTURER OF THE YEAR SPONSORED BY: AESSEAL WINNER: CLYDEUNION PUMPS - AN SPX BRAND An SPX brand, ClydeUnion Pumps Glasgow, is one of the world’s leading pump companies - a market leading centre of excellence in providing original equipment pumping technologies and full system solutions. Approaching 150 years Pumping Heritage, including Weir Pumps, we focus on delivering engineering excellence and customer satisfaction. With dedicated Aftermarket and Field Service, we provide full product life cycle solutions supporting Service, Repair, Overhaul and Spare Parts, Customer Training, RCA studies, Upgrades and Re-rates.

DISTRIBUTOR OF THE YEAR SPONSORED BY: WEG ELECTRIC MOTORS WINNER: DRILLING & PUMPING SUPPLIES (DPS) DPS designs, supplies and installs pumping equipment throughout the whole of Ireland. As a leading supplier, DPS’s successful track record in customer satisfaction stems from efficient pump selections and advice that often exceeds customer expectations. Excellent communication between the dedicated engineering and service functions ensures seamless delivery from supplier to customer. DPS’s vision is to be the leader in design, supply, and installation throughout Ireland. SUPPLIER OF THE YEAR SPONSORED BY: TOMLINSON HALL & CO WINNER: WEG ELECTRIC MOTORS UK Preparing for the 2015 change in legislation has been an ongoing process for WEG, IE3 motors were launched for general sale in 2009 with IE4 made readily available in 2013. A programme of training and education has continued throughout 2014 with customers and distributors invited to conferences bringing them together with industry experts to discuss the impact of these changes in legislation. Moving forward, WEG continues to develop products that exceed the European efficiency standards whilst growing stock holding throughout Europe to meet demands. ENGINEER OF THE YEAR SPONSORED BY: WORLD PUMPS WINNER: EMMA LAMBERT, CLYDEUNION PUMPS - AN SPX BRAND As Lead Engineer / Team Leader on the Statoil project Mariner, Emma has excelled and exceeded all expectations combining technical excellence and innovation with her notable project & people management skills to deliver three new design pump packages, valuing approximately $20 million, including the world’s largest cast NORSOK (ASTM A995 6A) injection pump. Emma has also created a dynamic, highly motivated team culture perfectly aligned to SPX core values: integrity, accountability and innovation. LIFETIME ACHIEVEMENT AWARD SPONSORED BY: BPMA WINNER: BOB WENT As an active member of BPMA’s Council and Technical Committees until his retirement in December, he has been involved in many key decisions and contributed, technically, to many international standards and guides that are available today. His hard work, support and technical competence have been greatly appreciated within the BPMA over the last 11 years and his contributions will now be sadly missed.

THE ENERGY SAVINGS OPPORTUNITY SCHEME (ESOS) & PUMP SYSTEM AUDITS The Energy Savings Opportunity Scheme (ESOS) Regulations 2014 came into force on 17 July 2014 and are a mandatory energy assessment and energy saving identification scheme for large undertakings (and their corporate groups). The scheme applies throughout the UK. ESOS Energy Audits have the potential to increase businesses profitability and competitiveness by identifying cost-effective savings which, if implemented, will improve energy efficiency. The scheme is estimated to lead to £1.6bn net benefits to the UK, with the majority of these being directly felt by businesses as a result of energy savings. ESOS is the UK Government’s approach to transposition of Article 8(4) of the EU Energy Efficiency Directive, which requires all large (non-SME) enterprises to undertake energy audits by 5 December 2015 and every 4 years thereafter. The scheme’s regulations are published on the government’s legislation website www.legislation.gov.uk/uksi/2014/1643/contents/made More information about the Energy Savings Opportunity Scheme can be found on the ESOS webpage www.gov.uk/energy-savings-opportunityscheme-esos Guidance has also been published to help potential participants in the scheme understand their obligations and on page 43 of the full ESOS guidance document you will see that the ISO/14414-Pump System Energy Assessment standard is referenced as an auditing methodology that can be accepted by “Lead Assessors” approved by the Environment Agency. Accordingly it is hoped BPMA CPSA accredited persons (who are trained according to the IS0 14414 standard) will be recommended by Lead Assessors to undertake the pumping system elements of company energy audits. And bear in mind: • Pumps are the largest consumers of global motive power COURSE DATES: 27-30 JULY 2015 • Pumping System improvements can deliver up to 40% reduction in energy costs - and COURSE VENUE: National Metalforming Centre, therefore improve user bottom line P&L account performance West Bromwich, West Midlands (1 min from J1, M5) • The fact that BPMA’s CPSA scheme has been designed to help by equipping people with COURSE FEES: £1,500 + VAT (BPMA Members), the skills to conduct a Pumping System Audit in accordance with ISO/14414 £1,750 (non-members). Fee includes 3 nights (b&b) So when considering auditing your pumping systems, remember the BPMA Certified accommodation Pump System Auditor Scheme (www.bpma-cpsa.co.uk) has established BPMA as THE CONTACT j.page@bpma.org.uk for registration form or body to train and certify personnel who undertake “Pumping System Assessments” as telephone 0121 601 6691 for more information referenced in UK Government Energy Strategy documents BPMA are now offering the opportunity to attend a four day residential course culminating in certification and eventual personal ID “Certified Pump System Auditor” status following approved audits.

NEW CONFIGURABLE BY DESIGN COMPONENT SEAL RANGE LAUNCHED BY AESSEAL® AESSEAL® has launched a completely reengineered modular component seal range that aims to raise the industry standard and allow configurable component seals to be built to order. With 10,000 product lines available from stock and over 44,000 product permutations configurable, it offers customers the greatest possible product availability, quality assurance, and service. The new range, in development for almost 4 years, incorporates unique patented features which help to improve pump reliability. These features include; improved seal face cooling through directed barrier fluid flow systems, hydraulically balanced seal face technology and “plug in” designs to improve performance and reliability. Incorporating a build to order philosophy the new range offers a larger selection of product variants, and standard product lines can be easily adapted to suit the customer’s requirements. By manufacturing the majority of the parts, and having full control of the supply chain AESSEAL® can offer a portfolio of seals suitable for the Food and Beverage industry. These seals are manufactured in accordance with Good Manufacturing Practice (GMP), assuring compliance with EC2023/2006,and allowing customers to be confident that they are sealing their equipment with seals that meet EU, FSA and FDA requirements. The new product range is further supported by the AESSEAL® Seal Selection Application enabling an equivalent AESSEAL® component seal to easily be selected knowing just the pump type, competitor seal reference, or dimensional information. Project Manager Tom Broadbent stated; “It has been a huge undertaking that not many companies would take on, but we now have the same modular build to order business model in our Component Seal Range portion of our business as our cartridge seals, allowing us to have complete control of the design, manufacture and supply of component seals so that we can provide our customers the exceptional service they expect from AESSEAL”. For more information contact AESSEAL Plc, Rotherham, South Yorkshire. Tel: +44 (0) 1709 369966 Fax: +44 (0) 1709 720788 E-mail: enquiries@aesseal.com Web: www.aesseal.com

ITT RELEASES I-ALERT®2, BREAKTHROUGH EQUIPMENT MONITOR WITH BLUETOOTH® SMART CAPABILITY We are excited to officially launch today the i-ALERT®2, a BluetoothSmartenabled machine health monitor that allows customers to identify potential problems before they become costly failures. It tracks vibration, temperature and run-time hours and wirelessly syncs the data with a smartphone or tablet through the iALERT2 mobile app. The i-ALERT2 combines the latest in Bluetooth low-energy and sensor technologies commonly used in the newest consumer health and fitness trackers and smart watches such as the Apple Watch and Fitbit®. The i-ALERT2 is the first to successfully integrate these technologies into an industrial package. It is engineered and rated for use in a wide range of industrial environments. It is chemical resistant, rated for extreme temperatures (-40 to 84°C, -40 to 183°F) and is rated to operate in environments with explosive gases, dust and fibers. “The breakthrough development of i-ALERT2 is industry-changing. It further solidifies ITT’s continued commitment to providing customers with the most innovative monitoring and maintenance programs,” said Aris Chicles, president of ITT’s Industrial Process business. “ITT’s i-ALERT2 delivers sophisticated technology so economically that it extends the practical reach of in-plant monitoring systems to all types of machines, enabling rapid connection of industrial machines to the Industrial Internet of Things,” said Dan Kernan, Global Product Director, Aftermarket Solutions, ITT’s Industrial Process business. With 24/7 monitoring, a wireless range of up to 100 feet (30 meters) and the ability to scan multiple i-ALERT2 devices at once with a mobile device, customers will be able to quickly and safely inspect multiple pieces of equipment and be alerted of potential problems before they become critical failures. “Customers will be able to spend less time collecting data and more time solving problems,” Kernan added. Through the i-ALERT2 mobile app, customers can now view real-time and historical data, diagnostic information and machine records. This provides them with the data necessary to make informed decisions. ITT’s i-ALERT®2 is available three ways: · Retrofitted to any rotating equipment in the field, · Included with an equipment repair or upgrade through ITT PRO Services, or · Added to newly purchased ITT pump equipment. The i-ALERT2 will be available globally to major industrial markets. Shipments will start in early July and the iOS mobile app will also be available for download then on the App Store on iTunes with an Android version to follow. For more information on ITT’s i-ALERT2 visit www.i-alert.com or follow the @ITTPROServices Twitter handle.

THE GRUNDFOS DRIVE TO REDUCE COSTS AND CARBON FOOTPRINT As a renowned pioneer of energy efficient pump technology Grundfos, wanted to reflect this into other areas of their business. This has resulted in their looking at local car rental requirements and subsequently cutting their expenditure on this aspect by 42% with the help of Business Mobility specialist Alphabet through their Corporate CarSharing solution. This proposition means that Grundfos employees have access to a BMW 320 EfficientDynamics that is booked out via an online system and controlled through an electronic card system. The AlphaCity vehicle remains on site providing multiple drivers with access, 24 hours a day, seven days a week, through an electronic card system. Jason Funnell, Operations Director says: “As a manufacturer of 10 million+ pumps annually, Grundfos have a global responsibility to minimise energy consumption, so it’s vital that we take any steps to reduce our energy consumption and improve our carbon footprint wherever possible.” Funnell continues: “Previously we were dependent on rental vehicles, which were not only timeintensive to manage, but there was no guarantee that the vehicle delivered would be environmentally friendly. Also due to the timing of business journeys, more often than not vehicles had to be delivered a day in advance, and returned a day after, tripling costs unnecessarily.” Grundfos has been an Alphabet customer for over four years and both companies continue to work collaboratively to drive down both direct and indirect car costs, whilst ensuring that staff have ready access to a well maintained, energy efficient vehicle. For more information or literature request contact Grundfos Pumps Ltd, Leighton Buzzard, Bedfordshire. Tel: 01525 85000 E-mail: grundfosuk@grundfos.co.uk

THE HYBRID HEAT EXCHANGER By Geoff Mahoney - AxFlow Product Manager Plate Heat Exchangers - London Within a great many sectors of industry, minimising energy consumption and maintaining plant uptime are essential to optimizing production costs. Process heat recovery is one significant approach to reducing energy consumption, whilst improving process performance will contribute to plant efficiency. Heat exchangers when used for heating, cooling, condensing or evaporation play a major role in recovering energy from process gases and liquids, so it follows that their efficiency will influence operating costs. Although a mature and well proven technology, heat exchangers are having to evolve in order to meet the ever-changing demands of industrial processes and the environments in which they have to work. Plate heat exchangers using the plate corrugation pattern in combination with a relatively narrow gap between the heat transfer plates deliver higher heat transfer efficiency and cost effectiveness combined with low downtime. Their relatively small size and weight allows them to be used where there is a small footprint area. However, they are rather limited to just handling clean liquids because the plates cannot handle solids or other contaminants very efficiently. Furthermore, the gaskets providing the seal between plates, limit the operating pressures and temperatures to around 20 bar and 200°C respectively. This issue of limited pressures and temperatures can be overcome by heat exchangers incorporating semi-welded plates. In this design, two plates are laser welded together to form a leak-proof or gasket-free channel. The channels between the welded plate pairs are sealed via an elastomeric gasket. However, it too can only accommodate relatively clean fluids. Where more viscous liquids or those containing particles and solids are encountered the shell-and-tube heat exchanger has long been the answer for many applications. The only drawback to this is that its thermal efficiency is limited. The ideal solution that accommodates the requirements of clean and dirty liquids, high temperatures and pressures and achieves high levels of energy efficiency is a heat exchanger that combines the benefits of both designs. In other words, a hybrid. Making the plate heat exchanger more like a shell-andtube heat exchanger without losing the inherent thermal efficiency advantages, means that a wider range of applications can benefit from improved heat transfer performance and reduced installed size. The solution comes in the form of welded plate technology. The hybrid design has optimized plate patterns on both the corrugated and tube sides, which delivers higher thermal efficiency than that of shell-and-tube heat exchangers and offer a more compact and efficient solution.

THE HYBRID

Hybrid fully-welded heat exchanger units (Fig. 1) offer a broad range of configuration options to optimize performance for a variety of thermal, physical and geometrical conditions. This means that the unit can be used for a wider range of applications than conventional plate and frame heat exchangers. Typical applications include heat recovery units, process heating and cooling, process condensers, steam heaters, vapors, gases highly viscous fluids, fluids containing particles and fouling fluids. The hybrid heat exchanger delivers many process engineering advantages when compared to shell and tube heat exchangers. Its compact design allows a heat transfer area of up to 1.800m m², whilst the unique flow pattern design ensures enhanced gas and liquid heat transfer as well as significant savings on material costs due to enhanced operating efficiency. The extremely efficient use of the plate surface maximizes the heat transfer area, thus optimizing heat transfer performance. The elimination of dead spots provides for very efficient heat transfer at low pressure drop values, enabling a closer temperature approach. The plate side flow and the tube side flow are arranged in a crossflow configuration with one or multiple passes over the plates (Fig. 2). The plate pattern forms elliptical tube channels on the tube flow side and wave flow passage on the plate side. Larger plate gaps are available to accommodate higher flow rates, reduced pressure drops, and media with larger particulates. This facilitates Fig. 1 - Hybrid fully welded heat exchanger.

optimum design for a wide range of process requirements. In the case of the APV hybrid plate heat exchanger, it can be designed for a pressure range from full vacuum to 40 bar. At the heart of the heat exchanger is a heat exchanger block consisting of one or more plate packs. The dimensions of the plate packs are determined by the length and number of plates included in the plate pack. Plates are Fig. 2 - The plate side flow welded together to form one or more gas-tight and the tube side flow are and pressure-resistant blocks. A hybrid welded arranged in a crossflow plate pack employs advanced pressing and configuration with one or welding technologies, absorbing alternating multiple passes over the plates. loads on the welds. The welds are not subjected to mechanical loading during thermal cycling (thermal expansion effects) and therefore are more resistant to fatigue. Hybrid heat exchanger design features are designed to provide good performance. For example, fluids containing solids or contaminants can pass more easily through the tube side because there are no obstructing contact points. Complete accessibility to the plate pack, combined with true mechanical cleanability on the tube side, ensure rapid, effective maintenance when cleaning is required. In addition to the heating and cooling of liquids, applications involving vapors and gases, which traditionally have been handled by shelland-tube heat exchangers, can benefit from the efficiency of the welded hybrid plate design.

APPLICATIONS

In process condensers, one hybrid heat exchanger’s profile is well suited for creating high U-values with a low pressure drop on the condensing side. A low pressure drop means a higher effective MTD and, thus, better recovery of vapors. The plate profile combined with a flexible connection size also allows gases to be heated as well as cooled. Also, a hybridplate heat exchanger is suitable for highly viscous fluids that benefit from the low-resistance flow channels combined with high film coefficients offered by both the tube side and corrugated plate pattern on the plate side. In the case of heat recovery units, the high heat-transfer efficiencies of the hybrid design help achieve close temperature approaches and approaches of 1.8°F (1°C) are possible, thereby recovering more heat to reduce process operating costs and improve carbon footprint. For applications involving high temperatures and pressures, a welded hybrid also can be used. Without gaskets to limit the temperature and pressure range, hybrid heat exchanger designs can accommodate temperatures from -40 to 350°C and pressures up to 40 bar pressure. The absence of gaskets helps to avoid compatibility issues and reduces the risk of leaks while making the welded hybrid design suited to hazardous or corrosive fluids. Plates can be produced in materials such as 304L and 316L stainless steels, high-performance austenitic stainless steels, Hastelloy and nickels to suit almost all corrosive product streams.

SUMMARY

Gasketed plate-and-frame heat exchangers deliver optimum thermal efficiency compared toshell-and-tube designs within a specific set of operating parameters. However, the range of applications for which they are suited is limited. Shelland-tube units are more accommodating for high temperatures and pressures and high fouling or contaminant-laden fluids but are heavier, take up a larger installed area, and lack the heat transfer efficiency of plate technology. A hybrid welded plate heat exchanger, with its tube-like plate profile and true mechanical cleanability and efficient use of installation space, takes the range of applications beyond the gasketed plate-and-frame configuration into new areas.

NEW SEALLESS RANGE BROCHURE

GRUNDFOS PERMANENT MAGNET MOTOR JOINS ECA LIST The Enhanced Capital Allowance (ECA) scheme is a government scheme that was introduced in 2001 to encourage businesses to purchase energy efficient products and thereby help to reduce CO2 emissions. Companies, who invest in products that are on the approved Energy Technology List (ETL) can get the benefit of being able to claim 100% first year capital allowances on their outlay. The claim also allows for the inclusion, not just the cost of purchasing the pumps/ pumping systems, but also any costs associated with the installation and transportation to site. For the average company this means an additional saving of £2,250 on an allowance of £10,000, which is addition to the standard first year depreciation saving. Grundfos Pumps and their pump products have been part of this scheme for many years and have now received confirmation that Grundfos permanent magnet MGE motors have been accepted onto the ETL listing – which considerably expands the range of Grundfos products that are part of the scheme. These figures do not include the on-going savings that will be enjoyed by companies who install approved energy saving equipment such as is available from Grundfos Pumps. Yet another reason to select Grundfos as your pump solutions partner. For more information or literature request contact Grundfos Pumps Ltd, Leighton Buzzard, Bedfordshire. Tel: 01525 85000 E-mail: grundfosuk@grundfos.co.uk

All Latest Sundyen HMD Komtro Products & Parameters Now FeaturedSundyne HMD Kontro has announced a comprehensive update to their main product range brochure. The opportunity has been taken to add in all of the recent product introductions and to give the publication an updated cover design, in yellow, to differentiate with the previous version. Many of the operating parameters for the existing pumps have also been updated. These details are now being integrated into their website and all other literature has now also been updated. In addition the recently introduced pumps are all featured in the range brochure including the following ranges: GSPX Multi Stage, GSPLF Low Flow and the LMV 801S Vertical Low Flow. You can download a copy of the range brochure by clicking on the downloads section of their website at www.sundyne.com/hmdkontro. Printed copies of the brochures can also be ordered, For further information, please do not hesitate to contact our Internal Sales Manager, Vince Lee, on +44 1323 452141 or by email to vince.lee@sundyne.com.

The path to a greener future... Efficiency l Strength l Reliability Since January 2015, EU MEPS have stipulated that any new motors on the market ranging from 7.5 kW to 375 kW power output have to meet the IE3 efficiency standard or IE2 efficiency standard if used with an inverter drive. WEG believe that all products should be energy efficient so we offer a complete range of W22 IE2, IE3 and IE4 low voltage motors. Our inverter drives will work with new and existing motors to help you reduce energy consumption. We have adopted the energy efficiency standard for our hazardous area motors although they do not yet fall within the scope of the regulations so our W22X motors are available to IE2, IE3 and IE4 efficiency rating.

To take your first steps on the path to a greener future visit www.weg.net LV

Watt Drive high performance gearboxes are built to withstand the toughest industrial applications meeting the demands for operation across different industries. Individually, our gearboxes, drives and motors are amongst the most energy efficient available. Together they give you unbeatable levels of reliability and performance

NEW CANNED MOTOR PUMPS FOR CHEMICAL AND PROCESS ENGINEERING APPLICATIONS ACHEMA 2015 will see KSB showcase totally leak-free canned motor pumps from the Ecochem Non-Seal range designed to transport hazardous, aggressive, flammable and explosive fluids. The pumps are also capable of handling toxic and extremely hot or cold media as well as volatile or valuable liquids. This new type series combines KSB’s MegaCPK – a standardised chemical pump successfully employed for years in process engineering – with groundbreaking canned motors built by Japanese cooperation partner Nikkiso. The pumps’ dimensions comply with ISO 2858 and meet the requirements of the DIN/EN/ISO 15783 and API 685 standards, with economic operation being ensured via a new energy-optimised electric motor design. The low-noise motor features a corrosion-resistant can made of Hastelloy (2.4610). The new type series will be available in four standard variants featuring one design each for standard chemical applications, heat transfer fluids, polymerising or ferrite-containing fluids and a special variant for low-boiling fluids and liquefied gases. The pump sets have been designed to meet the requirements of explosion protection class II 2 G c Ex de IIC to ATEX, TR and IEC Ex and temperature classes T1 to T5, and can handle fluids at temperatures from – 40°C to + 400°C as standard. For more information contact KSB Ltd, Loughborough, Leicestershire Tel: 01509 231872 Email: Sales@ksb.com Web: www.ksb.co.uk

SPP PUMPS HELPS BRING UNITED UTILITIES FACILITY FULLY UP-TO-DATE

SPP MANUFACTURERS PUMPS FOR STOCK SPP Pumps, one of the world’s leading manufacturers of centrifugal pumps and systems, is now manufacturing its standard products range of pumps for stock - giving customers fast access to pumps … all from the company’s base in Coleford, Forest of Dean, in the UK. This move marks a major investment into the growth of SPP’s business across this diverse industry. Its standard pump product range offers ‘fit and forget’ replacement solutions for almost any existing pump system, for applications including: water boosting, irrigation, heating and air conditioning, fuel transfer and process cooling. Bob Tichband, SPP’s Sales Director, comments: “Historically, SPP has not built pumps for stock, we have manufactured to order. However, we are seeing increasing demand for our standard products and this was an obvious next step - we can now offer 36 pumps of different sizes. Our aim is to stock at least 20 products at any given time, meaning we can turn customer orders around in as little as one day.” Alperton Engineering, SPP Pumps’ Irish parnter, was one of the first to benefit from this new service, when a Eurostream pump with 4kW motor was dispatched within just 24 hours from receipt of order. Jason Maher, Pumps Manager at Alperton, commented: “Speed of delivery and a cost effective solution was key to enabling us to win business from one of our own customers. It’s a win/win situation - we need to do something quickly, SPP helps us to do that, and everyone benefits.” By offering this ready-made portfolio of products, SPP’s customers can benefit from quality products which are British engineered - giving reliability and efficiency across a broader portfolio of products. Bob Tichband concludes: “At SPP Pumps we are committed to meeting industry needs when it really matters … and in this instance that is all about delivering when customers really need it. I think this move will make a really positive impact on our business and most importantly, on the lives of our customers.” For more information on SPP Pumps range of Standard Products contact Tel: +44 (0) 118 932 3123, Email enquiries@spppumps.com or Web: www.spppumps.com

As part of its continuous investment programme to improve services to customers, water company United Utilities has completed a major project to upgrade Heronbridge Pumping Station, with help from SPP Pumps. The facility, which sits on the banks of the River Dee, near Chester, helps supply a huge amount of water into a number of areas in North West England. Part of the upgrade work was to replace existing pumps with a new more efficient system to ensure the long term security of supplies. “For SPP, some of the key challenges included the sheer size of the four large vertical turbine pumps required, and the need to make them fit precisely with the existing foundations and pipework in a limited working space,” says Martin Bagg, Head of SPP’s Water Division. “The installation also had to be carried out without halting the station’s operation. Crucially, we had to be sure to specify pumps capable of handling river water with a heavy sand content and delivering the necessary high performance, flexibility, energy efficiency and reliability where it really matters.” Renowned as a leading manufacturer and global supplier of centrifugal pumps and systems, SPP won the contract not only to design and supply the pump equipment but to install it. “Because we were both the supplier and the installer, there was no split responsibility and our experienced installation team was able to ensure that all work was carried out to a high standard,” say Martin Bagg. “The overall development project was carried out very effectively in co-operation with United Utilities’ AMP5 partner GallifordTry-Costain-Atkins Joint Venture.” SPP chose four BHR80-18 pumps for the job, designed for a duty flow of 772 litres per second and a duty head of 85 metres, and specified Siemens 860 kW motors. A custom-made headpiece was fabricated to match the existing foundation and pipework centreline. This required precision measurement and manufacture, as there was little scope for error, but SPP has had plenty of experience in meeting such demands. Lineshaft enclosing tubes and a high-grade mechanical seal system were fitted to cope with the water’s high sand content. By using pump spacer coupling, SPP has allowed for future maintenance of the seal without having to remove the motor or thrust bearing. This is especially important in view of the site’s space restrictions. Martin Bagg concludes: “As well as a highly effective and dependable pumping system, United Utilities has gained much greater energy efficiency across a wide and varied operating range. I am delighted by the results, which give an excellent demonstration of our ability to provide turnkey solutions for large-scale projects, and our commitment to solving customer challenges where it really matters.” For more information on SPP Pumps, its products and its support contact Web: www.spppumps.com Tel: +44 (0) 118 932 3123 E-mail: enquiries@spppumps.com

QDOS DOSING PUMPS IMPROVE PRODUCTION ‘UPTIME’ AT ALUMINIUM COATING PLANT

Aluminium powder coating specialist, France Alu Color, has reduced its costsfor chemicals and further improved the reliability and safety of its surface treatment processes thanks to the adoption of Qdos dosing/metering pumps from Watson-Marlow Fluid Technology Group (WMFTG). So successful has been the project that the pumps generated payback on the investment within one year. At the company’s plant in Marcilloles, some 50 km south of Lyon, France Alu Color coats around 1,850,000 m2 (5000 tonnes) of aluminium every year, which equates to around 8500 m2 per day. The plant has one of the most modern vertical powder coating lines in France and operates under the Qualicoat product certification scheme, demonstrating both its quality and environmental credentials. Clearly there is little margin for downtime at this fast-moving process plant, where the powder coating operation comprises surface preparation, chemical conversion, application and baking. And yet, one year ago, the Head of Chemicals Mr Crouzet, was experiencing problems with acid etching and chemical conversion after the dosing pumps in place at the time became repeatedly clogged. In short, problems were being experienced relating to siphoning, clogged valves, and a lack of necessary precision to dose the injected chemicals. The only way to keep production moving was to regularly maintain the pumps, with all the time, costs and safety issues (due to potential chemical contact) this incurs. As a consequence, the company contacted Watson-Marlow, which recommended a trial of its Qdos30 model, a move that was to pay dividends immediately.“We installed Qdos pumps on the vertical powder coating line to dose specific chemicals at three essential points in our surface treatment process,” says Mr Crouzet. “This brought about a radical change because the siphoning problems consumption.” Furthermore, Qdos pumps do not have any valves, so the clogging problems that previously resulted from impurities in the chemicals, are a thing of the past.“The Qdos30 can be emptied easily and thanks to the design of the ReNu pumphead, the pumped liquid remains sealed within,” says Mr Crouzet.“ After using the pumps for one year, France Alu Color reports it has only changed a single pumphead. In fact, so pleased is the company with its Qdos pumps that one is now dosing flocculant on the effluent treatment plant. Today, France Alu Color has eight Qdos30 dosing pumps across two facilities. For more information contact Watson- Marlow Technology Group, Tel: 01326 370370 E-mail: info@wmfg.com Web: www.wmfg.co.uk

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

WEG SHOWCASES ENERGY-EFFICIENT DRIVE SOLUTIONS AT ACHEMA 2015 FOR THE FIRST TIME WEG, a leading manufacturer of drive technology, will showcase its latest energy-efficient drive solutions at this year’s ACHEMA (15-19 June 2015), on Stand A3, Hall 11, advising how companies in the process industry can boost energy efficiency up to IE4 standards while reducing operating costs. Visitors to WEG’s stand, can learn about WEG’s new W22X explosion-proof motor in IEC 800 frame size which has outstanding efficiency of up to 97.4%. Other highlights include ATEX-compliant geared motors, which combine W22X motors with robust gear units from WEG’s subsidiary Watt Drive, as well as high-performance variable speed drives, all designed to help process managers increase operational efficiencies. “ACHEMA is a great opportunity for us to show our commitment to helping the process industry achieve above-average efficiency not only in standard applications, but also in hazardous areas,” says Andreas Schulte Mesum, Energy Business Manager at WEG in Germany. “Explosion-proof motors are presently excluded from the latest EU IE3 efficiency regulations, however, WEG is committed to offering the highest possible energy efficiency even in demanding applications, where reducing energy costs is top of the agenda.” Designed for medium- and high-voltage applications, the W22X 800 can be used wherever extremely high reliability and robustness are needed in addition to explosion protection. With power ratings up to 5.6 MW and operating voltages up to 11 kV, the efficient W22X 800 motors extend WEG’s proven W22X motor series in the upper power range. Like the low-voltage W22X motor series, they are available in efficiency ratings up to IE4 which makes them one of the most efficient motors of their type presently available in the market. WEG’s latest generation of explosion-proof low-voltage induction motors in the W22X series have rated power from 3 to 1,000 kW, and WEG offers one of the broadest ranges of energy-efficient explosion-proof motors currently available. With its extensive portfolio of explosion-proof motors, WEG can supply the right explosion-proof drive solution for virtually all power ratings and applications in both gas and dust atmospheres, regardless of the form of ignition protection needed. For further information visit Stand A3, in Hall 11.0,.contact WEG Electric Motors(UK) Ltd, Tel: 01527 513800 E-mail: info-uk@weg.net Web: http://www.weg.net/uk

The new W22X 800 explosion-proof motor for medium-voltage and high-voltage applications combines robustness with high efficiency

CAT PUMPS INTRODUCES NEW TRIPLEX PLUNGER PUMP – MODEL 3550 Cat Pumps, manufacturers of high pressure triplex positive displacement plunger pumps, has extended its 35- frame series with the introduction of the Model 3550. Delivering pressures up to 414bar (6,000psi) and flows of 38l/min (10gpm), the new pump is ideally suited to operating in high-duty cycle applications in remote locations of where a mobile unit is required. Cat Pumps model 3550 has been developed for demanding applications requiring long-life and dependable performance. Available in direct drive and belt drive options, applications highlighted by Cat Pumps pumping hydrostatic and destruct testing, water jetting, high pressure tooling, water blasting, high pressure injection and surface preparation. Using advanced engineering design software, Cat Pumps have optimised every detail to produce a pump offering extended, trouble-free service life. Key features that deliver optimum operation include concentric, high density polished solid plungers for long seal life, V-packings and low pressure seals that are fully lubricated and cooled. As is to be expected from Cat pumps, maintenance is simple as servicing the wet end is undertaken without having to enter the crankcase. The Model 3550 is available from Cat Pump’s UK headquarters and is supported by an extensive range of accessories and engineering support.

For more product information contact: Cat Pumps (UK) Limited, Tel: 01252 622031 E-mail: sales@catpumps.co.uk Web: www.catpumps.co.uk

FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves CAT PUMPS INTRODUCES NEW TRIPLEX PLUNGER PUMP – MODEL 3550 Cat Pumps, manufacturers of high pressure triplex positive displacement plunger pumps, has extended its 35- frame series with the introduction of the Model 3550. Delivering pressures up to 414bar (6,000psi) and flows of 38l/ min (10gpm), the new pump is ideally suited to operating in high-duty cycle applications in remote locations of where a mobile unit is required. Cat Pumps model 3550 has been developed for demanding applications requiring long-life and dependable performance. Available in direct drive and belt drive options, applications highlighted by Cat Pumps pumping hydrostatic and destruct testing, water jetting, high pressure tooling, water blasting, high pressure injection and surface preparation. Using advanced engineering design software, Cat Pumps have optimised every detail to produce a pump offering extended, trouble-free service life. Key features that deliver optimum operation include concentric, high density polished solid plungers for long seal life, V-packings and low pressure seals that are fully lubricated and cooled. Also contributing to longer service operation are the drive end matched connecting rods and oversized bearings which accommodate greater loading capacity, whilst hard chrome-plated forged brass inlet/discharge block manifolds offer enhanced strength and fluid compatibility. As is to be expected from Cat pumps, maintenance is simple as servicing the wet end is undertaken without having to enter the crankcase. The Model 3550 is available from Cat Pump’s UK headquarters and is supported by an extensive range of accessories and engineering support. For more product information contact: Cat Pumps (UK) Limited, Tel: 01252 622031 E-mail: sales@catpumps.co.uk Web: www.catpumps.co.uk

ARI-ARMATUREN SET TO UNVEIL INNOVATIVE PRODUCT DEVELOPMENTS AT ACHEMA 2015 If you are heading to the ACHEMA exhibition in Frankfurt this year, be sure to visit the ARI-Armaturen stand (Hall 8.0, stand B45) where they will be revealing an exciting array of advanced technology and product developments. A new variable, compact control valve (STEVI® Vario) will be making its debut at the show along with a fully lugged version of the ZETRIX® premium triple offset valve (available up to DN 600) and a seal (DN 65 – DN 100), check valves and strainers. With over 60 years of valve experience, launching CONLIFT® mechanical condensate pump - was a first for ARI and the CONA® P now adds to the collection – a new pump trap with an innovative design combining a pump and steam trap – all to be revealed at ACHEMA! For more information contact ARI-Armaturen Tel: 01684 275 752 Web: www.ari-armaturen.com Email: enquiries@ari-armaturen.com

GRUNDFOS ARE IN-LINE TO INCREASE SYSTEM PERFORMANCE Since its launch in the UK in 2003, the TP family of in-line Grundfos pumps has proven itself many thousands of times over, in a huge variety of applications up and down the country. There are many reasons why they have been so successful, but a significant element has been that Grundfos have continued to invest, expand and improve this family, ensuring they remain at the leading edge. Today the extended and improved range offers the ideal solution for many applications including heating and cooling, in commercial building services, as well as in industrial processes and water supply systems. But the story doesn’t end there as now Grundfos has upgraded the electronically controlled TPE family that will bring an additional dimension, via a plethora of improvements. These new TPE2 and TP3 models will deliver unrivalled efficiencies and a wide range of upgraded intelligent functions that allow for the customisation of the operation of these pumps that will suit specific needs and frequently eliminate the need for pump throttling valves. In addition these models offer configurable relays and analogue inputs and are supplied complete with wireless multipump technology capacity.

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

Pick the perfect pump – from Pump Engineering

AB13-613

TEL: 01903 730900 sales@pumpeng.co.uk www.pumpeng.co.uk

For more information or Literature request contact Grundfos Pumps Ltd, Tel: 01525 850000 Email: grundfosuk@grundfos.com Web:www.grundfos.co.uk

PROCESS INDUSTRY INFORMER May 2015

FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves BRAMMER PARTNERS WITH GRUNDFOS TO PUMP UP THE VALUE As part of its commitment to providing customers with the broadest possible range of quality maintenance, repair and overhaul (MRO) products, leading supplier Brammer has announced a new partnership with Grundfos Pumps Limited, with an extensive range of pumps now stocked in its centrally-located National Distribution Centre (NDC). Grundfos is a UK leader in supply of pumps and pump systems for process industry applications, manufacturing some 16 million pump units worldwide each year. It offers a comprehensive selection of pumps for industries including food & drink, pharmaceutical, utilities and the machining industry, with specialist models suitable for applications such as boiler feed, heating, cooling, refrigeration, potable water supply and transfer, as well as wastewater and Cleaning in Place (CIP) systems. In addition to offering customers a wide range of Grundfos products and guaranteeing speedy delivery with stock held at its NDC, the company has recruited a new dedicated pump specialist, product manager James Boyle. With a wealth of experience in assisting customers with the selection and management of pumps, James worked within Grundfos for more than 10 years giving him a comprehensive knowledge of fixed and variable speed pump technology, booster sets, pressurisation equipment and waste water packages. Brammer has selected a hand-picked range of Grundfos pumps to meet the needs of its customers. Its comprehensive selection of centrifugal pumps includes close-coupled, end suction, multi-stage (horizontal and vertical) and sump and bore hole pumps. For customers requiring positive displacement pumps, Brammer now offers a range of reciprocating and rotary pumps including diaphragm, gear, progressive cavity, flexible impeller and peristaltic pumps. Also available from Brammer is the DMH range of hydraulicallyactuated piston diaphragm dosing pumps for enhanced dosing reliability in high-pressure applications, with models available to withstand pressures from 50 to 200 Bar. Offering high accuracies, DMH models offer dosing flow fluctuations of as little as <+/- 1% within the 10-100% control range. For further information please visit www.brammeruk.com or call 0870 240 2100.

HIGH CAPACITY TWIN SCREW PUMPS PROVIDE SMOOTH, PULSELESS FLOWS

When high capacity fluids transfer applications require a self-priming pump which can provide smooth, pulse less flows up to 1700 m3 / hour and at pressures up to 55 Bar; 3P PERA PRINZ Twin Screw Pumps are the ideal solution. Recently introduced in the UK by MICHAEL SMITH ENGINEERS, these high capacity pumps are available with either one, or two pairs of screws and in a choice of wetted materials These positive displacement pumps, feature one or two pairs of screws (depending on the model), which are driven by external gearing so the screws never come into contact with each other. This ensures smooth, accurate flows and suitability for pumping shear sensitive fluids. This twin screw ‘non-contact’ design also means high suction lift capability (typically 7 to 8.5 metres), very low NPSH values and less component wear and therefore a longer service life. 3P Prinz Twin Screw pumps are very well suited to pumping fluids with low, medium and very high viscosities up to 35000 cSt and at a wide range of pressures which makes them an ideal alternative to centrifugal pumps. They are also ideal for pumping applications in the chemical, pharmaceutical and food and beverage industries for transferring a wide range of challenging liquids such as; bitumen, tar, lubricating oils, crude oil, grease, paraffin, wax and molasses. Further details on 3P Prinz Twin Screw pumps are available from: Michael Smith Engineers, Tel: 0800 316 7891 Email: Info@michael-smith-engineers.co.uk Web: http://goo.gl/LvN1jo

IT’S ALL ‘GO’ FOR GRUNDFOS WITH MOBILE PUMP CONTROL The increasing demand for intelligent Building Management Systems and an ongoing need to make systems integration simpler took a leap forward with the introduction of the Grundfos GO. This tool is the most comprehensive platform for mobile pump control available to the market today. It allows intuitive, handheld assistance and unlimited access to online tools – as well as saving time in terms of accessing reports and collecting data. Grundfos GO allows the user to control all aspects of their intelligent pumps by acting as an intuitive assistant that will mean time savings on everything from commissioning, data collection, reporting, through to sizing and replacement that relate to a wide range of pumps and applications. The Grundfos GO App can be used as a standalone on a Smartphone such as an Android or iPhone device which means you can access key information – regardless of where you are. Since its introduction the Grundfos GO has continued to build a solid and loyal fan base and with it recently winning Technical Product of the Year at the recent Pump Industry Awards, this innovative tool has set a new high benchmark for pump communications. For more information or Literature request contact Grundfos Pumps Ltd, Tel: 01525 850000 Email: grundfosuk@grundfos.com Web:www.grundfos.co.uk

PROCESS INDUSTRY INFORMER May 2015

FLUIDS & LIQUIDS HANDLING inc. Pumps & Valves VERDERFLEX TAKING STRIDES WITH THE NEW STEPTRONIC RANGE OF PUMPS Verderflex is proud to launch its latest innovation in peristaltic pump technology, Steptronic. The new Steptronic range is designed to operate as either a panel mounted or “stand alone” OEM cased unit. The Steptronic features an accurate, high resolution, integrated stepper drive which is suitable for continuous duty and critical “multi-cycle” OEM applications. The units are highly adaptable, offering a wide range of flow rates (0.1 to 1,310 ml/min) with a class leading 4096:1 turn down ratio and speeds in excess of 400 RPM. Steptronic has multiple AC & DC input power options and can be controlled remotely by digital, analogue and HMI signals including 4-20mA and 0-10V. Steptronic has a wide range of accessories and options including IP66 rating, special casings, remote power packs, foot switches and the option for factory programmed custom configured speed, torque and ramp settings. Head options include the new VF “MiniLoad”, as well as the proven high performance Verderflex “EZ” pump heads. The Mini-Load is very sleek and compact in size with a number of features including the latest 4 roller design, unique tube clamp inserts, dual stackable/multiple pump head facility all with quick tube release functionality. The Steptronic is the ideal cost effective single source solution giving all users from design engineers to large OEM manufactures maximised performance and reliability. Steptronic can help you by reducing downtime and eliminating the design uncertainty and risks associated with the separate specification of pumps, drives and control systems. Typical life science applications include the bio-decontamination systems from dental to endoscopy equipment, as well as pharmaceutical equipment including bioreactors. We understand that the accuracy of dosage and reliability is critical for example in methadone dispensing systems, chlorine monitoring applications, water treatment, bench-top laboratory cross-flow filtration environments and industrial lapping machinery. For further information contact Verderflex Ltd Tel: +44(0) 1924 221020

Email. info@verderflex.com Web: www.verderflex.com

PROCESS INDUSTRY INFORMER May 2015

FEATURE FLEXIBLE CONNECTIVITY SOLUTIONS FOR INTEGRATED INDUSTRY by Kevin Canham, Product Manager with Northampton based HARTING Ltd. New developments in automation systems and industrial IT are the key technologies underpinning the concept of Integrated Industry. However, only when the field level is included will the claimed benefits materialise. This article shows how this challenge is being addressed by the development of flexible connectivity solutions which are consistently based on IT standards. Real automation data, which provides an objective view of the manufacturing processes and which is the basis for every optimisation, is only available at field level. All the higher-level layers of the traditional automation pyramid only consolidate the field-level data and, in doing so, very often destroy its chronological order. As a result, it loses any relationship to the actual process: something which is necessary for functions such as observing critical conditions as part of a statusoriented maintenance program or for efficiency optimisation. In order to manage data traffic at different communication levels, the data must be in a pre-processed form. For Integrated Industry to be successful, it is of key importance that it moves forward into the field level.

FIELDBUS SYSTEMS

With the introduction of fieldbus systems, the recording of sensor data is decentralised as sensor-actuator boxes with fieldbus connections are shifted into the field. A central control system then queries these boxes periodically. Knowledge of the significance of the sensor data is typically stored in a PLC. As a rule, the sensor is not intelligent – it merely measures. Communication allows exchange of a digital or analogue value, and analysis of this data is therefore meaningful only for the control system. Integration at the management level is difficult to achieve. The traditional fieldbus rules have not changed at all with the introduction of Ethernet as the physical layer for the fieldbus. Inclusion of the field level in a fully Integrated Industry system only works on the basis of standards. If one considers the volume of Internet-enabled communications devices available today and relates it to the number of automation devices, the automation devices make up less than 1% of the total. This means that new fully integrated automation devices must be compatible with the existing IT standards on which the remaining 99% of (non-automation-relevant) devices are based. True emancipation for field devices will be achieved only when they are completely and equally integrated into the Internet environment. However, this is not sufficient for automation devices because more industry-specific requirements must also be fulfilled, and they too must also be standardised.

THE NEED FOR NEW FIELD DEVICES

This means that new field devices are required for integration into the Internet environment: devices which act not only as slaves of industrial control systems, but also as masters. This concept also changes how these devices communicate with the IT level. Specifically, this communication must be possible via other channels than just gateways, something that makes these new field devices capable of more than their predecessors (Fig.1).

The foundations for this approach have already been laid with the decentralisation and modularisation of field devices, with high-performance computing available in very compact configurations to allow the integration of relevant services. With powerful and compact electronic modules, field devices can now pre-process and interpret the relevant information without overloading the infrastructure with large quantities of data. For example, it is not necessary to provide regular information about a system which is working correctly: information about a deviation from the target specifications is much more important. The combination of the fog computing approach with the use of intelligent field devices now allows constant monitoring that will not overload the infrastructure with the quantities of data that arise.

PROCESS INDUSTRY INFORMER May 2015

THE IMPORTANCE OF STANDARDS

To break new ground, Integrated Industry must be consistent in its use of standard IT technology. This simplifies the integration of the industrial automation infrastructure with the IT business applications within the enterprise. However, the use of field devices in automated environments requires functionalities that extend beyond compatibility with IT standards. The various requirements in terms of the sensors and actuators used necessitate a flexible and modular structure. Consistent use of open IT standards is thus crucial.

CYBER-PHYSICAL SYSTEMS

The result for customers is a new Integrated Industry device that can be integrated easily in IT applications such as ERP and MES. Furthermore, all the state-of-the-art interfaces to the Smart Object will be provided. The new Integrated Industry device will thereby forge a link between the object and the cyberworld and consequently act as the central component in a cyber-physical system (Fig.2).

ETHERNET DEVELOPMENTS

The key demands made on automation are high performance and determinism: the factor that provides a guaranteed response time to an event. This in turn provides an accurate date stamp which allows the control system to differentiate between cause and effect and to respond accordingly. Standard Ethernet does not offer this determinism by itself, because it is based on statistically distributed network access in which the performance falls as the load on the network rises. This is particularly critical for fast and synchronous drive regulators, for measurement and test facilities, or when synchronising networks with, for example, wind energy in-feed. Fast Tracking Switches (FTS) are active network components that transport automation frames or specially labelled frames preferentially: in effect, they switch on a “flashing blue light” that holds other frames back and thereby prevents congestion. The HaVIS FTS switches guarantee that the preferred frames always arrive at their destination within the time calculated, irrespective of the load on the network. In this way, the Ethernet communication solutions achieve the same performance as deterministic field buses. The new Ha-VIS FTS switches support the Precision Time Protocol (PTP) in accordance with the IEEE 1588v2 Standard, even with a hardware time stamp, and achieve an accuracy of within 0.1 µs. They can be operated as a boundary clock or a transparent clock, and can therefore assume the role of master or slave, allowing all the participants in time-critical applications to be synchronised and high speeds in automation to be achieved (Fig. 3). To summarise, the advance of Ethernet at the field level reduces media discontinuity, and enables accurate synchronisation of networks with the standardised PTP time protocol. This process is realised in the HaVIS FTS: a universal Ethernet switch that enables the construction of a deterministic Ethernet system in different automation environments.

CHILLERS AB SYSTEMS LAUNCH CHILLER WARRANTY AND AFTERCARE PROGRAMME

Cooling and materials handling specialist, AB Systems, has launched an industry-leading warranty and aftercare programme for new and existing chillers. Offering unrivalled customer support, the 3 Year Warranty 24/7 Plus and Service 24/7 Plus packages are characterised by a number of standout features, such as 24/7 alarm monitoring and GSM alarm text alerts to engineers, both of which enable AB Systems to proactively solve potential issues before they occur, thus significantly minimising the risk of expensive production loses. The warranty packages apply to market-leading Novafrigo chillers, for whom AB Systems is UK distributor, while all chiller brands are covered by the Service 24/7 Plus agreement. Companies looking to purchase new chillers can benefit from AB Systems’ 3 Year Warranty 24/7 Plus package. A standard service agreement Service Plus is also available and offers chiller servicing from just £200. Servicing on all packages will be carried out by AB Systems’ in-house, qualified engineers to maintain continuity and a high standard of technical skill. For more information contact AB Systems Web: www.ab-ltd.co.uk Tel: +44 (0) 1844 339 044

LIFT TRUCKS TEREX PORT SOLUTIONS LAUNCHES NEW GENERATION LIFT TRUCKS

Terex Port Solutions (TPS) has launched its new generation Liftace™ 5-31 reach stacker, which is the first of five new machines to be introduced by TPS in the next few months. The launch of the Liftace™ 5-31 reach stacker will be followed by the introduction of four new Stackace™ empty container handlers in the near future. The new products combine the strengths of proven TPS technology and the two legacy Terex brands of PPM and Fantuzzi with state-of-the-art innovative features. The machines are cost-effective, service friendly and ergonomic. They offer l, reduced tyre wear and lower fuel consumption for lower operating costs simple maintenance and an ergonomic cab design.Liftace 5-31 reach stacker with robust design for fast and precise stacking. With a wheelbase of 6,200 mm the Liftace 5-31 reach stacker can stack up to five high-cube (9‘6‘‘) containers in the first row, with typical load configurations of 45 t in the first row, 31 t in the second row and 15 t in the third row. The robust design of the new Liftace 5-31 reach stacker incorporates an advanced boom design. Its inherent rigidity and increased radius facilitate more accurate and faster operation. For more information contact Terex Port Solutions, Banbury, Oxfordshire. Tel: 01295 676100 Email: bnb-help@terex.com Web: www.terex.co.uk/en_uk/

PROCESS MEASUREMENT & INSTRUMENTATION EMERSON INTRODUCES WIRELESS TOTALISING TRANSMITTER TO MONITOR TURBINE METERS IN REMOTE APPLICATIONS Emerson Process Management introduces the Rosemount 705 Wireless Totalizing Transmitter for installation on new or existing turbine meters or pulse devices to deliver average flow and totalised flow volume over time. The totalising transmitter also delivers predictive diagnostics data to indicate instrument health and support timely maintenance to intervene on issues before they impact operations. “Unmeasured flow and volume in turbine meter or pulse applications can impact productivity and optimisation of other critical areas of production,” said Bob Karschnia, vice president of wireless at Emerson Process Management. “Locating traditional analogue flow measurement has often been demanding or even impossible to implement when and where you want it. The Rosemount 705 Wireless Totalizing Transmitter answers these challenges by connecting directly to any new or existing meter or pulse device, and sending data wirelessly to eliminate cabling costs, speed installation, and enable complete process data for better decision making.” The Rosemount 705 transmitter provides average flow rate and totalisation in an operator-configurable k-factor. One second updates ensure timely information, and remote mounting of the device allows for flexible installation. The transmitter can be installed in a location convenient for the wireless signal up to one kilometre away. The transmitter calculates the total from a pulse measured from 0 to 10 khz and provides an optional continuous read out display. The transmitter can be configured to reset at the unit or remotely via MODBUS, EtherNet/IP or OPC from the host system. For more information contact Email: InfoCentral@EmersonProcess.com Web: www.EmersonProcess.com

PROCESS INDUSTRY INFORMER May 2015

PROCESS MEASUREMENT & INSTRUMENTATION SPIRAX SARCO’S NEW B850 FLOW COMPUTER MAKES IT EASY TO MEASURE TRUE STEAM BOILER EFFICIENCY With the launch of the Spirax Sarco B850 Flow Computer, steam system operators can now accurately measure true boiler efficiency without the need for Building Management or Supervisory Control and Data Acquisition (SCADA) systems that can be costly and time consuming to implement. Typically, steam system operators use burner efficiency to indicate boiler efficiency. However, this ignores energy losses that can occur after the burner, such as scaled or dirty heat transfer surfaces or excessive boiler blowdown rates. The only way to obtain true boiler efficiency is to meter all energy into the boiler (in the gas and feed water) and compare this with the useful energy out of the boiler (in the steam). The B850 Flow Computer is an all-in-one unit that uses input data from gas, water and steam flowmeters to calculate the energy efficiency of the boiler system without the need for additional equipment. The unit can display real-time and historical data for an easy way to detect drops in boiler efficiency and identify their causes quickly. This enables swift action to be taken to prevent unnecessary costs arising from inefficient boiler blowdown procedures, degradation of insulation or a system failure (for example, in heat recovery equipment). Using burner efficiency data alone, such changes can often go unnoticed until an expensive fuel bill comes in. The B850 Flow Computer therefore enables energy and facilities managers to benchmark the efficiency of boiler settings and operating procedure, allowing energy and cost saving measures to be effectively implemented. It also provides proof of return on investment for any related expenditure. For more information contact Spirax Sarco, Cheltenham, Glos. Tel: 01242 521361 E-mail: UK.Enquiries@spiraxsarco.com Web: http://www.spiraxsarco.com/global/uk

CORI-FILL Technology TM

Replaces weighing scales (gravimetric principle) Very fast dosing time: from ca. 300 msec, from 40 µg per „shot“ Fill speed from 0,2 ml/h up to 600 l/h Compact assembly, low dead volume High accuracy due to Coriolis technique Mass and volumetric dosage possible Automatic overrun correction Time reduction due to simultaneous dosing of compounds Continuous density measurement with gas bubble and empty tube recognition

Innovation - Experience - Responsibility

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

PROCESS INDUSTRY INFORMER May 2015

FEATURE

BENEFITS OF USING WIRELESSHART INSTRUMENTS IN HAZARDOUS LOCATIONS

Simplify hazardous area inspections by using WirelessHART instrument

By Ian McDonald, Wireless Solution Architect at Emerson Process Management Instrumentation for hazardous areas come in many different forms with varying types of protection classification depending on the operating environment, this article highlights reductions in hazardous area inspections requirements choosing a WirelessHART device over a 4-20mA HART device. than every three years depending on the environmental conditions of the installation.

INSTALLING WIRELESSHART INSTRUMENTS

When instruments are required to be installed in hazardous areas, there is a requirement that all wiring must be installed and maintained to the relevant standards to prevent an ignition of the explosive environment. The costs of protecting wired 4-20mA HART instrument in hazardous areas is not just simply the installation cost but also ongoing inspections and remedial works that will inevitably follow. This can often be overlooked where the designer is Fig. 1: Installing and maintaining wired not the plant operator or maintainer. 4-20mA or fieldbus instruments in a WirelessHART devices certified to hazardous location can be difficult and the relevant protection level for the expensive. WirelessHART transmitters hazardous area can reduce the duration address these issues. and complexity of inspections due to the reductions of equipment installed in the hazardous area, such as the wiring, junction boxes, cables and IS barriers needed with a traditional wired installation. WirelessHART process transmitters (Figure 2) can be powered by an IS power module, which eliminates the need for power and signal wiring. Such power modules are field interchangeable in the hazardous Fig. 2: Example of a native WirelessHART sensor being used in a hazardous environment.

location. For example, a refinery in Mexico was having problems with its cooling towers. The wired cooling tower instrumentation was old and most measuring devices were out of service. Measurements were difficult because the process environment was corrosive to wiring, mainly due to hazardous chemical vapours. As a result, these areas were poorly instrumented. Consequently, control was poor, operations were inefficient and the towers required a great deal of maintenance. Installing wired instruments was deemed too expensive because of the cost of equipment and its supporting infrastructure, and because the corrosive environment would degrade the instrumentation and raise maintenance costs. Required inspections would add further costs, making wired instrument installation impractical. Instead, the refinery installed 122 Emerson wireless sensors and transmitters in enclosures to protect the instruments from the environment. Because these instruments are rated for use in the area, no special protective measures were required.

INSPECTION REQUIREMENTS

4-20mA HART field transmitters require wiring, conduits, cable trays, field junction boxes and marshalling cabinets. If the instrument is 4-wire, it must have separate power wiring. All wiring systems must meet the requirements of IEC 60079 for the type of protection that the circuit is certified for. This could be `EX ia’ for intrinsically safe, `Ex d’ for explosion-proof or one of the other types of protection permitted. Maintenance (Figure 3) is required to ensure that the protection level is being maintained. IEC 60079 covers the use of electrical equipment in hazardous areas. IEC 6007914 requires that an initial inspection must be carried out when the equipment is first installed. IEC 60079-17 says that the interval between following inspections shall not exceed three years without seeking expert advice. Typical inspections are done annually. Although complete inspections have to be done at least every three years, the grade of inspection and the interval between inspections should take into account the type of equipment; that is, some devices may need to be inspected more often

THERE ARE FOUR GRADES OF INSPECTIONS DEFINED IN 60079-17: 1. Continuous supervision − defined

as frequent attendance, inspection, service, care and maintenance of the electrical installation by skilled personnel who have the knowledge and skills to maintain the equipment in accordance with IEC 60079-17 Clause 4.5. Fig. 3: Instruments and wiring systems in 2. Visual inspection − an inspection hazardous locations must be inspected (Figure 3) which identifies, without use of regularly. During a close inspection, a access equipment or tools, defects which certified technician looks for obvious would be apparent to the eye, such as faults. missing bolts or damaged cables. 3. Close inspection − defined as an inspection which encompasses aspects covered by a visual inspection and identifies defects that are apparent only by the use of equipment and tools, such as loose bolts or damaged cable glands without opening equipment. 4. Detailed inspection − defined as an inspection which encompasses everything covered by a close inspection and identifies defects which are only apparent by opening the enclosure and using tools and test equipment. Detailed inspections can find loose terminations, incorrect grounds missing seals in glands. These inspections include all equipment located in the hazardous area, and any protection device located in the safe area (in the case of `[EX ia]’). Inspecting all the equipment in the circuit can be difficult due to cable routes and general access issues when the plant is running that may require permits to access hazardous areas. Once the inspection is done records have to be updated and any remedial works have to be scheduled and carried out before the circuit can be signed off as compliant.

CUTTING COSTS WITH WIRELESSHART

Adoption of WirelessHART equipment can have significant impact on both CAPEX (capital expenditures) and OPEX (operating expenses).In the CAPEX phase, designs using a wireless device can achieve cost savings. By removing the glands, wires, conduit/tray, field junction boxes and marshalling cabinets − wiring component costs are reduced, and further savings are realised by eliminating associated installation drawings and equipment lists that are required for maintenance and installation. The cost of installation must also be considered, as not having to install equipment required for wired instruments reduces labour costs, scaffolding etc. and speeds up installation and commissioning times. WirelessHART also reduces OPEX, especially the cost of hazardous area inspections. This is due to not having to have supporting infrastructure between the device and the host system for the measurement circuit. Only the instruments themselves have to be inspected and possibly the wireless gateways if they are installed in the hazardous area. In many instances, these gateways can be installed outside of the hazardous area, further cutting costs. This is especially important when the inspection is on the critical path of a plant outage. By reducing the volume of hardware to be inspected and maintained, outage duration due to inspections can be reduced or inspections taken off the critical path. In comparison the costs of inspecting and maintaining wired 4-20mA HART or fieldbus process instruments in a hazardous area is very high because of the need to support the instruments with an infrastructure including power supplies, wires, and conduit and marshalling cabinets. All of these items need to be protected from igniting a flammable or explosive atmosphere, all of this equipment needs to be inspected on a regular basis, and repairs are often required to keep the entire system safe. Using WirelessHART eliminates wiring infrastructure, and reduces required inspection tasks. In risk reduction eliminate and reduce offer the best protection over inspect and control.

PROCESS INDUSTRY INFORMER May 2015

PROCESS MEASUREMENT

& INSTRUMENTATION

New RUGGED 4-20mA Panel Indicator

NEW GUIDES ANNOUNCE ABB’S SERVICE OFFERINGS FOR FLOW CALIBRATION AND VALVE TESTING ABB’s flow and valve services explained by new publications ABB’s Measurement and Analytics business has released two new guides covering its services for flow calibration and valve testing. Available on request from abb. service@gb.abb.com, the guides explain how ABB’s flow calibration facilities at its Stonehouse and Workington factories can be used to help check the accuracy of flowmeters and control valves. For flow calibration, the facilities enable a wide variety of flowmeter types to be calibrated to the leading international standards. All calibrations are carried out to ISO9000, with the option of a UKAS accredited calibration where the certificate carries the ILAC and UKAS Calibration Laboratory 0255 logo. The flow calibration guide explains how the facilities can be used to calibrate meter sizes from 1mm to 2.4 metres at accuracies down to ±0.1%. It also covers the range of calibration techniques available, including gravimetric, volumetric or comparison methods, describing each technique and explaining how to choose the right method. The valve testing guide covers ABB’s ability to test control valves from 25mm up to six metres and weighing up to 10 tonnes in accordance with the EN ISO 60534-2-3 standard for control valve testing. The guide explains the testing process and outlines the benefits of ABB’s service, which enables valve users to ensure that their valves have been tested for their specific requirements. Both services are offered via ABB’s Measurement & Analytics Products Service team and are part of a wider service capability spanning ABB’s entire portfolio of instruments and analysers.

To request a copy of the guides, or for more information about ABB’s instrument and analyser service offering, please email abb.service@ gb.abb.com or call 03339 997 996

PROCESS INDUSTRY INFORMER May 2015

■ Stainless Steel & Toughened Glass ■ High Impact IP66 Front ■ Suitable for Ex e, Ex n or Ex p Equipment ■ Ex ia Model for Zone 1, 2, 21 or 22 ■ Ex nA Model for Zone 2 or 22 (Isolator or Barrier Not Required) ■ General Purpose Model also Available

www.beka.co.uk

Hitchin, Herts. SG5 2DA, UK sales@beka.co.uk Tel +44 (0)1462 438301

PROCESS MEASUREMENT

& INSTRUMENTATION

CORI FILL IS FASTER AND MORE ACCURATE THAN WEIGHING SCALES

The European market leader in mass flow metering and control, Bronkhorst, is offering a modern alternative to the gravimetric or weighing scale method of dosing additives, fragrances, flavours and colourants. This alternative promises shorter processing times, better product results and improved working atmospheres. Its latest CORI-FILL® compact fluid dosage assembly, which combines an extremely accurate CORI-FLOW or mini CORI-FLOW flowmeter with a suitable valve or pump, is capable of dosing the exact amount of fluid, whilst multiple instruments can be used for the simultaneous dosing of compounds. CORI-FILL® is suitable for a wide range of batching, blending, dosing, filling and sterilisation applications, at flow rates between 0.4g/hr and 600kg/hr. Aimed at the food & beverage, pharmaceutical, chemical, cosmetics, contact lens and life sciences industries, it has a compact footprint and requires no complex programming of additional hardware. With CORI-FILL® technology, you can dose the precise amount of compound into the collecting vessel, with just a brief reset command to start the next batch. The Coriolis direct mass measurement method eliminates volumetric variation caused by changing temperatures, viscosities and densities of the ingredients. As a result, the CORI-FLOW method is faster, more repeatable and more accurate than weighing scales and product results are better, due to less evaporation of volatile fluids. Moreover, it is possible to dose a number of fluid additives simultaneously, using multiple CORI-FILL instruments, leading to shorter production times, with no intermediate zeroing procedures that are required of weighing scales. The amounts to be dosed can be easily pre-set by digital communications, and the working atmosphere is also improved, as there is no dosing of additive into open storage vessels, of the kind needed for weighing scales. CORI-FILL assemblies are offered with a choice of CORI-FLOW instruments, for flow rates between 50g/hr to 600kg/hr, or the highly compact mini CORIFLOW series, for capacities from 50 mg/hr up to 300kg/hr. Either instrument type can be combined with a shut-off valve, for short batch sequences down to <2 milliseconds, a proportional valve, for longer dosing times >5 seconds, or a gear pump, for dosing without the need for pressurised vessels. The flowmeter’s on-board PID controller is optimised for controlling the valve or pump, for an instant start to dosing duties. Accuracy is 0.5% or better for mass dosing and 1% for volume. Thanks to a small footprint, the CORI-FLOW or mini CORI-FLOW instrument is able to be mounted close to the valve or pump, which minimises the internal pipework volume and results in fast response times, down to <0.3 sec, and a reduced risk of gas enclosure in the tubing, potentially causing delay effects. Ready assembled & pre-tested CORI-FILL fluid dosage are available from Bronkhorst UK, 1 Kings Court , Willie Snaith Road, Newmarket, Suffolk, CB8 7TG Tel 01223 833222 Web: www.bronkhorst.co.uk

PROCESS INDUSTRY INFORMER May 2015

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FUNCTIONAL SAFETY - SIL2 CERTIFIED CLAMP-ON FLOWMETER As the world’s first ultrasonic clamp-on flowmeters, the FLUXUS series from FLEXIM have proven their suitability for use in process control protection equipment according to the IEC 61508 norm and are certified as “SIL 2 capable”. The FLUXUS F/G70X and F/ G80X series meters, which are to be used for the permanent, non-invasive flow measurement of liquids and gases, are audited and certified. The available flow transducers cover a nominal size range from 6 mm to 6.5 m. It goes without saying, the SIL2certified measurement systems are also offered in versions approved for use in potentially explosive atmospheres (ATEX, IECEx Zone 1 and 2). In conjunction with the patented transducer mounting fixture “WaveInjector”, the FLUXUS meter can also measure at extreme pipe wall temperature ranges from -170 °C up to 600 °C. Thanks to carefully matched transducer pairs, unique internal temperature compensation and sophisticated internal signal processing, clamp-on ultrasonic FLUXUS meters are highly zero-point stable and drift-free, ensuring precise measurement data. FLEXIM calibrates transducer pairs and transmitters independently of each other which in turn guarantees that narrowly specified measurement uncertainties can in any case be respected, no matter which transducer is used with a particular transmitter. In addition to SIL-certified devices, FLEXIM will present the FLUXUS XLF for extremely low flow rates, or rather flow velocities at the Achema trade fair. A particular highlight is sure to be the introduction of the FLUXUS F/G 721 as the first representative of a whole new generation of clamp-on ultrasonic flowmeters. ACHEMA, hall 11.1, booth A16 For more information contact FLEXIM GmbH, Berlin, Germany. Tel: +49 30 936676 915 Fax: +49 30 936676 80 E-mail: ofoth@flexim.com Web: www.flexim.com

CLAMP ON & GO (YES REALLY!) Dynasonics have developed a range of simple-to-fit, ultrasonic clamp-on liquid flow meters for pipes from 13mm to 5000mm in diameter. Dynasonics meters clamp on to the outside of pipes and don’t contact the internal liquid, technology with advantages including: non-invasive installation, zero pressure head loss, no moving parts, no fluid compatibility issues and a bi-directional measuring range at low and high flow rates. The DXN™ is a portable, touchscreen meter with both transit time and Doppler modes. The TFXL™, the economical option, uses transit time to measure clean liquids with novel integrated pipe mounting sensors or remote transducers. The TFX Ultra™ incorporates all the features of the TFXL™ but with additional Modbus or BACnet comms and an aluminium enclosure. The DFX™ uses the Doppler technique to measure ‘difficult’ flows such as sewage and the UFX™ is a hand-held, battery-powered Doppler model. For more information contact Bell Flow Systems Ltd, Buckingham Tel: 0800 027 7786 E-mail: sales@bellflowsystems.co.uk / Web: www. bellflowsystems.co.uk

PROCESS INDUSTRY INFORMER May 2015

PROCESS MEASUREMENT

& INSTRUMENTATION

PACKAGE-SEALING TEMPERATURE CONTROLLER IS CONFIGURED IN A MINUTE MAXVU OFFERS FAST, RELIABLE TEMPERATURE CONTROL ON A BUDGET West Control Solutions, the global specialist in process temperature control, has launched MAXVU – a compact controller that can be set up in one minute for many packaging, food and beverage and textile industry applications. MAXVU offers faster set-up than rival products because its start-up configuration menu only shows the most vital parameters including sensor types, units, outputs, alarms and setpoint values, removing time spent scrolling through unnecessary options. MAXVU is particularly suited for packaging tray and bag sealers, textiles applications (such as seam sealing and thermal bonding) and processes in the food and beverage sector including fryers, micro-breweries and chocolate tempering. Ian Collins, Product Manager and Strategic Account Manager, West Control Solutions, commented: “Overspecifying temperature controllers can cause unnecessary expense at initial purchase and, more significantly, a waste of resources in terms of set-up time and ongoing operation. By limiting the parameters that need to be set, MAXVU simplifies configuration and increases efficiency for simple temperature control requirements.” MAXVU’s ease-of-use is supported by its large display. A unique button design on the 1/16 DIN product, with the buttons at left and right of the digits on the keypad, allows an impressive 18mm upper digit and 10.2mm lower digit height in a 48mm high device. The larger digits offer increased clarity and visibility from distance to view vital process information and alarm messages that help monitor a system is running effectively. An equally impressive 96x48mm unit is also available with 18mm digits upper and lower. For more information contact West Control Solutions, Tel +44 (0) 1273 606271 Fax +44 (0)1273 609990 E-mail: Enquiries@West-CS.com Web: www.west-cs.co.uk

HONEYWELL IMPROVES ACCURACY OF NATURAL GAS MEASUREMENT FOR INDUSTRIAL USERS EC 350 Helps Gas Distributors Optimize Custody Transfer May 19th 2015(NYSE:HON) Process Solutions (HPS) today introduced a new metering device that more accurately measures natural gas delivered to industrial customers, helping them meet government and industrial standards. The EC 350 PTZ Gas Volume Corrector allows for precise measurement in a design that is easy to maintain and reliable over extended operations. The EC 350 is the first member of a new HPS family of purpose-built, high-performance electronic volume correctors (EVCs) that meet these critical requirements. The EC 350 uses pressure, temperature and compressibility factors to more accurately measure gas volumes. Users can program this universal bracket-, walland rotary-mount device in the field, and employ its multi-line keypad interface for simplified operation. The new EVC offers improved accuracy, expanded memory and battery, advanced diagnostics, and integrated cellular Key to the EC 350’s updated design is a highly accurate, plug-and-play digital pressure transducer and an enclosure optimized for serviceability and outdoor operation. With long-term stability and extended battery life, this solution minimizes the need for site visits by technicians and simplifies field repairs. It also allows for very precise measurements and long-term reliability with minimal maintenance requirements. For more news and information on Honeywell, please visit www.honeywellnow.com.

PROCESS INDUSTRY INFORMER May 2015

FEATURE

MOTOR AND MACHINE PROTECTION PREVENTATIVE MAINTENANCE IS A KEY FACTOR IN IMPROVING PRODUCTIVITY AND REDUCING COST

Andy Turtle, Automation Product Manager at Rugby based WAGO, explains how advanced motor and machine protection can now be integrated directly into the control PLC bringing considerable benefits to both the installer and the end user. Traditionally, motor control and protection components have been sold as individual items (contactors, thermal overload relays and short circuit protection devices etc.) More recently, we have seen a trend towards combining these devices into an integrated system. However, where more exacting protection of motors, machines and processes is required, separate protection relays may be considered, but ruled out, as they are not always easy to integrate and can mean considerable extra upfront cost. For industrial motor protection, specifying the most appropriate solution depends on a number of key factors. These include: - Type of application (e.g. conveying, fans/pumps or hoisting etc.) - Specification of the motor and utilisation (current, duty, temperature class, starting frequency etc.) - Method of starting and control (Direct on line (DOL), frequency inverter, soft start etc.) However, an important consideration, and one that is often over looked, is preventative maintenance which can have a considerable influence on productivity. By considering this at the outset when specifying the type of motor and machine protection that will be used, substantial cost and efficiency benefits can be realised. These include: - Maximising plant ‘up time’ and increasing productivity - Efficient use of manpower through planned maintenance - Reliability of production or service provision to ensure customers are not inconvenienced. Most low cost motor protection devices incorporate an inherent flaw: they only let you know there is a problem when they trip. At this point of course it can be too late, as the machine, or indeed any other part of the process, may be already damaged due to overloading or overheating. Significantly, the process will stop whilst the problem is identified and rectified which can result in production being disrupted with potentially severe cost consequences. One solution is the advanced motor protection relay (or ‘motor manager’) that monitors the current to the motor and calculates the I2t heating effect. Such devices will also usually feature a pre-alarm function which provides the additional all- important warning of an impending problem. However, they can be expensive to purchase and difficult to integrate due to their size and their requirement to physically measure current. What’s more, they are not measuring actual motor temperature rise so performance can be compromised in applications where motor starting is arduous, e.g. high ambient temperatures, long starting times or frequent starting. Furthermore, whist it is often assumed that mechanical problems associated with the machine will be reflected in an increased motor current, this is not always the case.

THERE’S A SOLUTION AT HAND…

Fig. 1: WAGO Series 750 8-channel PTC module.

To get around this dilemma, the use of physical temperature rise monitoring is an effective solution. Not only can the motor be monitored using

PROCESS INDUSTRY INFORMER May 2015

probes embedded in the windings, but also other critical parts such as bearings, gearboxes and fluid couplings, etc. can be checked. It is also possible now, using products such as WAGO’s new thermal protection I/O modules, to integrate this capability approach, many critical areas of the machine and / or motor can be monitored easily within the automation solution as the compact modules can facilitate up to 8 PTC (positive temperature coefficient) thermistor channels. The 750-1425 8 channel module can monitor up to 6 PTC thermistors per channel, a total of up to 48 in one 12 mm wide I/O module. Even though PTC probes operate at a fixed threshold, they can provide advanced warning of a problem developing as a physical temperature rise will usually indicate deterioration of the equipment. If a more predictive, proportional temperature monitoring is required to enable even closer protection of very critical areas, then an analogue temperature measurement device such as a thermocouple or RTD (resistive temperature device) can again be connected via a specialised I/O unit (such as the WAGO 750-451 8 channel 2 wire RTD 12mm module). With these analogue devices integrated in the PLC, setting up one or more pre-alarms is a simple case of including threshold comparators within the machine’s control program. The status of these comparators can then provide alarms or directly apply remedial action such as switching to a standby system, reducing the load or enacting other measures that can prevent a stoppage from occurring. Recently there has been much discussion about the importance of productivity and how UK businesses are not necessarily as ‘productive’ as those in other countries. In simple terms, productivity can be described as the ratio of output to input. Manufacturers and process operators can clearly benefit from any improvement in this ratio. A key element in terms of input will be the cost of maintenance; conversely lost production directly impacts on output. Installing equipment that increases productivity will have long term benefits and improve the competiveness of the business by reducing the fixed cost base. Having said that, securing capital expenditure budget is not always plain sailing, so justifying the best returns on the budget available is very important. When it comes to maintenance, the choices that are made can have significant impact. A long term view will not only help productivity but improve the business’ reputation for being a supplier that can be relied on to make on-time deliveries whilst being competitive on price. In conclusion, choosing an integrated control and diagnostic monitoring motor control system can provide an extremely cost effective solution for a preventative maintenance approach and provide significant benefits.

BENEFITS FOR THE INSTALLER: - Cost reductions thanks to space saving, reduced wiring and lower overall equipment costs - Easier diagnostics and commissioning thanks to a fully integrated control and monitoring solution

BENEFITS FOR THE END USER: - Possibility of achieving a higher degree of motor and machine preventative diagnostic and remedial action whilst minimising the equipment and staff costs. - Ability to carry out maintenance at a time that does not impact production. - Reliability of deliveries to customers and avoidance of penalties associated with contravening a service level agreement. - Increased productivity.

CONDITION MONITORING ENCLOSURES OVERSPEED PROTECTION SYSTEM FOR TURBINES AND PUMPS Overspeed protection is a key requirement in the power generation industry where failure of the turbine or pump speed governing system can lead to rotor damage with expensive consequences. Independent speed monitoring and protection is therefore an essential requirement to minimise these risks as far as practicable. Condition monitoring specialists SENSONICS have provided high integrity overspeed protection systems for over 20 years with proven field reliability. Sentry G3 is Sensonics latest generation of protection equipment for overspeed protection applications. The four channel G3 module has been specifically designed with an independent digital signal processor (DSP) for each channel of measurement providing ease of scalability in combination with high integrity. The DSP can be software loaded with the specific measurement algorithm which not only controls the sensor selection, but also the protection relay status and analogue output levels. This provides complete hardware autonomy from sensor through to the protection relay combined with a high channel density (24 channels in a 3U format). When high integrity protection is required, the IEC61508 international standard for functional safety can be applied to ensure that sufficient integrity is designed into the electrical / electronic systems employed for the safety function. The Sentry G3 OSP achieves a SIL 3 rating in this respect. Key elements of the Sensonics Overspeed Protection System: • Voted arrangements - 2 of 3 and dual 2 of 3 as standard. • On line test trip and signal injection facilities. • Key lock inhibit. • High visibility displays and lamps. • Approval to IEC 61508. • Dual redundant or module independent power supply option. • Response time <20ms. For more information contact Sensonics Ltd, Tel: +44 (0) 1442 876833 Email: sales@sensonics.co.uk Web: www.sensonics.co.uk

CALIBRATION NEW pH CALIBRATION GUIDE FROM METTLER TOLEDO Reduce maintenance costs of your pH sensors Over time pH sensors are affected by their measuring environment and require cleaning, calibrations and adjustments to ensure accurate and precise measurements. Extend the operating life of your pH sensors when you download the latest calibration guide at www. mt.com/ism-calibration-guide Using METTLER TOLEDO pH sensors with Intelligent Sensor Management (ISM®) and iSense 2.1 software enables you to complete calibrations and adjustments in minutes. Calibrated sensors can be easily rotated in and out of a process allowing for valuable sensor recovery time. This not only extends the life of the sensor but also reduces maintenance time and costs. Download the calibration guide at www.mt.com/ism-calibration-guide Alternatively call 0116 234 5095.

AUTOMATION IN ENCLOSURE ASSEMBLY There are many and varied benefits to automation which a large number of industry sectors have clearly embraced. It seems strange then that so many panel builders, given they are regular suppliers to these sectors, have been slow to embrace the clear benefits of automation themselves. Rittal’s acquisition of Kiesling in 2013 was a milestone in the company’s ability to support its customers. The machines and solutions from Kiesling now facilitate the optimisation of the complete work-flow in panel building manufacture, from machining of the panel parts and automated wiring of the panels to testing of the finished panel, supported by a diversity of handling systems such as the Assemblex. This joint expertise aligned with Rittal’s other subsidiary companies Eplan (design) and Cideon (technical IT integration) means that automating the production of control panels has now become far more accessible. It means panel builders can, if they wish, provide end to end services and solutions throughout their value chain, while optimisation of the whole work flow is possible, from the design to the technical IT integration. As if to underline this point, Rittal’s sales in automation equipment and software are up year on year, indicating some, if not all, panel builders are taking advantage of the opportunities automation presents. For more information contact Rittal Ltd, Hellaby, Rotherham Tel: 01709 704000 E-mail: information@rittal.co.uk Web: www.rittal.co.uk

DEMAND BASED COOLING AND MONITORING…FROM A FAN-AND-FILTER UNIT! Rittal has launched a new EC Speed Control, compatible with larger models from the Top Therm EC fan-and-filter unit range (uninstalled air throughputs between 180 m³/hand 900 m³/h). Fan-and-filter units with electronically commutated (EC) motors for electrical enclosure cooling are already recognized for their lower energy consumption and extended service life. Furthermore, infinite speed control as well as a monitoring signal are much simpler to incorporate in an EC motor than on the AC motor equivalent. Rittal’s new EC Speed Control supports these benefits, and adds a number of others. It can be used to reduce noise output of EC fan-and-filter units, as well as lower energy consumption still further through the ability to control the speed of up to four units. Cooling demand - and hence the required fan speed – is determined by comparing the sensed temperature inside the enclosure with the setpoint temperature on the device, from +5 °C to +55 °C. The Rittal EC Speed Control is also able to closely monitor the status of the fan. The unit provides a local visual display of the operating status and incorporates an alarm relay for the remote monitoring of over-temperature, fan defect, cable break and sensor failure. This exciting and innovative new product sees the humble fan-and-filter unit come of age, providing demand-based cooling, greater temperature stability inside the enclosure, and performance monitoring, alerting users to any problems with their cooling system. It transforms the fan-and-filter unit into a smart solution perfectly suited to the modern technical era. Further information at www.rittal.com and www.friedhelm-loh-group.com, or on twitter @rittal_ltd.

PROCESS INDUSTRY INFORMER May 2015

FEATURE

THE BENEFITS OF CALIBRATION & THE IMPORTANCE OF DETERMINING THE CORRECT INTERVALS Jay Lakhani, Senior Applications Engineer, HBM UK explains the benefits of calibration to engineers involved in measuring technology and discusses the guidelines surrounding calibration intervals. CALIBRATION & THE BENEFITS

Calibration accurately determines the correlation between the input and the measured output of whatever quantity an instrument is measuring under specified conditions. This subsequently means that results are quickly and simply documented, which is particularly important for companies complying with ISO 9001 standards – the ultimate global benchmark for quality management – since it ensures that the equipment is working within its correct specifications. However, in practice, the question more frequently posed is how often should a recalibration actually be carried out and who is responsible?

DETERMINING CALIBRATION INTERVALS

In general, the operator or his supervisor are responsible for determining the calibration interval. With regards to intervals, if internal specifications for recalibrations are available, e.g. in the quality management manual, then these will be the official source for recalibration schedules. For some applications, such specifications may also be present in general standards (e.g. ISO 376 for force measuring instruments of certification of vehicle exhaust gas emissions). For those measurements where the highest demands are placed on precisely known measuring properties, it must be noted that the calibration can only make valid statements at the time of implementation. Consequently, an extremely complicated process is required: a calibration must be implemented both before and after every important measurement.

If a more pragmatic view is followed in industrial practice, as explicitly recommended in ISO 10012, it is of course sensible to allow a greater number of measurements or a specific time interval between two calibrations. If the deviations measured during a calibration compared to the previous calibration lie within the metrological requirements, then the measurement results obtained with the measuring equipment are justifiable. If, however, the deviations are greater, then the question is whether measurements are only meaningful to a limited extent and should they be repeated? The decision on how long a calibration interval should be must therefore take into

PROCESS INDUSTRY INFORMER May 2015

consideration, how high the costs are, on the one hand, for more frequent calibration (including time lost) and, on the other hand, for possibly worthless measurement results, re-measurements, recall actions, etc. An important aspect here is also the probability for changes in the measuring properties that may result in significant deviations in calibration results between one calibration and the next. Qualitatively, it is easy to ascertain that certain conditions may require more frequent calibrations, e.g. such as high operating hour values (shift operation), extreme temperature conditions, long-term alternating load operations with transducers and dirt and moisture. However, to produce quantitative statements about the measuring equipment used with the help of manufacturer data would require comprehensive statistical data for each type of transducer or measurement electronics that is normally not available. The operator can instead obtain a very good idea, by continuously tracking the calibration results, of the long-term behaviour of the equipment that he uses under the operating conditions valid for the application. In other words, if a measuring amplifier is used in a test bench where the operating conditions are hard and the costs high, and measurement results are shown at a later stage to be untrustworthy, it may be sensible to implement a recalibration after six or even three months. If, however, it is clear after the first or second recalibration, that the measuring properties remain stable, it is then probable that the measuring amplifier will also remain stable and one can then decide to lengthen the calibration interval. Such a procedure for determining under which conditions the calibration interval can be lengthened should be a part of the QM system. Equally it should also handle the shortening of calibration intervals, e.g. due to wear or drift behaviour. Comparison measurements of several calibrated test instruments among each other are another decision-making aid for adapting calibration intervals; for example, if a test laboratory uses several force transducers and has the equipment needed for comparison measurements on hand. Such comparisons can show whether a calibration interval that, initially, may have been rather generously calculated should be shortened in an individual case. We should also mention that the significance of the operating conditions naturally means that a recalibration should be implemented in all cases where a measurement tool is subject to stresses that lie outside the intended use. These range from greater overloads, falling down and extreme temperature conditions to interventions in the equipment for repair purposes.

THE REAL SIGNIFICANCE OF CALIBRATION

Calibration defines the accuracy and quality of measurements recorded when using a piece of equipment. In short, without calibration, you do not have a recognised method of ensuring that equipment being used between tests is accurate. Over time, there is a tendency for results and accuracy to ‘drift’ particularly when using certain technologies or measuring specific parameters, such as temperature and humidity. With this in mind, to be confident in the results being measured, there is an ongoing need to service and maintain the calibration of equipment throughout its lifetime, to ensure reliable, accurate and repeatable measurements.

FEATURE

LATEST CERAMIC PRESSURE T MEASUREMEN

When process protection and reliability are paramount for pressure applications, there is a wide choice of sensor materials and styles for pressure transmitters. For flush mounted installations, oil filled pressure cells are frequently the first choice, sometimes they are integrated into the sensor and most often they are used in conjunction with capillary’s and ‘chemical seals’. They are adaptable, well engineered and plentiful in supply. However, using a dry, oil free ceramic cell is now a real alternative for a wide range of measurements, offering major benefits to users. The ceramic substrate technology is now widely used by a wide number of pressure sensor manufacturers. As well as improved performance, excellent accuracy, linearity and process hygiene, dry ceramic cells are generally far more robust than traditional ‘oil-filled’ pressure systems. One of the main issues is that oil-filled transmitter membranes/ diaphragms on a pressure sensor are necessarily very delicate by design to transmit the pressure, which means they can be easily damaged or compromised. Careful consideration must also be given to the type of fill-oil used for the application, there are many variants, all designed to minimise any contamination should they rupture, but of course, most end users would rather not risk this occurrence at all! To accommodate the various types of oil fills that are needed on a typical plant and processes, often, multiple oil filled types need to be carried as spares. In many cases, one type of ceramic sensor can be an ‘all rounder’ across site, but still be the optimum choice for each application. They have shown can operate much longer in process conditions where traditional filled pressure cells will require regular recalibration, or even replacement on a routine basis.

WHAT ARE ‘CERAMIC’ PRESSURE SENSORS, ARE THEY ALL THE SAME ?

The ceramic substrate material is a basically a sintered product, a highly compressed powder with a ‘binding material’. The ceramic itself is extremely durable and hard, based on Aluminium Oxide - a substance used for many applications in industry. But not all ceramics are structurally the same, the finer and purer ceramic materials produce the highest performance. The best materials are Sapphire Ceramic based – because its very uniform, a dense crystal design provides excellent mechanical strength, corrosion resistance and reliable long term stability. In these materials, the characteristic surface finish is also very smooth at <0.7 m Ra, also making it suitable for use in the most demanding of hygienic applications, including those regulated by FDA and other pharma’ requirements. Some part ceramic designs use piezo-resistive circuits glued to a ceramic wafer. This article looks at the ‘all ceramic’ measuring cell, which is formed of a main ceramic body ‘block’ and a thinner front process diaphragm. The front diaphragm is glued/welded to the main body around its edge, gold plated electrodes measure the tiny deflection of the diaphragm as the pressure changes, most often using a capacitive technique, again some use the piezo-resistive system. (see Fig 1) Ceramic is attractive as a material as it is extremely predictable in behaviour, stable and very hard wearing. The main body will typically have ASIC chip(s) mounted at the rear, which will optimise performance and accuracy, along with a temperature sensor to compensate for changes in the process temperature and thermal expansion. As a mark of the stability, low nominal range cells as low as 25mBar, with a 20:1 turndown are now available. Fig. 1 - How a gauge ceramic capacitive dry cell works: ceramic diaphragm is deflected and measured by capacitive circuits. Pp = Process pressure + barometric, Pv= barometric breather to rear acts toLatest ceramic pressure transmitters offer real measurement benefits

SELF MONITORING

Some ceramic cells can have self-monitoring right through to the diaphragm surface

itself. This is done via a ‘reference’ electrode inside the measuring cell, it is achieved via a comparator with a known relationship versus the actual ‘measurement’. Any misalignment in expected performance is reported, this enables the smallest of defects to be detected if the ceramic diaphragm doesn’t behave/flex in its expected way (see fig 2). This means potential issues can be anticipated, rather than just ‘failure’. With oil filled systems, self monitoring, to this degree it isn’t possible.

Fig. 2 - Cm Measured value Cr = Reference value The measuring cell can self monitor its performance right to the diaphragm face itself

OVERLOAD, PULSATION AND VACUUM RESISTANCE

Most dry ceramic cells have high overload resistance, with an integrated overload bearing design. The highest overload is now up to 200 times the nominal measuring range in latest designs, in these the diaphragm, once in ‘overload’ will ‘press or seat’ against the rear main body of the sensor, there it cannot deform or drift and unlike other materials. It doesn’t have a yield point like metal, where in this range, irreversible damage occurs. Ceramic doesn’t age, fatigue or stress harden either, so it doesn’t react to pressure pulsation or shocks, which can permanently cause drift or damage many other metallic pressure element types. Ceramic has real benefits when it comes to high vacuum conditions, oil filled cells and seals can ‘degas’, this creates an air bubble behind the diaphragm, as the gas is ‘compressible’ it causes drift, and this error can go unnoticed by the user until the next calibration check, with a dry ceramic cell, this situation cannot occur. If the diaphragm membrane ruptures in an oil filled cell, the process will be contaminated by the fill oil, however compatible with the process, its always preferable to avoid it! Sometimes the pressure measurement may still continue; the leakage and the consequential product contamination may not be detected for some time. A dry ceramic cell with comprehensive diagnostic monitoring means neither a fluid-based process contamination event, or an undetected failure, can occur.

CHEMICAL RESISTANCE

Ceramic as a substance is of course resistant to many chemicals, the finer, higher purity ceramics offer the best all round resistance of all, although some care has to be taken with some alkalis and acids. A competent supplier will offer comprehensive resistance lists and advice on this. In general, with the right elastomer seal e.g. Kalrez®, they can be fully process compatible with some fairly aggressive and corrosive media. Some combinations can even have all ceramic/ polymer based mountings, threads and flanges (see figure 3), providing all non metallic wetted parts, for excellent resistance to aggressive process environments e.g. sea water, which will readily corrode many standard metals. These options mean ceramic cells can save costs over large flanged oil filled chemical and transmitter with a PVDF threaded capillary seals, using special and often expensive coatings or alloys. Fig. 3 - A pressure metals. These options mean ceramic cells can save costs over large flanged oil filled chemical and transmitter with a PVDF threaded capillary seals, using special and often expensive coatings or alloys.

CONDENSATION RESISTANCE

The majority of measurements are ‘gauge’ pressure, they have to be referenced and breathe to atmosphere/air. A gauge pressure dry cell will always have the ability to ‘ingress moisture from the environment around it. The air will inevitably have moisture in it and, in humid areas (which encourage moisture formation on

PROCESS INDUSTRY INFORMER May 2015

TRANSMITTERS OFFER REAL NT BENEFITS

By Doug Anderson – UK Marketing Manager, VEGA Controls Ltd

any temperature differentiated surface - even inside the sensor) microscopic droplets can even form on the sensitive electronics of any measuring cell, thus causing micro short circuits resulting in drift or an offset. This can materialise in days, weeks or months and, even if ‘dried out’ - the sensor is never the same. It can occur many months or years after a new plant is commissioned, then suddenly sensors can start to ‘misbehave’. Time and production is lost removing, exchanging, recalibrating and replacing sensors. Special Gore-Tex® style membranes and filters are mainly used to keep this at bay, but its still not always successful in the long run – humid air finds a way inside. To counter this, a new extra measure has been introduced to protect against this. Using an ‘insulating’ coating on the inside surfaces of the cell, protects the sensitive gold measuring elements against moisture and the microscopic droplets causing the ‘short circuits’ and drift thus delivering long-term reliability, even in the most humid of environments.

match the process. If this isn’t correct, the elastomer will expand, deform and leak. How this sealing is done varies, the majority of cells use the means of pressing the measuring cell outwards against a circular seal around the outer edge of the diaphragm against a lip slightly smaller in diameter, this compresses and forms the seal (See fig 5). It means the ceramic face can never be truly flush on the sensor, it will have a slight recess. The designs with ‘truly flush’ ceramic diaphragms perform best, as there are no elastomers exposed to abrasive scouring or contamination by sharp particles, as well as virtually ‘nil’ product retention in the fitting. A design uses glass welding that keeps both the pressure and chemical integrity of the cell intact, thus enabling sealing on the side to produce a fully flush face (see fig6, 7 & 8). This is very important for industries where absolute flush mounting is needed, with minimal product retention for hygiene or reduced cross process contamination in products such as foods, pharmaceuticals and paper stock.

TEMPERATURE PERFORMANCE

Higher specification ceramic cells can handle direct process temperatures up to 150°C, this is not limited by the ceramic itself, but the electronic components. Temperature measurement iextremely important for any pressure sensor and especially for ceramic designs. The compensation for the coefficient of expansion is crucial - as the temperature changes, so the materials expand, with direct effects on the minute deflection of the diaphragm. On most measuring cells, temperature is monitored behind on the main sensor body, so there is inevitably a lag behind the process temperature. This lag, and particularly the reaction of the ceramic to sudden temperature changes, means they will have an incorrect reading for a period of time, especially on applications directly against the process (e.g. flush diaphragm). This time period depends on the speed and size of temperature change and the mounting configuration, as the recovery depends largely on how long it takes the sensor to reach equilibrium with the process temperature to stabilise. However, an innovative new design seeks to improve this with a temperature circuit mounted directly onto the rear of the diaphragm, (see fig 3) and this also means that temperature measurement can now be transmitted as an additional process measurement, reducing connections and costs. Fig. 4 - Cutaway showing a new design of temperature measurement circuit on the outer edge of a ceramic cell, which helps measure temperature change faster and provides accurate process temperature.

SEALING: ABRASION RESISTANCE

With an oil filled sensor, the metal diaphragm is welded to the connection body material, giving it excellent sealing integrity, but the thin metal diaphragms are also easily susceptible to damage. Ceramic materials are already well known for their abrasion and wear resistance, delivering the same benefit for pressure cells. A low range ceramic cell can be cleaned with a wire brush and a flush mounted unit resists build up and clogging and comfortably withstands abrasive particles in slurry or pulp, such as the fine metals found in raw paper stock for example. For example, Ceramic cells have been used in mining slurry pumps, lasting many times longer than metal cells in the same application, with no drift, recalibration or replacement required (see Fig 4). Fig. 5 - How tough is ceramic? Application on slurry: The metal body is worn away, yet the ceramic cell is still functioning, the side elastomer sealing design means it is also protected from this abnormally high wear.

FLUSH MOUNTING AND SEALING

Ceramic cells need an elastomer to seal it into the body of the sensor, and it is important to have the right elastomer to

PROCESS INDUSTRY INFORMER May 2015

Fig. 6 - Traditional Flush ceramic – the radial seal in red creates a small ‘pocket’ and it is exposed to abrasion

Fig. 7 - ‘Truly Flush’ sensor side sealing on ceramic protects against abrasion, no pocket Fig. 8 - Truly Flush sensor: Side ‘form’ seal for hygienic applications, with no pocket

However in some chemical applications with highly toxic products, double sealing and a second line of defence is needed, the design in figure 5 is perfect for this – note the double sealing arrangement (red and black), as here a fully flush mounting is generally less important. This double sealing concept is used, sometimes along with a ‘second line of defence’ closer to the inside of the housing to avoid any risk of harmful process leaks into the environment.

SMALL FITTINGS

Generally on lower pressure ranges, especially on flush mounted tank level installations, most oil filled cells and chemical seals on DP transmitters need a minimum 3”/DN80 chemical seal diaphragm to deliver the resolution, linearity and accuracy of measurement needed. Flush mounting, dry ceramic cells are more sensitive and accurate as the materials are more stable, so they can be as small as ¾”/20mm, even on low ranges, which is ideal on smaller pipes and process vessels. These smaller connection sizes can reduce the cost and weight of process connections for vessel level measurement for example, as well as aiding cleaning via flush mountings (discussed previously) when its important for the user.

SUMMARY

Dry ceramic measuring cells avoid the risk of process and product contamination with fill fluid, but they also bring other advantages. The material is harder than steel with excellent overload, vacuum and pulsation resistance and it has the ability to resist the harshest abrasion. They lend themselves well to flush mounting to the process, but not all designs are the same and careful choice of elastomer and design to suit your process is important. Although temperature shock can be a particular issue for ceramic cells, the latest designs in this technology have an innovative temperature compensation system, which maintains stable measurement accuracy and reliability, whatever temperature swings the process delivers. The new ‘electronic DP’ systems, (see figure 9) some of which are also featuring the same ceramic technology too - remove the need for costly capillaries and have improved response and accuracy, even with temperature gradients. If you are looking for stable, accurate reliable pressure measurement with minimal recalibration and maintenance, then dry ceramic cell technology is worth consideration over more ‘traditional’ oil filled designs.

TEST & MEASUREMENT HBM INTRODUCES NEW MODULES TO ITS SomatXR DATA ACQUISITION SYSTEM HBM – a market leader in the field of test and measurement – is pleased to announce the arrival of the CX23-R data recorder and the EX23-R Ethernet switch, designed to make the SomatXR data acquisition system even more powerful and flexible. The SomatXR CX23-R data recorder with web interface provides direct access to measurement data without any software installation. This allows for convenient channel parameterisation, motoring of measurement tasks and visualisation of measured data to be conveniently and easily accessed off site. The EX23-R Ethernet Switch features 10GB Ethernet ports for connecting SomatXR measurement modules and other accessories, five of which are able to supply electrical power to external devices with Power-over-Ethernet (PoE). The EX23-R also supports the Precision Time Protocol (PTPv2), as defined by the IEEE-1588 standard, giving it an accuracy of less than one microsecond and guaranteeing a higher level of accuracy than standard Ethernet switches. Both the CX23R data recorder and the EX23-R Ethernet switch have an IP65/ IP67 degree of protection rating, meaning that they are both completely dustproof, protected against low-pressure water jets, and can be immersed in water up to 1m. In addition, they both operate at temperatures as low as -40°C and as high as +80°C and meet the vibration test requirements of the MIL-STD202G defence standard. Designed for agricultural and mining machines, summer and winter tests of road vehicles and for calculating measurements during road tests of construction, the SomatXR range from HBM offers some of the most rugged data acquisition products available on the market today. Featuring a modular and scalable design, other modules in the range include the MX1601B-R signal conditioning amplifier, MX1609KB-R thermocouple amplifier and the MX115-R strain gauge amplifier. For further information contact HBM Tel: +44 (0) 20 8515 6000 E-mail: info@uk.hbm.co.uk Web: www.hbm.com

NEW DRIVER FROM HBM OFFERS SIMPLE INTEGRATION

HBM OFFERS COMPACT & PRECISE AMPLIFIER SUITABLE FOR MANY DIFFERENT APPLICATIONS Now available from HBM – a market leader in the field of test and measurement – is the new eight channel universal MX840B DAQ amplifier, which supports the QuantumX data acquisition system and offers precision and adaptability to frequently varying measurement tasks. Like other models available from the QuantumX range, the MX840B features outstanding flexibility and offers excellent measurement performance and ease of use. Suitable for a wide range of different applications, its universal connectors make the MX840B ideally suited for all common sensor technologies, no matter what principles of measurement are required. The eight channels can all be individually configured and used to measure a wide range of mechanical, thermal, electrical and hydraulic quantities, such as force, strain, acceleration, torque, rotational speed, temperature, voltage, current, pressure and flow rate. The amplifier supports more than 15 different sensor and transducer types, for example half and full bridge circuits (strain gauge and inductive transducers), resistors, potentiometric, voltage, current, thermocouples, LVDT, Ohmic and rotary encoders. The amplifier also features an input for CANbus. In addition, the new module also supports current-fed piezoelectric transducers (IEPE/ICP) on each channel. Featuring a sampling rate of 40 kS/s and a signal bandwidth of 7 kHz, the new MX840B is ideal for measuring and analysing electrical vibrations, mechanical vibrations and noises in the time, frequency and angle domain. As with other QuantumX modules, the new MX840B can also be distributed up to 100m and used synchronously, using Ethernet and PTP, enabling it to be integrated easily into networks. Designed to complement the QuantumX amplifier system and featuring outstanding versatility, additional features of the MX840B include Advanced Plug and Measure (APM), which enables TEDS transducers and sensors to configure the channel automatically, minimising set up times and increasing efficiency and reliability. In addition to MX840B, other modules from the HBM universal range of data acquisition system include the MX440B and MX410B. Also available from HBM is a wide range of data acquisition system modules for special measurement tasks, gateways and transmitters, data recorders and accessories. For further information contact HBM Tel: +44 (0) 20 8515 6000 E-mail: info@uk.hbm.co.uk Web: www.hbm.com

Now available from HBM – a market leader in the field of test and measurement – is the LabVIEW Driver, which for the first time allows HBM’s QuantumX, SomatXR, PMX and MGCplus data acquisition systems to be conveniently integrated into LabVIEW measurement and control system design software. The new Driver simplifies instrument control and reduces test programme development time, meaning data from multiple devices and channels can now be acquired with only eight Virtual Instruments (VIs). These VIs come complete with ready-made user interfaces for device scan and channel selection, which help make this software extremely suitable for users. Designed to suit all levels of programming knowledge, HBM has supplied detailed examples and documentation on the new Driver, as well as a video on how to use LabVIEW with HBM Data Acquisition Systems, to ensure users are quickly and simply guided to the desired measurement results. Customers using different data acquisition systems from HBM can also save time, as general commands such as device scan, channel selection and measurement are the same for all systems, so that no re-programming of these components is required when changing over to the new hardware. Device specific LabVIEW Drivers are also available from HBM, including the QuantumX CANape Driver which, when integrated with QuantumX data acquisition, allows users to record high-speed signals from external sensors with measurement rates of up to 96,000. For more information contact HBM Tel: +44 (0) 20 8515 6000 E-mail:info@uk.hbm.co.uk Web: www.hbm.com

PROCESS INDUSTRY INFORMER May 2015

TEST & MEASUREMENT NEW HBM SENSOR LAUNCHES A NEW SOLUTION FOR DYNAMIC WEIGHING HBM – a market leader in the field of test and measurement – is pleased to announce the new FIT7A Digital Load Cell, specifically designed to meet the needs of demanding requirements of weighing in modern manufacturing lines. Suitable for use in a very wide range of production environments which require dynamic weighing, sorting, filling and dosing, the robust FIT7A load cell offers manufacturers high precision and processing speed. Based on the very latest HBM strain gauge technology, the innovative new sensor features class C4 accuracy per OIML R60 and a maximum scale division Y of up to 25,000 and addresses the problem of bottlenecks, which can often slow down production rates. In comparison to existing sensors which are only able to handle up to 100 weighings per minute, sophisticated new technology incorporated within the FIT7A means that it is now possible to perform 180 weighings per minute, therefore dramatically increasing production speed and reducing costs. Even with such increased rates, accuracy remains key with the FIT7A. The FIT7A offers increased precision and can perform accurate measurements under temperature fluctuations and in dynamic applications which means load cells can be installed on multiple production machines in a variety of production environments. More economical than existing sensors, which are based on Electromagnetic Force Compensation (EFC), the new FIT7A from HBM is expanding the market for machine manufacturers by enabling them to develop completely new machine types and new market segments. This is particularly important for sensitive markets with a necessity for precision and a growing need to achieve the lowest possible overfilling in product packaging. Compatible with corresponding HBM software PanelX, which combines support for the configuration process with an intuitive user interface, HBM also provide a downloadable free professional software package, AEDPanel 32: version 3, to provide diagnosis and analysis of measurement data, as well as debugging and bug-fixing. For more information contact HBM United Kingdom Ltd Tel: 0208 515 6000 E-mail – info@hbm.com Web – www.hbm.com.

HBM GO ABOVE AND BEYOND THE STANDARD WITH LOAD CELL RANGE Following recent changes to the European ATEX Directive 94/9/ EC, HBM – a market leader in the field of test and measurement – is pleased to announce that nearly all standard load cells are now available for various zone areas. The ATEX Directive 94/9/EC outlines the requirements suppliers must meet to achieve compliance for their equipment and protective systems for use in hazardous areas. It applies to both electrical and mechanical equipment and covers potentially explosive areas below ground, on the surface and on offshore fixed facilities. Under the ATEX regulations, hazardous areas are now divided into ‘zones’ relating to the likelihood of an explosive atmosphere existing. Almost all standard load cells from HBM cover device groups I (for mining) and II (non mining) and are suitable for use in categories 1, 2 and 3, corresponding to zones 0, 1, 2 ,20, 21 and 22. The range of C16 load cells from HBM is also certified to T6, meaning it meets the most stringent of temperature requirements. As with other ranges available from HBM, the C16 series of load cells has also been awarded with the IECEx Certificate of Conformity, which covers equipment for use in explosive atmospheres. This means that export outside the EU is possible. Historically strain gauge load cells were often treated as non-energy storing devices or ‘simple apparatus’ and use of such products in some hazardous area applications was accepted provided they were used with recognised zener barrier systems. Due to this new legislation and a growing focus on liability and accountability, users of weighing systems in hazardous areas now insist on ATEX certified load cells, such as a range of standard load cells now available from HBM. For further information contact HBM Tel: +44 (0) 20 8515 6000 Email: info@uk.hbm.co.uk Web: www.hbm.com

HBM PROVIDES PRECISE MEASUREMENTS IN TOUGH CONDITIONS

As more and more applications in harsh environments require powerful force transducers, which feature a high resistance to external influences, HBM – a market leader in the field of test and measurement – is pleased to announce it has expanded its range of IP68 rated products to meet this need. The new Stainless Steel C10 Force Sensor provides maximum precision in compressive force measurement, for even the most demanding of environments. The new sensor offers 75 ppm and presents excellent linearity and hysteresis values. The sensors accuracy classes, which are between 0.03 and 0.06, depending on the nominal force which ranges from 2.5 kN to 1 MN, can be freely configured according to the application with a variety of options. The sensor’s core is optimally protected from external influences such as dirt and moisture in a Stainless Steel measuring body which comes complete with an optional integrated cable to achieve IP68 rating. The U10M range of transducers from HBM also features the option of an integrated cable to achieve this high level of protection. Providing excellent accuracy, the U10M is currently the only flat shaped force sensor on the market to achieve IP68 protection. Suitable for use in ambient conditions, the U10M range from HBM can measure nominal (rated) forces from 1.25 kN to 500 kN. Also achieving the equivalent level of protection under the same conditions is the S9M Force Transducer from HBM. Featuring an accuracy class of up to 0.02 for nominal (rated) forces between 500 N and 50 kN, the S9M provides clear and precise measurement results. Suitable for use in multiple applications in experimental stress analysis, OEM applications or test equipment, the S9M complements the wide range of force transducers now available from HBM. In addition to IP68 rated products, HBM also provide a full range of force sensors and transducers to measure static and dynamic tensile and compressive loads – with virtually no displacement. For more information contact HBM United Kingdom Ltd Tel: 0208 515 6000 / E-mail – info@hbm.com / Web – www.hbm.com.

PROCESS INDUSTRY INFORMER May 2015

FEATURE

MAKE ESOS EASY

By Darryl Mattocks, Managing Director, Enistic

Recent statistics have indicated that nearly three quarters of businesses (73%) have not started their mandatory energy audits to comply with the new ESOS legislation by the deadline of 5 December 2015. The new rules apply to all ‘large organisations’ in the UK and will include many in the processing industry. So, does this apply to you? And, are you ready? I have put together a quick guide to all you need to know about ESOS compliance – see the boxed panel. If you haven’t made a start, I strongly urge you not to delay a moment longer. With fewer than 500 lead assessors available for the 10,000 plus organisations which need to comply with ESOS, I have real concerns over the pressure on supply. Leave it too late, and you might not be able to find a lead assessor to work with you. And the holiday season is upon us. The same survey, by Energy Live News, reported that 52% of organisations are citing lack of time and resources as the biggest barrier and 27% admitting identifying and collating data as the main challenge to complying with the scheme. My advice is to get advice from a company that specialises in ESOS compliance. For example we operate a ‘one stop shop’ to guaranteed ESOS compliance for a fixed price. We are offering a free scoping meeting without obligation. If you would like to take advantage of this offer, please contact the team on 0844 875 1600 or email info@enistic.com or see www.enistic.com

- Compliance method(s) used to cover each area of significant energy consumption - Cost-effective energy savings opportunities identified along with a Return on Investment and Life Cycle Cost Analysis - Certifications for alternative compliance routes - Details of any areas where you are not fully compliant with the rules

WHAT IS THE BEST APPROACH?

The two most common approaches to ESOS compliance are: - Undertaking ESOS audits and producing an evidence pack to be signed off by a lead assessor or - ISO 50001 certification for the whole of the organisation which will count as compliance. Below I have outlined the pros and cons for each so you can decide which approach is likely to work best for your establishment.

AN EASY GUIDE TO ESOS

The Energy Savings Opportunity Scheme Regulations 2014 (ESOS Regulations) were introduced in 2014 to promote energy efficiency. According to government figures, organisations could save £1.9 billion on energy bills a year. Enistic’s monitoring and targeting campaigns typically identify energy savings averaging 28% but in some cases of as much as 45% or more. The scheme is being administered by the Environment Agency.

DOES ESOS APPLY TO YOU?

Large enterprises need to conduct mandatory energy audits every 4 years. This covers: - All organisations with over 250 members of staff. - Or turnover of over 50 million Euros (£38,937,777) and an annual balance sheet total in excess of 43 million euro (£33,486,489).

WHAT DO YOU HAVE TO DO?

If your company falls within the scope of the Regulations, you need to: - Monitor and report your energy use across 90% of your site by 5 December. - Appoint a ‘Lead Energy Assessor’. You can find a list of registered Lead Assessors at https://www.gov.uk/energy-savings-opportunity-schemeesos#approved The Lead Assessor will conduct an ESOS Assessment to: - Measure your total energy consumption for buildings, industrial processes and transport over at least a 12 month period. This assessment period must include 31st December 2014. - Identify areas of significant energy consumption, accounting for at least 90% of your total energy consumption. - Identify practical, cost-effective energy efficiency recommendations for areas of significant energy consumption (based on a life-cycle cost and effectiveness analysis) - Have the ESOS Assessment reviewed and approved by a Board-level Director, or where no Directors exist and approved by a Lead Energy Assessor. - Report compliance to the Environment Agency by 5 December 2015.

THE ESOS EVIDENCE PACK

You need to compile and keep an evidence pack for your report to the Environment Agency. This should include details of: - The structure of your organisation - The Board level Director(s), or equivalent who have taken the lead on signing off compliance with ESOS - Your Lead Assessor and registration of approval - The calculation of total energy consumption - Areas of significant energy consumption listed

HOW LONG DOES IT TAKE?

On average compliance takes between 2 – 4 months from the first scoping meeting to submission.

THE BENEFITS

The monitoring and targeting systems implemented for ESOS compliance will highlight key areas for saving energy. As a result, the benefit from energy efficiency and cost savings can be considerable. The ESOS assessment will: - Identify energy saving opportunities with a pay-back period - Analyse life cycle costs to determine effectiveness - Provide clear energy improvement project costs along with estimated energy There is no obligation to implement these energy savings opportunities.

HOW MUCH DOES IT COST?

Prices for compliance can range from £3,000 – £20,000+. Each organisation is different, which is why we take a tailored approach.

WHAT HAPPENS IF YOU MISS THE DEADLINE?

You could be fined up to £50,000 plus extra charges of £500 per day (for up to 80 days) There is more details guidance on the ESOS scheme and compliance at https://www.gov.uk/energy-savings-opportunity-scheme-esos

PROCESS INDUSTRY INFORMER May 2015

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Protecting Your Plant Before Things Start To Go Wrong AE2000 Heavy Duty

NEED PROCESS COOLING?

Motion Sensors for Every Industry Standard Units

Bespoke Units

End of shaft mounted

Tailored to suit individual requirements

Speed

Chillers · Dry Coolers Cooling Towers · Chilled Air

Safety

Vibration Speed Relay

Belt driven

Rotation Interlocking

UK distributor for the new JACIR TOPAZ “Dry Cooler on Steroids”

Rotech End of shaft or belt driven units are used for monitoring of: •Distance/Direction •Stop/Slip •Rotation Control •Underspeed/Overspeed •Belt Weighers •Interlocking/Sequencing

PROCESS COOLING

Protects:

• Conveyors • Crushers • Valves & Pumps • Bucket Elevators •And many more!

Proven track history of Reliable and extremely high Quality products with hundreds of Simply Choose R TECH FOR RELIABILITY! Applications worldwide Less? Why Accept Anything

0845 057 3097 appliedthermodynamics.co.uk

Web: rotechsystems.co.uk Tel: +44 (0)151 356 2322

Monitoring Solutions

TRAINING

VACUUM CONVEYING

WATER ANALYSERS

WEIGHING SOLUTIONS

Water Analysis Equipment & Reagents

UNIT 30, WALKERS ROAD, NORTH MOONS MOAT INDUSTRIAL ESTATE, REDDITCH, WORCS. B98 9HE TEL.: 01527 590300 FAX: 01527 590310 EMAIL: sales@preciamolen.co.uk web: preciamolen.com

01980 664800

VACUUM PUMP TECHNOLOGY

VALVE SOLUTIONS

TO ADVERTISE HERE EMAIL INFO@PIIMAG.COM OR CALL 01428 751188

lovibondwater.com