Process Industry Informer Magazine May 2013 Edition by Process Industry Informer

PROCESS INDUSTRY INFORMER.

MAY 2013 Volume 9 No. 3

THE UK’S BIGGEST PUBLICATION SERVING THE PROCESS INDUSTRIES

Introducing the NEW www.piimag.com and the latest release of Process 118 - Working in unison to bring you news and suppliers faster than ever before

In this issue... • TOTAL Preview • BPMA News • 8 Features • Over 60 news items

Discover 3 alternative ways to reduce, save and control energy costs, see why vibration monitoring gets cool, we measure up if Automation System success really is down to cost and schedule, ask if your lubricant makes the grade and find out if your control instrumentation is smart enough.

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

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Contents BPMA News

editorial features

News & Events 4-5

Manufacturers Association

Applications 8-10

Fluids & Liquids Handling inc. Pumps & Valves 37-41

from The British Pump

23-34

Process Lubrication 11 Automation System Project Implementation 13 & 14/15 Optimise with Field-Based Intelligence 19

Heat Transfer & Energy 10

Tank Cleaning 42

Approved Pressure Sensors 22 PUMP Protection 36

Electrical Connections 12

Filtration & Separation 49

Real-time Condition Monitoring for O & G 12

Compressed Air Solutions 49

PUMP Efficiency 40 Steam Trap monitoring using Wireless Technology 44/45 Tailored Drive Solutions 47

Instrumentation 17-18

Analysers 50

Network & Communications 21

TOTAL Processing & Packaging Show - Preview 51-54

Drive Solutions 21

Suppliers Directory OBC

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

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

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

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

News & Events SIMPLE ONLINE ORDERING FROM ENDRESS+HAUSER Electronic purchasing provides the opportunity to optimise your business processes, significantly reducing the time spent in sourcing and purchasing products. Now Endress+Hauser’s complete product portfolio is available to purchase via our Online Shop. Whether your role is purchasing, engineering, maintenance or stores, the Online Shop gives you instant access to the information you need as well as enabling you to buy new instruments or spares at the click of a mouse. Endress+Hauser ’s Online Shop allows you to download technical information, operating instructions and certificates, easily identify spare parts, check product availability and view suggested replacements as well as compare products side-by-side for accurate product selection. In companies where access to online browsers is prohibited, we can provide a tailored solution that can be integrated into your existing procurement process. For more information contact Endress + Hauser, Floats Road, Manchester Tel: 0161 286 5000 Web: www.uk.endress.com/online-shop

ABB appoints UK service manager for oil, gas and petrochemical business Power and automation technologies leader, ABB, has appointed Troy Stewart as head of service for its oil, gas and petrochemical business in the UK and Caspian regions. The role sees Troy leading ABB’s service operations in the UK and Caspian, with a combined team of over 100 personnel. “It is a rapidly expanding and growing market that requires increasing service levels to meet customer demands now and future,” says Troy. “While we are seeing continuing demand for traditional healthcare services, operators are looking to companies such as ABB to provide advanced services such as alarm management, advanced control and remote operations.” The growth in the market is primarily from ABB’s installed base as its customers strive to maximise production by updating or modifying their automation systems while ensuring optimum safety requirements are met. For more information contact ABB Ltd, St Neots, Cambs. Tel: 01480 475 321 Fax: 01480 488 283 E-mail: oilandgas@gb.abb.com Web: www.abb.com/oilandgas

Sponsored by

BOOTH WELSH DEPLOYS WIRELESS MONITORING SYSTEM Ayrshire-based engineering services business Booth Welsh has developed a wireless monitoring system for the industrial process sectors following a collaboration project with Glasgow Caledonian University. The two-year development project was delivered under the Knowledge Transfer Partnerships (KTP) programme, a scheme led by the Technology Strategy Board, the UK’s innovation agency, and co-funded by the Research Councils and the Scottish Government. The programme is widely recognised as Europe’s leading knowledge transfer scheme and is focused on supporting business innovation in collaboration with the UK’s knowledge base. The project allowed the University to impart its theoretical expertise in wireless technology, whilst Booth Welsh utilised its gained knowledge and technical understanding of process control to develop a wireless instrumentation monitoring system for a pneumatic conveying line within the university’s research labs. The conveying line is used in University research projects to analyse the resistance effects of varying types of particles through common process lines. The wireless system was tested against the existing wired solution and is now being used to develop new research in the fields of wireless control and faster monitoring of various forms of conveyed materials. Booth Welsh managing director Martin Welsh said that Booth Welsh is now deploying the wireless technology with clients across the oil and gas, whisky, pharmaceutical, nuclear, petrochemical and chemical, utilities and food and beverage industries. He added: “At Booth Welsh we are continually exploring opportunities to enhance our expertise and drive improved efficiencies back to our customers. For more information contact Booth Welsh Automation, Stevenston, Ayrshire. Tel: 01294 605123 E-mail: sales@boothwelsh.co.uk Web: www.boothwelsh.co.uk

CKF Systems - an ABB authorised value provider Independent automation and robotics specialist, CKF Systems Ltd, is one of just three companies in the UK to receive the accolade of ‘Authorised Value Provider’ from ABB, one of the world’s leading engineering companies. The appointment is in recognition Kevin Staines (right), of CKF’s success in delivering Sales Director, CKF Systems integrated robotic solutions with Alan Spreckley, Channel to the food industry that Development Manager, improve efficiencies and long ABB Limited term sustainability. As more and more manufacturers turn to automation to secure a competitive advantage, CKF recently delivered its 35th solution utilising ABB robots across a range of picking, packing and palletising applications from 3kg to 250kg capacity. “We are delighted that a company of ABB’s stature should recognise our work in this way,” enthuses Kevin Staines, Sales Director, CKF Systems. “ABB has an outstanding record of achievement in the field of robotics and our customers rely upon us to work with exceptional products and software, backed by the highest standards of service and training.” “We value the important role that CKF plays in delivering integrated robotic solutions to the food industry,” says Alan Spreckley, Channel Development Manager, ABB Limited, “From computer simulation of the robot movements through to programming and commissioning, CKF is a totally self sufficient business underpinned by a commitment to provide the best possible solution to any challenge. ABB recognises the expertise of CKF across all areas of automation, including project management, design engineering, controls and system integration.”

The Badger Meter RECO range of process valves provide precise and reliable control however tough the application. ● Cv down to 0.0000018. ● Cryogenic and Bellows Sealed versions for hazardous applications. ● Wide selection of materials ie; stainless steel, titanium, Hastelloy C.

For more information contact CKF Systems Ltd, Gloucester. Tel: 01452 424565 E-mail: Kevin.Staines@ckf.co.uk or visit the website www.ckf.co.uk

Process Industry Informer May 2013

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Process Industry Informer May 2013

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News and suppliers for engineers on the go Process Industry Informer May 2013

applications

Association of ‘Spiroflow’ aero mechanical conveyor Austrian Cement handling some difficult materials at Robert Industry chooses McBride Ltd, Middleton, Manchester Morphologi g3-id particle imaging system to extend research capabilities The Association of the Austrian Cement Industry (VÖZ) (Vienna, Austria), a partner organization for the Austrian building and construction industry, is using the Morphologi G3-ID from Malvern Instruments to gain new insight in work involving the characterization of cement and other construction materials. The Morphologi G3-ID is an advanced particle characterization system that combines automated static imaging with chemical identification of individual particles using Raman spectroscopy. Currently at an early stage in its work, the Association is leading the way in applying the Morphologi G3-ID to the analysis of the various components of cement.

“The Morphologi G3-ID is an excellent tool for the characterization of size and morphological form, with the added advantage of enabling chemical identification of the species present,” said Dr Ameneh Schneider at the Association of the Austrian Cement Industry. “Although we are only just beginning to explore its potential we believe that the added insight it brings will significantly enhance our research. The Morphologi G3-ID has proven straightforward and easy to use and we’ve already been successful in expanding our application of it into areas beyond construction materials, testing food samples for example. This makes the system a valuable addition to our overall contract research capability.” The capability of the Morphologi G3-ID to analyze and characterize specific particle populations within a diverse dispersion brings new insight for conventional cement manufacture. For more information on the research capabilities of the association of the Austrian Cement industry contact Dr Ameneh Schneider at Schneider@smartminerals.at Malvern, Malvern Instruments and Morphologi are registered trademarks of Malvern Instruments Ltd For more information contact Malvern Instruments Ltd, Malvern, Worcs. Tel: +44 (0) 1684 892456 Fax: +44 (0) 1684 892789 E-mail: salesinfo@malvern.com Web: http://www.malvern.com/labeng/products/ morphologi/raman.htm

Spiroflow have supplied one of their Aero-Mechanical Conveyors (AMC) to Robert McBride Ltd to assist them in improving production efficiency, safety and reduce manual handing of 25kg sacks of products such as Butylated Hydroxy Toluene and Urea Microprills at their site in Middleton, Manchester. Robert McBride is Europe’s leading provider of Private Label Household and Personal Care products; they develop, produce and sell these products to leading retailers throughout Europe and beyond. Although AMC Discharging Into private label is their core Dissolving Tank business McBride’s also have a growing portfolio of their own brands, such as Oven Pride, Surcare, LimeLite and Clean and Fresh. As part of the efficiency improvements at the Middleton plant, McBrides recognised an opportunity to eliminate the manual loading of the chemicals used in the manufacture of de-scaling gel into a dissolving tank that, previously, involved the carrying of sacks up two flights of stairs to a mezzanine floor. Phil Moss, Project Engineer at McBride’s confirms, “We contacted Spiroflow because we had worked with them on previous projects and we know the level of service we can expect from them.” The additives are introduced into the dissolving tank via a sack tip station. At the outlet of the sack tip hopper is a short ‘Spiroflow’ Flexible Screw Conveyor which meters the additives in to a 7 metre ‘Spiroflow’ AMC operating at an angle of 80 degrees. The loading of the tank takes approximately one hour during which 3 tonnes of materials are conveyed.

Phil continued “Given the job specifics, ‘Spiroflow’ invited us to their test facility in Clitheroe, Lancashire and recommended an AeroMechanical Conveyor fed by a Flexible Screw Conveyor in order to regulate flow, it’s like mixing wallpaper paste so, regulating flow is paramount to prevent undesired agglomerates.” The AMC was installed by McBrides’ Engineers in November 2011 ready for Spiroflows commissioning engineer to check the Sack Tip Station installation before starting With Dust Hood and testing the equipment. This was carried out with the assistance of Phil Moss and his team. Following the testing and trials, full training was given to all operatives and the engineering maintenance team, culminating in the handover and acceptance certificates being completed. Phil Moss, went on to say “Overall I’m extremely happy with the performance of the ‘Spiroflow’ Aero-Mechanical Conveyor and Flexible Screw Conveyor, they do exactly the job we want them to do and have improved the efficiency and safety of the job at hand”. To learn all about Robert McBride, their products and services, visit their website at www.mcbride.co.uk

To learn more about ‘Spiroflow’ Aero-Mechanical Conveyors, and their ranges of Drag Conveyors, Flexible Screw Conveyors, Pneumatic Conveyors and Vacuum Conveyors and also about their Big Bag Fillers and Big Bag Dischargers too, visit their web site at www.spiroflow.com or call them on +44 (0)1200 422525 to discuss your specific requirements.

T CARDS ONLINE MANAGES PERFECT SAFETY RECORD After initially considering a conventional wall mounted T Cards system for monitoring and tracking health and safety services provided to an ever increasing client base, Ray Smith, Managing Director of RSP Safety spoke with Philip Heine of T Cards Direct and was convinced of the tremendous benefits to be gained by opting for the T CARDS OnLine system. “The system has been live now for a number of months and I am delighted with the systems flexibility, it has enabled us to improve significantly the way we monitor and track client status”. The system gives RSP Safety an immediate overview of client status, identifying work in progress, flagging contract renewal dates, helps pre-plan and schedule client visits, factors that the business can easily manage its work flow and safety consultants work allocations each month. The company has also decided that the online system can improve managing its business development programme. The basis of the online system is that a t-card is moved across a pre-set grid, normally from left to right, placement in a specific column cell indicates either a call to action or completion. The T Cards Direct system gives immediate at-a-glance workflow status for improved management control and work allocation. For more information contact T Cards Direct, West Malling, Kent Tel: 01732 871417 Fax: 01732 840470 E-mail: sales@tcardsdirect.com Web: www.tcardsdirect.com

Process Industry Informer May 2013

Pharmacy made simple. Life is complicated enough. So make it simpler - with the new solutions for process automation from B端rkert designed with the needs of the pharmaceutical industry in mind. Featuring a hygienic design, easy cleaning and simple operation, they can also be sterilised and validated. A complex automation task can therefore become simplicity itself in a matter of seconds. Perfect for high process yields and your peace of mind. ELEMENT process valves: A highlight in our system. They simply keep everything under control. We make ideas flow. Please call +44 (0)1285 648 720, email sales.uk@burkert.com or visit www.burkert.co.uk B端rkert experts will be on hand to provide free advice on all your process equipment needs at the Total Processing & Packaging show. Please visit stand M50.

applications NOV MONO SOLVES SLUDGE TRANSER PROBLEM FOR GERMAN WASTEWATER PLANT The installation of an EZstrip™ TR Muncher® from NOV Mono has solved an ongoing maintenance problem at the Käranlage Jagersfreude WWT plant in Germany, and also helped minimise downtime and maintenance costs. An existing macerator had been experiencing frequent blockages due to the 8-12% dried solids and fibre content of the raw sludge it was handling. The process of repeated de-ragging was both time-consuming and expensive. The Mono EZstrip™ TR Muncher was designed specifically to provide efficient maceration in this type of application, as it features layback cutter shafts set at an angle to the incoming sludge flow. This makes it extremely effective in providing protection and minimising wear for equipment further along the process line. The complete drive, gearbox and cutter assembly can be removed from the Muncher’s casing, without disturbing the pipework “This makes any maintenance activities much quicker to complete and it also reduces the downtime and the associated costs,” explains Jagersfreude plant Abwassermeister, Ewald Stresser. “The Mono Muncher handles around 30m3/h of raw sludge and has worked very efficiently since it was installed.” For more details contact Nov Mono, Martin Street, Manchester Tel: +44 (0)161 339 9000 Web: www.mono-pumps.com

AJ & RG BARBER LTD CHOOSE AXIUM’S PURESCREEN FILTERS AJ & RG Barber Ltd, World Cheese Award winners and farmhouse cheese makers since the early 1800’s, is now using Axium Process’ Pure-Screen wedge wire filters exclusively throughout its operation for applications associated with softened water, whey protein concentrate, raw milk and curd fines. The company, which traditionally used mesh filters, changed to Axium’s 316L stainless steel wedge wire filter range as this versatile range of filters is easy to maintain and clean and is available with interchangeable screens providing filtration levels of 25 micron up to 6000 micron. As well as providing both product smoothness and consistency, the Pure-Screen filter range offers high security for critical applications where filter failure or collapse is not an option. The filters, which require no tools for access, are designed with a 316L stainless steel safety clamp closure, metal to metal seal, and are suitable for backflushing, clean-in-place and steam-in-place operations. “AJ & RG Barber is delighted with the performance of Axium’s filters”, says Julian Ing, Head of Engineering, “they have proved to be extremely reliable, robust, hygienic and simple to clean”. For more information contact Axium Process Ltd, Hendy, Swansea Tel: +44 (0) 1792 883 882 Fax: +44 (0) 1792 886 049 E-mail: info@axiumprocess.com Web: www.axiumprocess.com

Umicore increases production capacity and improve the quality of zinc oxide granules by replacing an existing centrifugal sieve with the Russell Finex Separator™ Umicore’s production site in Eijsden in the Netherlands is one of Europe’s largest zinc oxide production sites. A final step in the production process is the sieving of the zinc oxide granules. Umicore use the Russell Finex Separator™ to achieve the correct particle size and to remove the fine dust, making the final zinc oxide granules dust-free. Key benefits of the Russell Finex Separator™ with the Vibrasonic” Deblinding System Improves product quality, achieving accurate particle size and optimal fluid properties Increases productivity by doubling production capacity Safeguards health and safety of operators by minimizing exposure to dust fumes Production Manager Erwin Van Eester explains: “Zinc oxide is a powder which gets sticky easily because of the fine dust in the powder. By making the zinc oxide dust-free and granulating it into the right particle size, optimal fluid properties are obtained. When the optimal fluid properties are obtained, the zinc oxide is easier to dose and to transport.” The company was previously using a centrifugal sieve, which needed to be upgraded. Firstly, the sieve was not removing all the fine powdered dust from the product, meaning the zinc oxide could not obtain the optimal fluid properties. Secondly, the centrifugal sieve did not achieve the accuracy and high capacity, which was needed. Finally, as the sieve was not sealed, operators were exposed to the dust fumes. As a result, Umicore searched for a high capacity and accurate grading sieve. Through recommendation from another company using their equipment, Umicore approached Russell Finex for a solution. Following a number of successful tests, Umicore purchased a 60” Finex Separator™ for their production site in Eijsden. With the Finex Separator™, Umicore are now able to supply their customers with dust-free zinc oxide granules containing the optimal fluid properties. In order to reduce mesh blockages, Umicore applied the Russell Vibrasonic® Deblinding System with the Finex Separator™. Using ultrasonic frequency to break down surface tension on the mesh, the powder is able to pass through the mesh more easily. With the Russell Vibrasonic® Deblinding System mesh blockages have been reduced, enabling capacity to be increased. Erwin Van Eester concludes: “By using the Finex Separator, we have an accurately sieved product, which meets our customers’ needs. This is an extremely effective sieving solution which we would highly recommend to any processor of sticky powders.” For more information contact Russell Finex Ltd, Feltham, Middlesex. Tel: +44 (0) 208 818 2000 E-mail: enquiries@russellfinex.com Web: www.russellfinex.com

heat transfer & energy

RITTAL CLIMATE CONTROL ACCESSORIES Climate control applications vary in many different ways, from control to air routing. Rittal offer a range of accessories that may be tailored to satisfy specific requirements. Energy-saving philosophy that has resulted in many motors being controlled by inverter drives may also be applied to Rittal’s fan-and-filter unit; a speed control device may be used to vary the fan speed in response to the

cooling demand, ultimately switching the fan off when not required. Ingress protection of Rittal’s fan-and-filter unit may be improved by installing an additional fine filter mat or an IP56 hose-proof hood fitted with the same blue sealing material that is used in Rittal’s Hygienic Design enclosures, a proven success, particularly in the food and beverage industry. To direct cooled air towards the bottom of an enclosure, Rittal’s air diverter may be used, or an internal fan may be fitted to optimise air distribution, as natural convection currents and the flow of air through wall-mounted cooling products will pull it upwards immediately upon entry.

Rittal’s roof-mounted cooling products have multiple supply air spigots to offer a great degree of flexibility when air distribution is being considered. Rittal’s air duct systems, duct extensions, angled deflectors and stoppers provide the ability to target those areas in the enclosure in which cooled air is required. This particular range of accessories has recently been extended to include an adaptor that allows the shallow air duct system to be used with Rittal’s smallest roof-mounted cooling units. For more information contact Rittal Ltd, Rotherham, South Yorks. Tel: 01709 704000 E-mail: information@rittal.co.uk Web: www.rittal.co.uk

Process Industry Informer May 2013

KEEPING YOUR PROCESSES AND BRAND SAFE 2013 has been quite a year for the food and drink processing

industry. ‘Horsegate’ has put food sourcing and production under the microscope in a way not seen since the BSE crisis of the 1990s,

and some processors have been hit hard through reduced demand for products in the face of weakened consumer confidence.

While the closest scrutiny has been on the origin of foodstuffs - meat in particular, there are lessons for the whole food and drink processing sector in terms of supply chain integrity and giving retailers and consumers credible assurances about product safety. For processors, that means establishing safe, ethical working practices and assessing where the risks for contamination lie. A key part of this is assessment of the risks posed by process lubricants and plant maintenance procedures so the potential for contamination at any production stage can be minimised. The solution begins with independently-certified food grade lubricants. Just one incidence of product contamination is enough to irreparably damage a brand - and that could be contamination by a lubricant which is not certified safe for incidental contact with food. Although by no means new to the market, the range of food grade lubricants continues to grow as innovation by R&D teams like those in house, continue to develop solutions for specific applications and further improve plant-wide processing safety. Typifying this continuous innovation is the new FOODLUBE® Auto SF, launched earlier this year. A food-grade semi-fluid grease, it delivers efficient and effective lubrication in even the smallest bore pipework. It was specifically developed to overcome the potentially costly issue of pipe blockages and splitting in automated lubrication systems within clean processing environments.

Making the grade Food grade lubricants should be NSF® H1 registered to provide independent, authoritative assurance that product formulations meet the required hygiene requirements for incidental food, cosmetics or animal feed contact. Being NSF H1 registered means the product is tested by NSF to ensure it complies with the latest safety standards. Once checked and certified, the lubricant is deemed safe for use in factories producing food, drink, cosmetics and animal feeds, and guaranteed to be manufactured only from FDA listed ingredients which are free from animal derived materials, nut oils, soya, dairy and genetically modified (GM) ingredients. This safe formulation comes without compromising product performance. By using the finest food-grade base oils, including synthetics, renewable oils and silicones,

Process Industry Informer May 2013

and treatment with the most effective anti-oxidants and additives to address specific applications, the complex demands of today’s food, drink and clean industries can be comfortably accommodated.

in numerous sectors including bakery, pet foods and brewing, the company has proven how lubrication management can be used to achieve a more efficient and more profitable manufacturing plant.

For more comprehensive safety assurance, processors should also look for lubricant manufacturers who are ISO 21469:2006 certified. Like NSF H1, this certification is globally recognised and ticks an important box for EFSIS / BRC auditors as it provides highly credible, independent assurance that products are formulated, manufactured and supplied hygienically and safely.

A lubrication management programme starts with a survey of lubrication needs across the plant to reveal where lubricants are being used incorrectly and where rationalisation is possible.

ROCOL became the first UK lubricants manufacturer to become ISO 21469:2006 certified in 2010 to ensure processors could take advantage of this additional layer of safety assurance. As part of the ISO 21469 certification process, lubricant manufacturers provide risk assessments in the use of lubricants, conduct factory audits, help customers develop and police effective quality assurance procedures and monitor product composition through on-going sampling and retesting. For processors, sourcing NSF H1 lubricants from an ISO 21469:2006 certified manufacturer represents the beltand-braces approach to reducing lubricant contamination risk - the importance of which cannot be understated in today’s climate.

Safety you can see - and now detect NSF H1 registered lubricants are easily identifiable thanks to the blue dot which appears on the label. That makes at-a-glance monitoring of food-grade lubricant usage throughout the plant much easier. But contamination risks can still go un-noticed, especially in busy, highly automated production environments. That means a focus on more practical solutions such as the use of metal detectable plastic in lubricant packs to reduce foreign object contamination. Just introduced are the DETEX™ metal detectable caps and actuators on all aerosol cans containing FOODLUBE products. It means that, unlike traditional aerosol packaging, caps and actuators can be identified using standard metal detection equipment should they become loose in food and drink processing areas. The patent-pending DETEX caps and actuators are themselves manufactured from safe materials deemed acceptable by the US Food and Drug Administration for use in food processing plants. As smart as these solutions are, used in isolation they do not give processors full protection against production risks. That requires a comprehensive lubrication management programme applied across the entire processing plant.

Surveying, planning and long term application management ROCOL has long advocated the importance of structured lubrication management as part of a proactive maintenance strategy and with over 30 years of working with processors

The survey will identify where a poorly performing product is being used on an application. It will also show where the lubrication intervals and application procedures could be improved which may well point to the need for training. With the availability of technically advanced lubricants, maintenance managers can also switch to products which make a significant contribution to improving manufacturing plant efficiency. The number of different lubricants which are used in any one plant may also be rationalised thanks to the availability of more universally suitable products. For example, a multipurpose spray grease can provide effective lubrication of slides, bushes, pins and bearings on machinery where previously several custom designed products were being used. This sort of rationalisation helps manufacturers to reduce the number of products being ordered, delivered, stocked and invoiced, simplifying the lubricant supply chain. However, only a comprehensive survey by experienced consultants will deliver the maximum improvements to the maintenance regime. Without detailed knowledge of the technical performance of the products which are available there is a danger that the wrong changes will be made with costly consequences. There may also be a need to develop a bespoke solution where an issue has previously been identified but the available solutions have failed to address it satisfactorily. The outcome of the lubrication management survey will depend on each individual manufacturing process but it should provide lubrication reports showing daily, weekly or monthly lubrication jobs. This allows maintenance managers to manage their plant lubrication effectively through a simple software package. In addition to staff training, the survey may also recommend simple improvements such as clearer signage and equipment labelling. Leading lubricant manufacturers are also able to offer a team of service engineers who conduct the lubrication tasks on behalf of maintenance managers as part of a total support package. Ultimately, the implementation of a structured lubrication management which uses NSF H1 lubricants from an ISO 21469:2006 manufacturer is the lowest-risk approach to process lubrication. And it is an important part of protecting your reputation and your brands, and to give confidence to retailers seeking to restore industry and consumer confidence. ROCOL Ltd, Leeds, West Yorkshire Can be contacted on: Tel: 0113 232 2600 E-mail: enquiries@rocol.com Web: www.rocol.com

Real-time Condition Monitoring for O & G As a proven performer in the oil and gas industry, ABB’s industrial solutions for the hydrocarbon supply chain, encompass production, processing, transportation, storage and distribution providing: • Integrated automation and electrical products and systems • Consultancy services • Full life cycle support Active across the entire oil and gas value chain, serving: • Oil and gas exploration and production • Marine supply, transport and support • Oil and gas transportation and distribution • Refining • Petrochemical • Chemical The typical plant is teeming with information. The challenge lies in having relevant information available at the right time, in the right form and to the right people. System 800xA offers plant-wide, realtime condition monitoring of all types

ELECTRICAL CONNECTORS

of critical assets. By assigning asset diagnostic and maintenance data to any object in the system, 800xA presents an end-to-end, overall view of plant assets to allow operations and maintenance staff to increase asset availability and performance. A close collaboration bet-ween operations and maintenance creates a streamlined overall workflow where data from disparate systems and computerised maintenance management systems are communicated and shared to all throughout the enterprise - from production, maintenance to management. Benefits include: • Increased plant availability • Reduced maintenance costs • Increased overall equipment effectiveness • Improved collaboration between operations and maintenance

For more information contact ABB Oil & Gas Tel: 01480 475 321 E-mail: oilandgas@gb.abb.com Web: www.abb.com/oilandgas

See Us At:

Oil & Gas Conference & Exhibition 3-6 Sep 2013

Stand: 4 C161

ATEX-COMPLIANT COMPACT CYLINDRICAL CONNECTOR: PNCX SAFE SOLUTIONS FOR WORK IN EXPLOSIVE ATMOSPHERES Rugged and long-lasting in explosive atmospheres Marechal Electric has designed a range of compact, watertight PNC connectors for your electrical installations. Today the company unveils an ATEX version: the PNCX 10 A, designed specifically for harsh conditions and explosive atmospheres. Featuring Marechal®’s technically advanced silver-nickel butt contact system, PCNX connectors deliver industry-leading performance in any configuration. Ergonomic design for zones 2 (gas) and 22 (dust) PNCX is a compact connector that is both quick and easy to use. It features an intuitive, easy-grip handle design and is simple to disconnect. Once the connector has been connected or reconnected, a locking ring prevents accidental disconnection on load. This system ensures that the plug resists vibration and shocks (IK08) no matter how many times it is used (tested at 2,000 load cycles). Watertight and fluid resistant The Marechal® connector is designed for use in aggressive conditions and industrial environments bearing explosion risks. With a protection rating of IP66/ IP67 (up to IP68 on request), the PNCX can be used in humid, corrosive, and polluted environments. It delivers excellent resistance to fluids of all kinds, including engine oils, petrol, grease, and cleaning products. This new range of connectors has also undergone salt and fog testing (1,000 hours in connected position). Compliance and worker protection PNCX cylindrical connectors comply with international standards, EU Directives, and local installation standards. They are also compliant with worker protection regulations in Belgium, Spain, and Italy. Technical features

PNCX

Rated current (In) and polarity

10 A, 3P+N+T

Contacts

Voltage

440 V

Ambient temperature range

-20°C to 60°C

IP protection

IP66/IP67 (IP68 on specification)

Salt and fog performance

200 hours minimum not connected > 1,000 hours connected

Load cycles

> 2,000 cycles

Shock resistance

IK08

ATEX zones

Zones 2 (gas) and 22 (dust)

ATEX markings

II 3 G D Ex nA IIC T6 Gc or Ex nAc IIC T6 Ex tc IIIC T76°C Dc or Ex tc IIIC T76°C

Applications Manufacturing industries such as food, chemical, pharmaceutical, wood, and steel Zone 2: presence of explosive gases is unlikely, estimated < 10 h per year. Zone 22: presence of combustible dust is unlikely, estimated < 10 h per year. For more information contact Marechal, Chester Tel: 01244 851926 E-mail: contact@marechal.com Web: www.marechal.com/en ARI-250x185-zetrix.indd 1

25/04/2013 17:00

Process Industry Informer May 2013

Reducing Cost, Risk and Schedule During Automation System Project Implementation Matthew Willmott, Honeywell Process Solutions

Often the success of Industrial plant projects has historically been measured by cost and schedule only. As such, automation system technology decisions sometimes are totally cost-driven without consideration for integration, long-term sustainability and maintenance. Yet those systems significantly influence the overall operating performance of the facility. Many industrial organizations are now extending Engineering, Procurement and Construction (EPC) contracts into the operational life of the plant, so the EPC is held accountable for on-time startup as well as actual performance against stated objectives. As a result, process control system decisions are now being introduced at the Front-end Engineering Design (FEED) stage, or even earlier. This often requires EPCs to engage the engineering talent of automation suppliers to design and engineer the right solution-not only for the project-but also for the lifecycle of the plant. The following article describes how EPC firms and automation suppliers can work together to complete automation projects sooner, with lower costs and less risk throughout the life of the customer’s control system investment.

Typical Project Challenges There are many factors contributing to risk for EPCs, such as poor alignment of project and supplier safety processes and T&Cs, failure of equipment to meet performance specifications, supplier project staff turnover, and introduction of new technologies. Multiple supplier interfaces and incompatible products and technologies can also create unforeseen challenges. There are multiple critical factors related to cost on EPC projects in the automation industry. These include: • Incomplete FEED packages

Background

• Mismanaged third-party integration

Procurement, fabrication, and construction on industrial plant projects represent a complex balancing act between profit making and risk-taking that requires effective planning and control. Otherwise, these activities could severely hinder a company’s ability to supply a product, design and construct a plant, and start up a facility on time and within budget (See Fig. 1).

• Involvement of multiple suppliers

Frequent changes in market conditions, global sourcing, geographically distributed plant design and engineering, and remote locations of construction sites also make the project lifecycle increasingly dynamic by nature. EPC projects are highly schedule-driven and frequently massive in scale, utilizing skilled employees and complicated methodology/technology, and requiring fast information flow between different Figure 1. Procurement, fabrication, and phases and close collaboration of multi- construction on industrial plant projects disciplines. Failure to meet prescribed represent a complex balancing act performance guarantees can put the between profit making and risk-taking. future of the firm at risk. Moreover, performance and schedule related penalties can increase costs and potentially erase profits for the entire project or worse.

Today’s Business Requirements For EPC firms, today’s business directives are clear: reduce costs, improve schedules and minimize risks wherever possible. Coupled with these three core requirements, EPCs are also concerned with total installed cost, clean handover and customer satisfaction. On any given control system package, the EPC is tasked with ensuring that the system design meets specified time, budget, ROI and operating cost criteria. Their specific challenges include: 1.) setting scope boundaries by quantifying and justifying the investment required for a given benefit, 2.) minimizing changes with better change management, and 3.) identifying and planning for project risks early so that actions can be taken to lessen their impact. Plus, it is essential to involve key stakeholders to make certain the system design meets the end user’s overall needs and to achieve faster implementation of technology.

Process Industry Informer May 2013

• Unfamiliarity with supplier and products • Inefficient project processes and communication • Missed end user operational requirements • Late changes to project requirements • Unanticipated site support costs In terms of project schedule, EPCs want reliability of execution that meets the project timeline and milestones. Major liquidated damages are commonly associated with EPC contracts. The process of getting a plant up and running or revamping an existing facility is further complicated these days by a shortage of experienced personnel. Within a few short years, a good portion of baby-boomer-age engineers with deep knowledge of plant technology will leave the workforce. In emerging regions, experienced engineers are often very hard to find.

Justifying Investment Costs Some EPC project teams once had a short-term perspective when it came to initial purchased price versus total installed cost. They primarily cared about meeting the schedule, passing inspections, and coming in at/or under budget. Their focus during the procurement process was on getting bids that helped them stay under budget, and consequently, an innovation that paid off later in the lifecycle got little attention, and could even be viewed negatively, if it had a higher initial cost. However, supplier execution capabilities are increasingly important in the selection criteria. EPCs are less concerned about lifecycle costs than past costs incurred on projects due to poor vendor performance. In the current environment, most EPCs seek to choose plant automation suppliers providing the best overall business value, which comes from predictable costs, reduced cycle times, low capital expenses, and project risk mitigation. At the same time, compromising safety is not an option (See Fig. 2).

How Technology Can Help Automation suppliers have developed a wide range of solutions to ease configuration, visualization, maintenance and optimization of processes and critical plant equipment, enabling industrial organizations to address key market drivers such as productivity, innovation, globalization and sustainability. The latest control system platforms help EPC firms improve the operational and business performance delivered to customers. This includes new capabilities designed and embedded into systems to reduce cost and risk to projects, keep automation systems off the critical path, and align supplier schedule with overall project schedule.

Reducing Cost, Risk and Schedule During A

Figure 2. In the current environment, most EPCs seek to choose plant automation technologies providing the best overall business value.

Figure 4. New “flexible I/O” solutions allow for key modifications after control systems are commissioned and online.

With the right automation approach, plants can achieve flexible and efficient project execution, as well as greater agility in management of change throughout the system lifecycle (See Fig. 3).

type of I/O module is needed for each project, engineers need only worry about I/O count and not I/O mix.

Greater design flexibility

Reduced equipment footprint

New-generation control systems provide options at every stage of the plant and system lifecycle. They ensure greater flexibility during the system design phase by incorporating all industry standard protocols, including smart fieldbus, OPC, TCP/IP, wireless and fully integrated SCADA. Human-Machine Interface (HMI) graphics based on Abnormal Situation Figure 3. The latest control system platforms Management (ASM®) improve the operational and business performance Consortium guidelines can delivered to customers. typically be designed once and deployed on multiple types of operator stations-without reengineering of any kind-depending on whether the user requires critical local plant control or remote access. In addition, today’s technologies such as distributed system architecture allow multiple independent systems or system clusters, geographically spread over communications links, to form a single control system, which can be operated from any location. Once the systems come to site, they can easily combine to form a large, integrated architecture with no extra effort. Each cluster can optionally be managed independently from an engineering perspective.

Easier system modifications New “flexible I/O” solutions for both process and safety I/O allow for key modifications after control systems are commissioned and online. This approach drives on-site delivery schedules, since system engineering can be completed without impact from external design dependencies (See Fig. 4). With flexible I/O technology, system designers can integrate more field devices while simplifying installation and maintenance. These systems employ innovative technology allowing instant configuration of I/O channels without additional hardware. They enable maximum architectural flexibility, lower cost of ownership and support safety integrity level (SIL) 3 application requirements, and are ideal for facilities that must integrate equipment, units and other assets spread over wide geographic distances. Thanks to the flexible I/O approach, late changes resulting in costly project delays can now be done through remote access rather than manipulating hardware in the field. On site changes that previously took days or even weeks can be accomplished in minutes. Every day gained in the project schedule is an extra day of production. Since only one

Flexible I/O also limits the amount of training that is required for plant personnel. Only one category of I/O is needed to meet all of the input/output requirements on a typical automation project. There are fewer interconnections with this type of solution-and consequently fewer failures-so testing and installation are easier. The technology simplifies hardware engineering loop drawings and reduces maintenance tasks, too.

Developments in I/O technology offer an opportunity to liberate safety and process I/O, as well as control cabinets, from channel type dependency. This concept enables multiple remote locations to be controlled out of a single centralized unit, with each channel of I/O individually software-configured either as analog input (AI), analog output (AO), digital input (DI) or digital output (DO). It reduces wasted I/O space and provides savings on both installation and operational costs since users no longer have to worry about having enough modules for AI, AO, DI or DO configuration. The I/O connection can easily be configured and reconfigured at any point. Plants implementing these solutions can also standardize on universal cabinet designs with a generic configuration, since any field signal can be connected to any I/O channel. Engineers are able to reduce documentation cost by knowing how much I/O needs to be supported, as well as its installation space requirement. In addition, I/O systems have now been designed to support electronic “soft” marshalling, which allows the I/O module to be mounted close to the process unit to reduce or eliminate the need for homerun cables, marshalling panels, junction boxes and field auxiliary rooms. This marshalling technique also improves noise immunity, as sensor signals are converted to digital signals before being transmitted long distances through noisy environments. With the new way of I/O deployment, field wires can be terminated on any I/O module or channel, regardless of signal type. This eliminates the scrambling needed in conventional marshalling approaches, thus reducing hardware complexity around installation, commissioning and maintenance of the system, and resulting in savings on marshalling cabinets, inter-panel wiring, cabinet space, power requirements and the traditional time involved in deploying these items.

Efficient virtual infrastructure Virtualization is a game changer in the way it addresses today’s plant operating challenges. It holds the key to consolidating server environments, standardizing computer platforms and optimizing system management. This, in turn, delivers the flexibility needed to quickly respond to changing business demands. In simple terms, virtualization is intended to emulate the various layers of a typical computing environment. Through a process of abstraction, it removes many of the limitations experienced when dealing directly with these layers. In the context of process control systems, manufacturers require separate servers to support different applications. Virtualization allows a single server to simultaneously run multiple operating systems and applications. It does this while insulating “virtual machines” (VMs) from the underlying hardware and also from each other. In an industrial plant setting, virtualization enhances ownership of process control systems through reduced PC hardware requirements, fewer disruptive operating system and hardware changes, easier overall system management, and ensured availability and reliability of critical assets. By applying targeted virtualization technology, plants under construction can minimize

Process Industry Informer May 2013

Automation System Project Implementation upfront installation hardware requirements, which subsequently reduces space and weight. They can also allow design freeze dates to extend, providing valuable time for engineers to make configuration changes. Plus, the technology enables a “virtual” FAT that avoids or significantly reduces costly travel, staging and labor by validating configurations remotely (See Fig. 5).

latest high-value capabilities, or just move to a new supported hardware platform without the need to bring down the plant. Virtualization of these systems provides additional migration workflow benefits and safeguards.

Choosing the Right Partner By partnering with an automation supplier with proven expertise in delivering large, complex global projects, EPCs can lower total installed costs through: • Reduction in engineering requirements for procurement specifications and vendor evaluation through collaborative engineering • Reduction of supplier engineering through reuse of optimized solutions on subsequent projects • Reduction/elimination of data-related supplier change orders and rework through integrated work processes and engineering data management • Reduction in system acceptance testing and staging costs through collaborative workflows and virtual validation environments A well-integrated project team also leads to lower risk for the EPC as well as minimizing the impact of change. This is facilitated by standard-builds for everything from cabinets to graphics and databases with extensive use of common tools to limit human error. EPC execution risk is further minimized through standardized work process tool alignment and collaborative engineering data management (See Fig. 6).

Figure 5. By applying virtualization technology, plants under construction can minimize upfront installation hardware requirements. With virtualization, the EPC and/or end-user can have secure remote access for early validation of HMI displays, as well as simplified snapshots/rollback, automatic system backup, patch management, cyber security, etc. This capability can result in a major reduction in time and labor (T&L) for these activities and is particularly helpful on large distributed projects, where virtual teams can collaborate and perform tasks more progressively. For existing control systems, virtualization reduces the frequency of hardware refreshresulting in a compounding decrease in the quantity of hardware. It allows hardware to be upgraded or replaced without having to take a node offline, eliminating costly interruptions to process operations. Virtualization even provides facility and utility savings in the areas of space, power, cooling and maintenance.

Keys to Operational Readiness The latest generation of Integrated Control and Safety Systems (ICSS) includes a true integrated HMI designed to ensure utmost operational readiness at all stages of a plant automation project. This not only provides any operator station with a view to normal control graphics, but is also the window to the entire system with advanced applications, diagnostics and engineering tools. Modern HMIs include components such as asset management systems, alarm management, SOE, historian, video, wireless, networks, engineering tools, physical security systems, and more.

Fully qualified personnel Current ICSS architectures, with integrated operator training solutions and advanced control capabilities, makes it possible to have fully qualified control room personnel able to safely drive production from day one as well as handle difficult situations. Operator training systems can be highly representative of the target live system, using the same displays and database, and leveraging standard training activities such as speeding up, slow control operations, pausing, rewind, etc. In some cases, advanced control applications-which keep throughput and efficiency at the highest possible levelintegrate into the training system so operators are trained in full context with modelbased control and are comfortable with the live system.

Figure 6. A well-integrated project team leads to lower risk for the EPC as well as limiting change requests. In addition, an integrated project approach reduces EPC schedules where possible with local content and improved customer acceptance. Standardized procedures and tools have been shown to reduce customer handover issues by 20 percent. Finally, remote access to the control system during development of a project enables end users to maintain project oversight and monitoring of deliverables while the system is still being built, saving EPC firms from expensive T&L costs.

In addition, plant automation systems may incorporate a procedural operations capability allowing workers to turn manual procedures written on paper and stored in a binder into automated or semi-automated procedures. Automated procedures run in real-time controllers and prompt operators through the same graphical interface they are accustomed to using for standard operations.

Easy path to upgrades Although a relatively small portion of the overall investment in new industrial plants, automation systems can have a large impact on the successful outcome of the project and return of the investment throughout the lifecycle of the facility. A well-executed migration plan delivers significant operational and business benefits through seamless integration of new and existing plant automation assets. By incorporating existing data, events and operator messages into the control architecture, and establishing a common operator interface, the legacy system appears as an extension of the new system. On-process migration solutions make it easy to update control systems to obtain the

Process Industry Informer May 2013

Honeywell Process Solutions, Bracknell, Berkshire Can be contacted on: Tel: 01344 655741 or 01344 656000 E-mail: ukinfohps@honeywell.com Web: www.honeywellprocess.com

The dawn of a new standard in level control Prepare for a total ECLIPSE® of current level and interface control solutions. With superior signal performance, powerful diagnostics and a full line of overfill capable probes, Magnetrol’s ECLIPSE Model 706 guided wave radar transmitter delivers unprecedented reliability. From routine water storage applications to process media exhibiting corrosive vapors, foam, steam, buildup, agitation, bubbling or boiling, the ECLIPSE Model 706 will take your operation to a new level of safety and process performance. Contact Magnetrol – the guided wave radar innovator and level control expert – to learn more about the ECLIPSE Model 706.

eclipse.magnetrol.com • (0)1444 871313 • sales@magnetrol.co.uk

instrumentation Ocean Optics introduces miniature spectrometer for process and OEM applications EMBED offers OEMs simplicity and robustness Ocean Optics has expanded its line of customised products for optical sensing with the EMBED miniature spectrometer. EMBED is a small-footprint optical bench with minimal electronics targeted at industrial process control and OEM optical measurement systems. Designed around a next-generation optical bench, EMBED provides excellent thermal stability and measurement reliability, yet is packaged with only essential electronics to reduce footprint and simplify integration. The on-board electronics provide fundamental spectral pre-processing and multi-channel capability, as well as native SPI communication support that establishes a direct, stable and fast interface with microcontrollers and industrial control systems. Like all Ocean Optics spectrometers, EMBED’s design allows for extensive optical component customisation to support a wide variety of applications, while maintaining excellent quality in high volume production. In its standard configuration, the EMBED includes a robust 2048-element CCD-array detector and selectable optical bench components - including entrance apertures, gratings, order sorting filters and more - that make it possible for the EMBED to support low-light and high-throughput measurements. Its design provides the EMBED exceptional thermal and environmental stability - attractive features for process and other applications where temperature and environmental factors can affect measurements. To learn more, visit www.oceanOEM.com . For more information contact Ocean Optics, Geograaf 24, 6921 EW Duiven, The Netherlands Tel: +31 (0)26 319 05 00 Fax: +31 (0)26 319 05 05 E-mail: info@oceanoptics.eu Web: www.OceanOptics.eu

COST-EFFECTIVE SOLUTION FOR BULK FOODSTUFFS, DRY SOLIDS INVENTORY MEASUREMENT The application of the latest non-contact scanning technology to a new range of level measurement systems has resulted in a breakthrough in providing an accurate and costeffective solution for inventory measurement of dry ingredients and finished food products. The revolutionary 3D Volume Scanner System is available from level and flow specialists ALLISON ENGINEERING and is designed specifically for food ingredient, bulk inventory measurement applications, where accounting for large quantities of materials has traditionally been largely guesswork. This new system eliminates the problems associated with conventional ‘point-level’ devices which only measure distance to a single point. Whilst this may be adequate for liquid applications it is not suitable for dry ingredients where the product is uneven. Allison Engineering’s new 3D Volume Scanner System is designed to take multiple measurements of the product profile to build a three dimensional map of the bay, silo, vessel or stockpile. Based on the volumetric measurement and also the product density, operators are able to identify both the total inventory and also the product profile. With this information, which has until now has been unavailable, operators can reduce safety stock levels which can have an immediate and beneficial effect on cash flow. The advantages of the system for the food and beverage industries clearly come into focus, for example, with dry ingredients and spent-grain storage, the materials can have a tendency towards product build-up, leading to the incorrect assumption that the silo, or storage vessel is empty. This can result in either product overfill or deliveries being sent away without unloading, each of which is an expensive process which can be avoided. Also, end of week or month stock discrepancies, which can also create considerable friction between finance and operations departments, can be better understood with more accurate and realistic inventory measurement and 3D imaging. For more details about these 3D Volume Scanners, contact: Allison Engineering, Basildon, Essex Tel: +44 (0)1268 526161 E-mail: generalsales@allison.co.uk Web: www.allison.co.uk

Process Industry Informer May 2013

Locate process information in seconds? Certainly. ABB’s distributed control system, System 800xA, is based on Aspect ObjectTM technology which means all information associated with a drive, motor, valve or instrument can be accessed with minimal engineering. From video camera monitoring, shift handover and LOPA displays through to entire documentation libraries, everything can be instantly seen. Maintenance teams can access electronic work orders (CMMS functions) and asset management information directly, allowing them to see the complete history of an object. Tracking and monitoring of operation actions is easy, regardless of where they occur in the system. To learn more about information navigation visit: www.abb.com/800xA or scan the QR code using your smartphone App.

ABB Limited Tel. +44(0)1480 475321 E-mail: info@gb.abb.com

instrumentation

NEW GUIDE TO PROCESS pH MEASUREMENT The Theory and Practice of pH Applications

pH measurement and control is vital in a wide range of processes across the pharmaceutical, chemical and food and beverage industries. METTLER TOLEDO’s new guide to pH measurement, available to view online or download, focuses on the theory and practice of pH applications in process industries. Subjects covered in this 100-page guide include: • The general principles of pH measurement • Choosing the correct sensor • Advantages of Intelligent Sensor Management (ISM) • Signal processing and environmental influences • Accuracy and reproducibility of measurement values • Avoiding contamination • Application examples and solutions • Troubleshooting To download this free guide visit: www.mt.com/uk-pro-pHguide For more information on products and solutions contact Mettler-Toledo Ltd, Beaumont Leys, Leicester Tel: 0116 234 5095 E-mail: enquire.mtuk@mt.com Web: www.mt.com/pro

Brain Wave Pulsar’s Intelligent Transducer range is designed to monitor level or volume in tanks or vessels to 15m

New

Installation is easy, set up by PC or programmer, integrating data to PC or laptop is simplicity itself whilst Pulsar patented DATEM echo processing ensures extreme accuracy even in continuously changing tank conditions. n control i u o dBi – The new range of ts y u p Intelligent Transducers. h at

nt t e m ure s a e m Level

Malvern, Worcs WR14 1JJ, UK Tel: +44 (0) 1684 891 371 info@pulsar-pm.com

www.pulsar-pm.com 18

ULTRA-LOW PRESSURE DROP FLOW METERS AND CONTROLLERS CONSERVE EXPENSIVE GASES Whisper series from Alicat have industry’s lowest differential pressure ranges Alicat Scientific, Inc.’s new line of mass flow meters and controllers overcome the challenges of low pressure systems to deliver accurate metering and control. The Whisper series saves time and money in semi-conductor and other process industries with systems using very low pressure differentials or exotic gases. All Alicat meters and controllers are based on its patented laminar flow technology, resulting in fast and accurate responses. The Whisper Series also incorporates a very low differential pressure sensor and redesigned flow body to achieve a differential pressure range of .01PSID to 2.0PSID, depending on flow rate and configuration. Prior to Whisper series instruments, users relied on larger pumps or supply sources, higher feed pressures, or the use of more bottled gas to overcome pressure drop requirements imposed by mass flow instrumentation. Compatible with 30 field selectable gases and gas mixes, Whisper flow meters and controllers can operate as standalone devices or integrate easily into process control instrumentation. In addition to mass flow, a single device quickly and accurately measures pressure, temperature and volumetric flow. For applications requiring precision gas flow control, Whisper series mass flow controllers deliver accurate flow regulation of gases with the ability to respond to upstream gas flow changes, attaining and maintaining flow setpoints in less than 100ms. To learn more about Alicat’s Whisper series flow meters and flow controllers, contact Alicat Scientific, Tucson, USA Tel: +1 520.290.6060 Fax: +1 520.290.0109 E-mail: info@alicat.com or visit www.alicat.com

Radar for bulk solids! 100,000 bulk solid radar sensors from VEGA installed worldwide

Milestone reached: In February 2013 VEGA produced its 100,000th non-contact radar sensor for bulk solids. This makes VEGAPULS a best-seller in radar sensors for bulk solids measurement. This February 2013, less than 9 years after introducing VEGAPULS 68, the first non contact radar sensor for bulk solids, VEGA have delivered the 100,000th sensor. “This production milestone carries forward the success story of radar level sensors in process automation. Today, they are the all-round level transmitter for liquids and bulk solids”, commented Günter Kech, Managing Director, “Radar technology is on a success trajectory and we will ensure that it stays there by even further simplifying it for level measurement of bulk solids in future.” The 100,000th bulk solids radar instrument is a VEGAPULS SR68. The landmark sensor went to Bühler in Switzerland, who are using it for level measurement in a 25-metre-high cement silo. VEGA Grieshaber KG launched VEGAPULS 68, the first radar sensor specifically tailored to applications in the bulk solids industry, on the market in 2004. Compared to radar sensors for liquids, the bulk solids radar sensor is capable of detecting and measuring signals a 1,000 times smaller - signals that were previously masked by ‘noise’. The two-wire loop powered sensors have since become ‘the’ alternative to maintenance-intensive mechanical ‘plumb bob’ systems, or ultrasonic sensors, which require a clear, dust-free view to the product. Thanks to simple application parameters, only a few settings are needed to fine-tune the radar sensor to the measurement. The result is reliable reading, completely independent of dust, filling noise, strong air currents and high temperatures, with no loss of echo issues. Three sensor variants ensure the advantages of non contact radar technology can fit all kinds of applications, as well as measuring and temperature ranges. VEGAPULS 68 is optimized for ranges up to 75 m and temperatures up to 400° C, while VEGAPULS 67 and VEGAPULS SR68 are designed for standard applications. One basic technology covers a wide spectrum - from level measurement in clinker coolers at 1,500° C, or grain silos, to level monitoring in rock crushers. For more information contact VEGA Controls Ltd, Burgess Hill, West Sussex. Tel: 01444 870055 E-mail: info.uk@vega.com Web: www.vega.com/uk

Process Industry Informer May 2013

Optimise and save with field-based intelligence Boost your operational efficiency and optimise your maintenance programme by making the most of today’s intelligent instrumentation. The intelligence available in today’s field instrumentation is chronically underused so says Tony Hoyle, ABB Measurement’s General Sales Manager - UK & Ireland. More than half of plant operators report that less than 20% of their control instrumentation is currently equipped with intelligence, such as Hart, Fieldbus or Profibus communications. Furthermore, even where there is the potential for intelligent control, almost half (43%) of plant operators report that they don’t use it.

operating high-volume, low-margin businesses, a small incremental improvement can have a huge impact on the bottom line. Against this background, field-based intelligence can typically improve overall efficiency by at least 2% during normal operations, with much greater savings possible during the plant start-up phase. Exactly how much value intelligence and improved efficiency can deliver depends on the specific application and the value of the products being processed. Built-in software can improve measurement accuracy during normal operations, enabling operators to achieve more precise control. The ability to compensate automatically for changing conditions means that pressure instruments are 10 times more accurate today than they were 20 years ago, for instance. On-board intelligence can also impact on a range of other expenditure by enabling controllers to see what’s going on remotely, rather than having people constantly out and about gathering information. A reduction in downtime thanks to on-board instrument diagnostics and predictive maintenance can help to drive down costs substantially.

Today’s intelligent field devices can play a vital role in wider preventive maintenance programmes, which can be crucial in maximising the uptime of valuable plant assets

Efficiency drivers Process efficiency is near the top of most companies’ priority list - especially in today’s atmosphere of economic gloom where every penny counts. With many firms

Today’s control software is designed to be straightforward and user friendly, enabling plant operators to easily get to grips with their process with minimal training Take calibration, for instance. Self-diagnosis has increased the calibration interval required for many instruments from six months to as much as five years. In other examples, diagnostic tools have become so sophisticated that they can even pinpoint when a particular area within a valve assembly or positioner is becoming worn. It’s hard to overestimate the potential efficiency savings that can result. According to some reports, as many as 35% of trips into the field are for routine checks, 28% are for non-existent problems, 20% are for calibration shifts, 6% are for “zero off” issues and 6% for plugged lines. Just 4% are actually for failed instruments. So it’s no surprise to find that of those companies already making use of on-board intelligence, more than three quarters (77%) are looking to improve their maintenance programmes.

Easier than you think

Like any large-scale process plant, oil, gas and petrochemical plants will have hundreds of instruments installed, holding untapped stores of data that can be used to help enhance process efficiency

Process Industry Informer May 2013

a leading international standard. The most popular option in the process industries is 4-20mA HART communications protocol, but digital alternatives such as Profibus and Foundation Fieldbus also have their supporters. The results of our recent benchmarking survey suggest that this is likely to continue, with almost 4 in 10 operators expecting to use HART in the future, almost a quarter preferring the prospect of Profibus and around 1 in 10 saying they’re most likely to adopt Foundation Fieldbus. The rise of wireless technologies is also making it easier to engage plant-wide communications, and some 23% of respondents say they see it as the way forward. It’s just as important for a wireless solution to be properly standardised as it is for wired schemes, and that recently got easier with the introduction of WirelessHART (IEC 62591, EN 62591), which gives users even more ways to get connected.

These companies are missing out on a raft of potential benefits, including an opportunity to optimise the running of their plant and substantial reductions in the maintenance burden, in terms of maintaining both the instruments themselves and their wider plant assets. The instrumentation that generally populates oil, gas and chemical facilities includes on- and at-line analysers and lab-based analytical instruments, flow, level, temperature and pressure instruments and valve automation products. And while some of these instruments are almost “fitand-forget”, it takes considerable care to keep others operating at peak performance. Looking beyond the maintenance needed to service the instruments themselves, some intelligent field devices can also play a key role in wider preventive maintenance programmes, which can be crucial in maximising the uptime of valuable plant assets.

The rise of wireless technologies is one of the current developments making it easier to engage plant-wide communications

With such substantial benefits on offer, why are so many plant operators reluctant to take the plunge and get smart with their instrumentation? Many do not have a software tools in place to process the information that comes in, while others are anxious that it will be too difficult and complicated for them to manage. But today’s control software is designed to be straightforward and user friendly, with systems and interfaces that typical plant and control room operators can easily get to grips with minimal amounts of training. Of course, site operators will make life much easier if they opt for intelligent instruments and systems that comply with

WirelessHART, the first interoperable wireless communication standard for process industries, builds on the existing foundation of HART, enabling users to tap into the benefits of wireless automation while ensuring that new systems are with their existing devices, tools and systems. This will enable major cost savings, since it eliminates the time and effort associated with installing the cabling for conventional wired solutions. It can cut the time needed to configure new instruments within the plant-wide network by a quarter. The main drawback with wireless solutions is that they are relatively slow, so they can’t replace wired alternatives in every application. The extent to which plant operators are embracing smart technology varies enormously, in part because the age and condition of their current crop of control instrumentation will determine how big an investment is needed. However, the situation is changing gradually, with over half of the companies in our benchmarking survey reporting that their control systems are already over 10 years old. The important thing is to ensure that any new systems make full use of the available intelligence when the time comes to renew the old equipment. In the meantime, companies looking to see how they measure up against their peers can use an online benchmarking tool to check how they’re performing. The free tool is available online at www.howdoyoumeasureupabb.com. ABB Measurement Products St. Neots, Cambridgeshire Can be contacted on: Tel: 0870 600 6122 E-mail: moreinstrumentation@gb.abb.com ref ‘Intelligent instruments’

We make tough choices easier

Intelligent I/O – compact, modular, fieldbus independent systems for decentralised solutions. Suitable for all process industry applications TO-PASS® – delivers advanced telecontrol solutions including fault detection via GSM connection. Option of IP66 protection.

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

TOTALLY DEPENDABLE AUTOMATION CONTROL SOLUTIONS – WHATEVER THE APPLICATION With a range of over 25,000 products, WAGO is the world leader in advanced interconnection technology solutions. Whatever the process, we have a comprehensive range of automation control systems which will deliver optimum product quality, easier operation and lower costs

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

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

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

For more information, call 0870 264 0773 or email ukmarketing@wago.com 20

Process Industry Informer May 2013

network & communications New industrial connector series combines large number of mating cycles with protection against harsh environments The new Han® HMC industrial connector series from HARTING combines the capability for more than 10,000 mating cycles with protection against harsh environmental conditions. The new connector family is designed for use in applications - in the medical, laboratory and test engineering sectors, for example - where equipment may be employed in different locations and can often be connected and disconnected several times a day. Similar situations occur in the automation environment, where the trend to modular and interchangeable machine tools and control systems also requires connectors that can handle a large number of mating cycles. HARTING’s Han® HMC connectors are based on the Han® industrial connectors that have been tried and tested for decades, offering the additional benefit that all existing processing tools can also be used for the Han® HMC. The complete Han® HMC series consists of Han® B

DRIVE SOLUTIONS

HMC housings, Han® HMC connector inserts with crimp connection in four different versions, Han® HMC crimp contacts in two sizes, a range of Han-Modular® modules together with the Han® HMC crimp contacts, and two different docking frames. The Han® B HMC housings are equipped with durable locking levers in order to continue to provide the connector with IP 65 protection against dust and water after more than 10,000 locking cycles. Han® HMC connector inserts contain high-performance

grounding contacts, while the crimp contacts are equipped with a special HMC gold surface and constant spring force. These special properties guarantee the complete connector’s flawless function - even after 10,000 mating cycles. For more information contact HARTING Ltd, Brackmills Ind Estate. Northampton Tel: 01604 827500 Fax: 01604 706777 E-mail: gb.harting.com Web: www.harting.co.uk

Low Flow Coriolis Mass Flow Meters/Controllers for Food and Pharma Industry

Clean drive solutions for food technology, conveyors, and beyond: Lightweight, hygienic helical bevel gear units For hygienically demanding applications, NORD DRIVESYSTEMS supplies aluminum two-stage helical bevel gear units in five sizes with a maximum torque of 660 Nm that are easy to clean. The washdown design is based on smooth inclined surfaces, transitions with large radii without dead spaces, and requires no assembly covers. Cleaning liquids wash off easily and completely from the surfaces, which also remain considerably cooler than those of conventional drives thanks to the special construction. The design is optimized, amongst others, for use in the food industry and complies with international guidelines and standards such as EHEDG, ANSI / BISSC, and ANSI / NSF. If required, the gear units can be fitted with double shaft seals. They can be ordered as open or closed frame versions with hollow or solid shafts. Designed according to the proven UNICASE principle, the housings are very torsionresistant and withstand high mechanical stress. With the optional NSD tupH surface treatment, they become extremely resistant to corrosion as well as acids and alkaline solutions. For more information contact NORD GEAR LTD. (U.K.), Abingdon, Oxfordshire Tel: +44 (0)1235 534404 E-mail: Andrew.Stephenson@nord.com Web: http://www.nord.com

Process Industry Informer May 2013

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The , approved pressure transducers CNG has proved a safer, cheaper, more environmentally clean fossil fuel substitute for petrol, diesel fuel and propane that must be harnessed to the maximum potential. ATEX-approved pressure transducers now offer a realistic solution not only in oil and gas but also in a wide range of commercial applications, says Mike Powers, Product Marketing Director for Gems Sensors and Controls. Pressure transducers are widely used in process and industrial applications, where they often have to withstand aggressive operating conditions, ranging from high pressure hydraulic spikes to extremes of temperature, mechanical shock and vibration. In each case transducers have to function reliably, consistently and accurately without maintenance or recalibration. Within each transducer there is typically an extremely sensitive pressure sensing mechanism, combined with a sophisticated electronics package. Together, these can provide a response to changes in pressure of 1msec or less, and an operating life in excess of 100 million cycles. Despite the exceptional performance of these components, the application of pressure transducers in potentially explosive working environments that contain inflammable gases, fumes, chemicals, powders, dust and so on has been limited - until now. Market-leading sensor suppliers now provide solutions that offer enhanced safety and reliability in the presence of compressed natural gas (CNG), which, with sustainability high on the agenda, has been warmly welcomed. These sensors are now available as approved components, certified for both European (ATEX) and North American / Canadian (CSA) use, providing a range of powerful solutions for oil and gas applications dealing with automotive CNG refuelling, CNG compressors and beyond, such as wellhead automation, storage tank level monitoring and vapour recovery.

combined with ASIC electronics packaging, offer a powerful package of accuracy and reliability to the increasing number of engineers who investigate the advantages of pressure transduction technology, while approval for potentially explosive working environments extends their reach still further. Enabling pressure transducers to perform under such a wide range of operating conditions has depended upon methods by which sensor elements and electronics packages are constructed. The outstanding levels of performance offered by these components have been made possible as a result of some highly innovative and carefully controlled methods of construction; in particular the advanced strain gauge technologies of sputtered thin film and chemical vapour deposition. The use of sputtered thin film, a molecular layer of material atomically fused to the beam or diaphragm, results in a sensitive, robust sensor that is suitable for direct contact with almost all liquids, oils and gases. In addition to the CVD and sputtered thin film manufacturing processes, which have greatly enhanced the capabilities of pressure transducers, advances in electronics have also made a strong impact. The integral electronic signal conditioning that has been supplied with pressure transducers over recent years often incorporates advanced ASIC (application specific integrated circuits) technology, which has been estimated to have reduced the unit cost of transducers by a factor of 10. The fact that such high performance components are available at such affordable prices is one more reason why pressure transducers are becoming even morewidespread across a growing number of industries. By consulting with an expert manufacturer and supplier of sensor components, engineers can take advantage of recent developments in sensing technology and meet the on-going need to increase efficiency in CNG applications. As a result of rising petrol prices, CNG is used in vehicles that have been converted into bi-fuel vehicles using both petrol and CNG. Public transportation vehicles have been early adopters, as they have been able to amortize investment, but the number of vehicles that use CNG continues to rise on a global scale. Its advantages are many: CNG-powered vehicles demand lower maintenance costs when compared with other hydrocarbon fuel-powered vehicles; CNG fuel systems are sealed, which prevents any spill or losses through evaporation; also, the fuel delivers less pollution with more efficiency - it is estimated that CNG releases over 1.6 times as much energy as that released from petrol, and nearly 40% less CO2 for the same amount of energy.

Sensing out safety... As operators seek to capitalise more efficiently on hydrocarbon resources, solutions such as these are vital in ensuring safe and consistently reliable business operations. Advanced sensors for the ever-changing and demanding needs of oil and gas customers are required and these must be built and certified to withstand rugged environmental conditions if they are to provide not only the safest but also the most cost-effective solutions. With the global recession putting pressure on all operators, engineers are designing for efficiency, not just performance.

In oil and gas applications, large natural gas compressors, for instance on gas pipelines, must be equipped with components that enable increased machine availability, significantly reduced maintenance, and environmental savings. Consider, for example, extreme conditions such as those found in the northern regions of Russia; if less replacements are required to be shipped to distant areas, and less personnel are needed to service the compressor unit, operational savings accompany those of reduced energy consumption and environmental responsibility. ATEX and CSA-approved pressure transducers therefore represent a powerful solution for such applications, especially in remote locations.

Certification increases the range of applications... Pressure transducers already exhibit a strong presence across many industries and are set to become even more widespread as they achieve new certifications that can enhance more applications. CVD and sputtered thin film technology,

In summary, CNG has proved a safer, cheaper, more environmentally clean fossil fuel substitute for petrol, diesel fuel and propane that must be harnessed to the maximum potential. ATEX-approved pressure transducers now offer a realistic solution not only in oil and gas but also in a wide range of commercial applications. Indeed, the latest technology can enhance the capabilities of rotating equipment by providing robust, cost-effective and easy to implement solutions. These revolutionary components can now operate at optimum performance levels with exceptionally high levels of reliability - adding measurable value to the bottom line of any company and an exceptionally powerful solution for the oil and gas industry. Gems Sensors and Controls, Basingstoke, Hampshire Can be contacted on Tel: +44 (0) 1256 320244 E-mail: sales@gems-sensors.co.uk Web: www.gemssensors.co.uk

Process Industry Informer May 2013

NEWS

MAY 2013

It’s good to have growing pains!!! Over the past couple of months we have welcomed 4 new member companies - we have sealed a relationship with M.Barwell Services (see page 5) joined services with MI Pumps Co.UK (See page 11) and will be motoring along with Lafert Electric Motors Ltd (See page 11) and made a powerful impact with the Hayward Tyler Group (www.haywardtyler. co.uk), clearly Brian Huxley has been “out & about”... On the subject of “new” - there is a new approach to the Motor Driven Systems Conference, instead of being an annual eventit’s going “on tour” with 5 regional events. It’s a great move and now “opens the doors” to a more accessible audience. (See page 4) What isn’t new!!! is the Pump Industry Awards, which this year celebrated its 10th anniversary and was deemed to be the best yet, now there’s a target for the organisers, Touchwave Media, to beat for 2104 and it is never too soon to book your places for next for next year. You can check out the 2013 winners on page 6. This is just a “taster” - in the following pages you can also catch up with more news from both the BPMA and its member companies.

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

Here’s a big reason you can save even more energy. Etanorm is a classic that keeps getting more efficient. It meets the energy efficiency requirements of the ErP Directive for 2015 already today – for three good reasons: optimised hydraulic components for pace-setting efficiency, individual impeller trimming, and ideally matching drives and automation components. Etanorm is available really fast, comes in numerous variations, and provides the unique reliability of a globally identical product. For more information, please visit www.etanorm.com KSB Limited • 2 Cotton Way • Loughborough • Leicestershire • LE11 5TF • www.ksb.co.uk

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EagleBurgmann Germany GmbH & Co. KG EagleBurgmann Aeussere Sauerlacher Strasse 6–10 Wedgnock Industrial Estate 82515 Wolfratshausen, Germany Warwick, Warwickshire Tel.: +49 (0)8171 23 0 Tel: +44 (0) 1926 417600 Fax: +49 12 14 Fax: +44(0)8171 (0) 192623417616 info@de.eagleburgmann.com E-mail: sales@eagleburgmann.com www.eagleburgmann.com www.eagleburgmann.co.uk

NEWS BYTES  Mandated Energy Audits for Pumping Systems BPMA responds to the auditing requirements of the Energy Efficiency Directive (2012/27/EU) The Energy Efficiency Directive came into effect on the 4 December 2012 and is currently in its transition period. During this time the UK Government needs to put in place schemes to ensure those carrying out an audit are sufficiently competent. The mandated audits will be applicable within buildings and industrial processes - remember, Pumps consume 20% of global motive power and Pumping System improvements can deliver up to 40% reduction in energy costs. The British Pump Manufacturers’ Association Ltd (BPMA), as referenced in recent UK Government Energy Strategy documents have developed CPSA Scheme (Certified Pump System Auditor) an independent training package to fulfil the requirements of mandated energy audits for pumping systems. CPSA is a new industry specific professional qualification designed to equip individuals with the skills to conduct a Pumping System Audit. The course focuses on industry proven methods for assessing the actual system demand. These are subsequently tested with an exam after 3 days study. Students will also be trained on the benefits of; • Load profiling • System curves • Valve CV sizing Plus many other important system related issues. Furthermore BPMA is able to offer a “one off” subsidised opportunity to become CPSA qualified by attending a 5-day residential CPSA courses in June 2013 - at a delegate cost of £950 + VAT instead of £2,500 + VAT There is a choice of two dates: 10-14 June or 17-20 June 2013. Courses will be held at the National Metalforming Centre, West Bromwich (1 min J1, M5).

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

 New Training Dates We are pleased to announce the following dates for BPMA Pumping Fundamentals courses: 4 September - Module 001, Part 1 - Pumping Fundamentals 5 September - Module 001, Part 2 - Pump Selection 5 July - Module 007 - Pump Testing 11 July - Module 008 - Pump Systems 18 July - Module 009 - Hydraulic Design and Performance of Centrifugal Pumps Course costs - £300 + VAT per delegate, per course (£250.00 + VAT BPMA Members) Download full brochure from our website: www.bpma.org.uk

 BPMA Insurance Scheme FREE Insurance Health Checks for BPMA Members The British Pump Manufacturers Association (BPMA) has arranged an additional insurance service for its members insurance through its scheme provider “Blythin & Brown”. Not only have members access to exclusive insurance products and competitive premiums through the arrangement, there is now available a FREE Insurance health check of their current insurance arrangements. This is to ensure members’ insurance policies meet the requirements of the business. “As businesses grow” says Richard Gibson the BPMA Scheme Director of Blythin & Brown. “it is very easy for their activities to fall out of the scope of their insurance policy. This could be devastating for a business and could leave to them being uninsured or underinsured if they have to make a claim. We have had many instances of this happening over the past few years.” The BPMA appreciate that some members may have been with their current insurance providers for many years and are perhaps not looking to change. So for these members this service is still of benefit to you! It will provide you with peace of mind that the service, premiums, cover and advice that you currently enjoy is the best available. Also following the review, if any areas of concern are identified you can speak to your current insurance broker to amend your current policy mid term, ensuring your business is fully protected. Please remember, Insurance health checks through the BPMA can be done at anytime during the year and do not need to be conducted at the renewal of the policy. In addition, for members that arrange an Insurance Health Check and then at next renewal incept a commercial combined policy with Blythin & Brown, they will be entitled to a further 10% discount from their insurance premium in the first year. So don’t delay, book your Insurance Health Check today by contacting Richard Gibson on 07510 695335 or rgibson@blythinandbrown.co.uk. Alternatively for more information please speak with the BPMA on 0121 601 6350.

Europump Guidelines BPMA now has a direct link on their website to Europump’s “Guides and Guidelines” www.bpma.org.uk 3

NEWS BYTES  Call For Papers Conference Time Lines

Call For Papers Call For Papers

Abstracts are due to be received by no later than Friday 31st May 2013 and should be sent to the event organiser at andrew@touchwavemedia.co.uk . Authors will be notified by email as to whether their abstracts have been accepted or rejected. Instructions for the preparation of final papers will be sent with the notice of acceptance.

Call For Papers

Each Abstract will be reviewed by the most suitable steering committee member.

Call For Papers

Authors will be notified if abstract has been accepted by 28th June 2013 Draft Papers are to be returned by 26 July 2013 Motor ConferenceDriven Time LinesSystems Roadshow – Autumn 2013 th

Motor Driven Systems Roadshow – Autumn 2013

Comments on draft papers returned to author by 23rd August 2013 Abstracts are due to be received by no later than Friday 31st May 2013 and should be sent to the Five Events, Five Regions, Same GreatwillContent th event organiser at andrew@touchwavemedia.co.uk . Authors Final papers and presentations required by 20 September 2013 be notified by email as to whether their abstracts have been accepted or rejected. Instructions for the preparation of final papers will be As you know, the second Motor Driven Systems Conference was staged in November of last year, and As you know, the second Motornotice Driven Systems Conference was staged in November of last year, and Conference sent with theContacts of acceptance. following a detailed post-show review by the five Trade Association Stakeholders – BCAS, BEAMA,

Five Events, Five Regions, Same Great Content

following a detailed post-show review by the five Trade Association Stakeholders – BCAS, BEAMA, For further information of the MDS 2013 Roadshow please contact any of the following Steering Each Abstract will be reviewed by the most suitable steering committee member. BPMA, FETA, GAMBICA – andMembers:the numerous Sponsors and Event Partners it has been agreed to Committee Authors will be notified if abstract been accepted by 28th June 2013 develop a programme of regional events for thishasyear. Again scheduled to take place in Autumn, the events will continue to press home the importance of BPMA, FETA, GAMBICA – and the numerous Sponsors and Event Partners it has been agreed to develop a programme of regional events for this year.

Andrew Castle, Touchwave Media – andrew@touchwavemedia.co.uk adopting a systems approach to motor driven apparatus for optimum energy efficiency, with the key Draft Papers are to be returned by 26th July 2013 Again scheduled to take place in -Autumn, the events will continue to press home the importance of Chris Dee, BCAS chris@bcas.org.uk areas of Regulatory Affairs, Systems Engineering and Product Technology being addressed. onto draft papersdriven returned to author byfor 23rd August 2013 adopting a systemsComments approach motor apparatus optimum energy efficiency, with the key John Parsons, BEAMA – johnp@beama.org.uk As with last year’s event however, there will again be a strong emphasis on Case Studies; real life th areas of RegulatoryFinal Affairs, Systems Engineering and Product Technology being addressed. papers and presentations required by 20 September 2013 examples of how industry and commerce are saving significant amounts of money through the proven Steve Schofield, BPMA–– techdir@bpma.org.uk and successful application of 'energy efficient motor driven systems'. Conference Contacts As with last year’s event however, there will again be a strong emphasis on Case Studies; real life Mike Duggan, FETA – miked@feta.co.uk Plant managers, engineering staff and financial heads within end-user organisations find enormous examples of how industry and commerce areMDS saving amounts money throughSteering the proven For further information of the 2013 significant Roadshow please contactof any of the following value in learning how others are developing increased efficiencies across their operations, and so this Steven Brambley, GAMBICA - sbrambley@gambica.org.uk and successful application of Members:'energy efficient motor driven systems'. Committee approach will form an important aspect of the 2013 Roadshow. Andrew Castle, Touchwave Media – andrew@touchwavemedia.co.uk For a resume on the MDS 2012 event, please visit the website at www.motordrivensystems.com.Plant managers, engineering staff and financial heads within end-user organisations find enormous

value in learning how others are developing increased efficiencies across their operations, and so this Chris Dee, BCAS - chris@bcas.org.uk This Motor Driven Systems Roadshow will provide a strong regional forum to discuss and debate the approach will form an important aspect of the 2013 Roadshow. latest developments on the impact of electrical motor systems on energy and the environment. The John Parsons, BEAMA – johnp@beama.org.uk energy efficiency policies and programmes adopted and planned, and the technical and commercial For a resume on theSteve MDSSchofield, 2012 event, please visit the website at www.motordrivensystems.com. BPMA–– techdir@bpma.org.uk advances made in the application of energy-efficient motor systems will also be addressed.

Mike Duggan, FETA – miked@feta.co.uk Each regional conference will include sessions where key representatives from the UK government This Motor Driven Systems Roadshow will provide a strong regional forum to discuss and debate the together with end-user organisations, product manufacturers and technical experts will present their latest developmentsSteven on the impactGAMBICA of electrical motor systems on energy and the environment. The Brambley, - sbrambley@gambica.org.uk views.

energy efficiency policies and programmes adopted and planned, and the technical and commercial

To contribute to the success of this series of ‘information transfer events’, we invite you to participate advances made in the application of energy-efficient motor systems will also be addressed. and to submit paper abstracts on the following topics. All papers shall address existing, new and future developments and shall not be of a strictly commercial nature. The key areas to be addressed are as follows:1. Regulatory Affairs

Each regional conference will include sessions where key representatives from the UK government This event is organised by Touchwave Media together with end-user organisations, product manufacturers and technical experts will present their Registered Office Anderson House / PO Box 523 /Eastleigh Road / Eastleigh / Hampshire / SO50 0DW Company Registration Number 07250009 VAT Registration Number 992575370 views.

To contribute to the success of this series of ‘information transfer events’, we invite you to participate The latest information from the Motor, Pump, Fan, Compressor and Controls industry on the various international standards that are currently being, or have been developed, with an influence on energy and to submit paper abstracts on the following topics. usage and the resultant financial and environmental impact on end users.

Call For Papers 2. Systems Engineering

 Sustainability Live

All papers shall address existing, new and future developments and shall not be of a strictly commercial nature. The key areas to be addressed are as follows:-

An effective ‘systems strategy ‘ has for some time been identified as offering the largest potential 1. energy savings in all Motor Driven Systems. What are the best practices being used today and what

This event is organised by Touchwave Media

Registered Office Anderson House / PO Box 523 /Eastleigh Road / Eastleigh / Hampshire / SO50 0DW are the future considerations for improved andNumber financial return? Company Registration Number 07250009 VATefficiency Registration 992575370

This event is organised by Touchwave Media Regulatory Affairs

Registered Office Anderson House / PO Box 523 /Eastleigh Road / Eastleigh / Hampshire / SO50 0DW Company Registration Number 07250009 VAT Registration Number 992575370

The latest information from the Motor, Pump, Fan, Compressor and Controls industry on the various 3. Product Technology international standards that are currently being, or have been developed, with an influence on energy What are the new technologies that the Motor Driven Systems industry has developed to overcome usage and the resultant financial and environmental impact on end users. the pressure to reduce electrical energy consumption? 4. Case Studies Probably one of the most important elements of the overall programme is the presentation of real life MDS applications. End users and their respective suppliers/contractors/integrators will illustrateThis the event is organised by Touchwave Media clear operational and commercial benefits of applying best practice engineering solutions to motor Registered Office Anderson House / PO Box 523 /Eastleigh Road / Eastleigh / Hampshire / SO50 0DW Company Registration Number 07250009 VAT Registration Number 992575370 driven apparatus. Submitting an Abstract

Authors interested in submitting papers for oral presentation at each of the five events are kindly requested to send a one-page abstract, with name, mailing address, e-mail and the relevant topic number (1-4 in the list of topics above). The papers presented are to be technical in nature. Both the written and oral presentations are to be free of commercialism. The author(s) may identify their company/organisation as part of the author’s data. Company name or logo or vendors name and logo shall only appear in the cover page of the presentation. Authors should submit their paper in Word for Windows™ format. The papers will be peer reviewed, and comments will be sent back to authors. Final papers will be accepted only when the peer reviewers' comments have been satisfactory addressed. The final paper in electronic form will be included in the conference proceedings. Abstracts will be selected by the steering committee based on the following criteria:• Clarity of thought and presentation • Relevance to the focus of the conference • Presentation of new material • Likelihood of stimulating a debate.

This event is organised by Touchwave Media Registered Office Anderson House / PO Box 523 /Eastleigh Road / Eastleigh / Hampshire / SO50 0DW Company Registration Number 07250009 VAT Registration Number 992575370

BPMA exhibited at the IWEX show which is part of Sustainability Live in April. The exhibition held at the NEC, Birmingham attracted a large number of visitors. Several of our members who were also exhibiting reported good attendances on their stands Sustainability Live is the ‘no1’ event for sustainable business management, providing a comprehensive showcase of the latest products and services across the energy, water and energy from waste sectors. With three shows all under one roof, NEMEX energy Live, IWEX water Live and the new EfW Expo energy from waste Live work alongside each other to provide a focused world class environment in which to do business. With the latest solutions, the chance to network with like minded individuals and a comprehensive seminar programme highlighting the latest industry challenges and opportunities, this free to attend event was a must for anyone who works across these fast moving sectors.

NEWS BYTES   IMECHE Seminar BPMA will be sponsoring IMECHE’s Site Testing: System Performance Optimisation course to be held on 12 June 2013 at IMECHE, London In the search for reduced operating costs, the overall efficiency of fluid handling systems becomes ever more important for many industries. Studies have shown that 20% of all energy consumption is absorbed by fluid machinery, and that the equipment is often incorrectly matched to the demands of the systems in which it is installed. There is wide scope to improve the overall efficiency of fluid handling systems, but first we must be able to measure and assess the machine’s performance in the field accurately. Site performance testing offers many challenges: scale, equipment availability in live systems, measurement accuracy and, importantly, installation effects. Exploring some of the modern techniques for assessing machine and system performance, this is your chance to learn about the latest developments in testing and monitoring. Ensure your understanding of relevant standards and the type of instrumentation necessary for performance monitoring is up-todate and share your experiences. For further information visit www.imeche.org/events/S1764

BPMA Job Seeker Service

Attention - Are you currently seeking a career within the pump industry? BPMA has launched a new service for talented individuals seeking a career in the pump industry. Our members have interesting positions to fulfill within their company structures. Simply forward your CV j.page@bpma.org.uk and we will do the rest. A profile and details of the career you are looking for will be posted on our website free of charge for a maximum of three months. No personal details will appear, only a reference number. We will also include your profile on our weekly News-link bulletin which is circulated to key personnel at member companies. British Pump Manufacturers Association Limited National Metalforming Centre, 47 Birmingham Road, West Bromwich, West Midlands B70 6PY Telephone: +44 (0)121 601 6350 Fax: +44 (0)121 601 6387 www.bpma.org.uk

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

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

Sponsored by: WEG Electric Motors Winner: Tata Steel - ABB Limited

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

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

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

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

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

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

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

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

• Technical Innovation - Products

Engineer of the Year

Sponsored by: Sterling Fluid Systems

Winner: Owen Shevlin, SPP Pumps

Winner: Repowering of Tranque El Mauro Reclaim Water System Chile, Neptuno Pumps

Owen was recognised for his outstanding contribution to the UK pump industry, in a career which has spanned some 4 decades and included numerous achievements. The full citation can be found on the awards website.

Antofagasta Minerals’ Minera Los Pelambres, located in Chile, wanted to increase their reclaim water pumping capacity without changing its pipeline. After making a complete engineering analysis of Tranque El Mauro pumping system, Neptuno Pumps custom engineered ten high-head vertical turbine pumps that would operate at their best efficiency point. This allowed a 22% increase in pumping capacity and a 33% reduction in equipment, while saving more than US$ 1M in energy costs per year. 6

• Environmental Contribution of the Year

For further information about the Pump Industry Awards, and to view the photo gallery of this year’s event please visit the website at http://pumpindustryawards.com. If you are interested in sponsoring, nominating and/or attending the 2014 event please contact Andrew Castle on andrew@touchwavemedia.co.uk.

Save operational costs with WEG’s new energy reduction initiative

DART1

Wireless Machinery Monitoring System (ATEX Zone 1 Certified) As part of our commitment to continually reduce the cost of clients’ condition monitoring and improve safety in collecting data from hazardous or inaccessible areas, John Crane has developed an advanced technology, intrinsically safe wireless machinery monitoring system. Specifically designed for condition monitoring of rotating machinery in hazardous areas (ATEX Zone1), the system is battery powered, designed to be easily installed and virtually maintenance free.

WEG, a leading manufacturer of energy efficient electric • Fit in a day motors, has launched a new • Easily moved from skid to skid for bad actor RCA energy reduction initiative, which • Up to 16,000 point data spectrum is designed to help manufacturers • Real time and long time trending graphs optimise efficiencies of existing • Monitor in hazardous areas equipment throughout their • Monitor in inaccessible areas plants and processes. The free • Monitor infrequently run equipment with “wake up” feature • Dashboard GUI with alarm function assessment reviews equipment • Can run on standard PC and outlines a number of steps • Free issued software and no annual charges manufacturers can take to reduce • 3 to 8 year battery life energy use and increase equipment efficiency and reliability, enabling John Crane UK Ltd John Crane UK Ltd Nash Road, Trafford Park, Aberdeen Oil and Gas Support Unit, them to minimise costs, reduce Manchester, M17 1SS Asset Management Solutions, carbon footprint and total cost Grampian House, Mugimoss Road, 24hr Emergency: of ownership. Bucksburn, Aberdeen, AB21 9NP 0800 917 2408 In partnership with Sulzer, WEG is educating UK customers in selecting Colin Ure Rod Mackenzie suitable plant equipment with energy saving potential, and giving objective, T: 07786 727997 T: 07917 227825 professional advice on improving productivity while reducing energy consumption and costs. Experts will assess existing plant equipment and can install drives on-site www.johncrane.com to monitor and demonstrate existing energy usage. Then a variable speed drive (VSD) can be fitted, energy savings proven and potential savings related to project payback, on-going operational savings and total cost of ownership can be calculated. The free energy assessment is a simple process and enables 28/01/2013 the customer to trial equipment before purchase. It is suitable16617 BPMA 112x150mm Ad_AW 2.indd 1 for all plant equipment, including pumps, compressors, fans and conveyor belts. “Today there is greater pressure than ever on organisations to minimise their carbon footprint and reduce their costs and at WEG we’re committed to increasing energy efficiency, offering customers valuable choices on how they can best enhance their bottom line,” says Daniel Griffiths, product specialist - automation, at WEG. “Our energy efficient technologies like Grundfos Pumps are underthe W22 electric motors and our CFW inverter drives can play a real role standably proud of the reputation in helping them to do both. Our products are always designed to increase they have earned for developing energy efficiency, reduce noise and temperature levels, reduce size and and producing energy efficient increase reliability.” pump solutions that are suitable Motors are responsible for generating over 40% of total global energy for use within a wide range consumption. Selecting motors that have been designed with energy of applications. efficiency as a priority, such as WEG’s W22 Super Premium motor Today they can add yet another that exceeds the yet to be implemented IE4 regulations, will enable official accolade to their already manufacturers to make significant energy savings, reduce operational costs impressive environmental portand increase productivity. folio through their attainment of WEG’s new frequency inverter CFW501, which has been designed the coveted CEMARS (Certified Emissions Measurement and Reduction to meet the needs of the heating, ventilation and air conditioning (HVAC) Scheme) certification. industry, is another example of energy efficient technology. The robust, This award is the world’s first internationally accredited greenhouse compact and easy-to-use drives are currently available with a power range gas scheme that provides certification to ISO14064-1. It has a wide scope from 0.18 to 7.5 kW and are suitable for all pump and fan applications. that looks at six known greenhouse gas emissions and is recognised by all the Thanks to their advanced features and design, they help users to optimise major economies. This means it is a real reflection of company’s willingness to the operation of their motors, while being quick and easy to install and costfully embrace a commitment to the environment. effective to maintain. Andrew Ball, Water Utilities Director for Grundfos Pumps explains WEG is one of very few companies in the global market that designs, “Grundfos is committed to the environment and sustainability and the CEEMAR manufactures and tests all these components and, as a result, can accreditation reinforces this commitment and provides our customers with further tailor the most suitable and energy efficient solution that meets the confidence from a 3rd party that we live these values.” individual customer’s needs exactly - from low and medium to high But this in itself is not an end result, as at Grundfos we plan to use this as yet voltage applications. another driver to help us to achieve even greater environmental savings. As a To arrange an energy assessment visit www.wegreducingenergy.com or corporate citizen of the world, we believe businesses have a responsibility to act contact WEG on 01527 513800. as we know businesses are directly or indirectly responsible for a major part of For more information contact WEG Electric Motors (UK) Ltd, the CO2 emissions that are destabilising our climate. And since businesses are a Redditich, Worcestershire. big part of the problem, they should also be a big part of the solution. This is why Tel: +44(0)1527 596748 Fax: +44(0)1527 68726 Grundfos are fully committed to continue on their environmental journey. E-mail: wegsales@wegelectricmotors.co.uk For more information of Literature request contact Grundfos Pumps Ltd, Leighton Buzzard, Bedfordshire.Tel: 01525 850000 Web: www.weg.net E-mail: grundfosuk@grundfos.com Web: www.grundfos.co.uk

Grundfos attain prestigious certification

16:52

NOV® MONO® delivers third EZstrip™ cake pump to major UK food supplier A major supplier of prepared vegetables to the UK food industry has recently taken delivery of another EZstrip™ cake pump from NOV® Mono®. Meashambased AB Produce trialed an EZstrip™ cake pump before installing its first unit a year ago, and the latest pump is the third that the company has ordered. AB Produce supplies a wide range of potatoes and prepared vegetable to customers in the food wholesale, retail, catering and processing sectors. The company had previously used

a system of screw augers, steel collection bins, macerators and pumps to collect and process vegetable peelings before transferring them on to an on-site treatment plant. “However we were having problems with this,” comments AB Produce spokesman Carl Woolrich. “The physical location of the system, only a little way off the floor, meant that there was very little head of waste forcing its way into the macerators. The system was basically relying on the original pumps below to draw the waste slurry down into the macerators and this was

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resulting in blockages. “When we began looking for an alternative solution, we realized that the Mono EZstrip™ cake pump offered some very attractive advantages. Mono could provide the pump with a modified inlet blending flange and auger which helps convey the vegetable waste product into the pump. This greatly increased the flow of slurry through the macerators and into the pump. “The first unit we tested performed extremely well and had a capacity of 4-5m3/h. It allowed us to replace the previous auger, bin and pump combination with a single, compact alternative. The Mono pumps operate very well indeed and we’ve been happy to order more to help eliminate the problems that we had previously.” The Mono EZstrip™ cake pump has been designed specifically to provide outstanding performance whilst also simplifying and speeding up the maintenance process. It features a specially designed feed chamber which can be easily disconnected to provide access to the rotor and screw conveyor assembly. The rotor can then be separated from the conveyor, allowing removal of the rotor and stator while in-situ, with no need to disconnect any of the suction or delivery pipe work. This dramatically reduces the time required for maintenance work and ensures maximum availability. The EZstrip™ cake pump is ideally suited to a wide range of duties, including the transfer of thickened sludge cake (with up to 40% dry solids content) plus sludge blending, dewatered sludge handling and lime slurry dosing. Each of the pumps supplied to AB Produce features a widethroat hopper and a modified inlet blending flange, to ensure efficient collection and pumping of the vegetable slurry at a rate of 4-5m3/h. For more information please contact NOV® Mono® (Mono Pumps Ltd) Audenshaw, Manchester. Tel: +44 (0) 161 339 9000 E-mail: info@webenov.com or visit Web: www.mono-pumps.com

ErP Directive implemented - which changes can users expect in 2013? The ErP Directive, also known as Ecodesign Directive, aims to permanently reduce CO2 emissions by lowering the power consumption of the components concerned. Besides electric motors, the Directive also covers centrifugal pumps, e.g. circulators and water pumps. As far as water pumps are concerned, the relevant Regulation will be implemented in stages, important reference points being the years 2013, 2015 and 2017. On 1 January 2013, the first ecodesign requirements for water pumps as laid down in Regulation 547/2012 became applicable. The user should perhaps make a mental note of the so-called MEI, or minimum efficiency index, which provides useful guidance in this context. It is a dimensionless scale unit for water pumps which specifies how many pumps have an inferior efficiency. An MEI of 0.4 means that 40 % of the pumps available on the market have an inferior efficiency. So the higher the MEI value, the better. The European Pump Trade Associations believe that, based on the water pump population of 2010, forty percent will have to have their hydraulic systems modified by the beginning of 2015. Users may feel reassured, however, by the fact that the products of renowned companies are largely unaffected by the requirements of round one, because they have already invested a great amount of effort in terms of energy efficiency. KSB pumps meet the requirements of the ErP Regulations for 2013, and the majority already meet those not taking effect until 2015. The KSB

SuPremE® - the world’s most efficient magnet-less pump motor- even exceeds the ErP requirements becoming effective in 2017. The ErP Directive provided KSB with the important impetus to develop their Etanorm series. Although many pumps already today meet requirements that will not take effect until 2015, it was KSB’s goal to become better still. KSB’s trendsetting FluidFuture campaign is the logical further development of this approach. FluidFuture is the name of a concept consisting of all products and services that together make for an energy-efficient way to run a system. The concept is holistic in nature, i.e. besides the pump itself, it also looks at the system as a whole through the eyes of a pump expert. However, what remains true is that, if a pump is to meet the objectives of high efficiency and low energy consumption, its hydraulic system is key. KSB precisely match the pump to the specific requirements such that energy consumption and maintenance costs are minimised and total operating costs are reduced. In addition to the hydraulic system and

the trimmed impeller, variable speed operation in connection with PumpDrive and a standard IE2 motor is equally instrumental in keeping energy costs, and hence the cost of operation, down. Combined with the innovative KSB SuPremE motor, efficiency level IE4 with at least 15 percent less power loss can be achieved already today. KSB newly developed version of the Etanorm pump series is a good example to show how the ErP Directive can provide fresh momentum to find new ways of saving energy at component level. Highly efficient pumps such as the new Etanorm are, however, only one aspect. Precise impeller trimming, the perfect matching of pumps and valves, and, last, but by no means least, the sizing of pipelines are just as important for efficient operation. Real energy-saving potential cannot be leveraged unless the overall efficiency of a system is optimised. Optimisation in this case means a combination of a detailed analysis, a sensible selection, a high-efficiency drive and demand-driven operation. That’s why KSB uses the FluidFuture energy efficiency concept to analyse and optimise the entire hydraulic system and make full use of its savings potential. For more information please contact KSB Limited, Loughborough, Leicestershire. Tel: 01509 231 872 Fax: 01509 215 228 E-mail: sales@ksb.com Web: www.ksb.com

E-mail: sales@wilo.co.uk BPMA News_Advert.Wilo_155x225mm_X3_2002_print 14 May 2013 15:21:45

Sealless Goes Underground REDUCE COSTS WITH A SUNDYNE HMD KONTRO SEALLESS SUMP PUMP Sundyne HMD Kontro has extended its range of vertical inline sealless pumps with the development of a sump pump variant. The new GSPVS, which meets the requirements of API 685 (as applicable to this style of pump) and is fully ATEX compliant, has been designed for use in tank farms for tank fuel transfer, as well as in oil and gas refineries, chemical and petrochemical processing plants. The vertically mounted GSPVS pump provides all of the

benefits of a magnetic drive pump in a compact package, using fewer parts with no seal systems for reduced cost operation. Composed of modules which can be joined to reach a total assembly length up to five metres / sixteen feet, the GSPVS is mounted on a base available to ANSI B16.5 or to customer specific requirements, including lifting points as standard. The modular construction uses a flexible jaw coupling to join drive shafts and to absorb misalignment, decreasing vibration and increasing life expectancy.

TRUST IN MONO

We’re proud to be the company Britain trusts to pump, screen and grind across all process industries. The only British manufacturer of progressing cavity (PC) pumps in the industry, we’re committed to delivering the services and products you rely on. Round the clock. Day in, day out. Our unique heritage and experience allows us to offer a wide range of innovative PC pumps, munchers, screens and Universal spares. Trust Mono to deliver solutions you can rely on.

MON-13-016 BPMA 254 x 173 Portrait Ad.indd 1

Mono Pumps...

At the heart of British ingenuity For more information, visit:

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15/05/2013 16:34

Greased for life ball bearings are used along the column, removing the need for lubricating or cooling the intermediate sleeve bearings using system fluid. The use of labyrinth bearing seals and a suction strainer avoids external contamination to maximise seal and lubrication life. Sundyne HMD Kontro has more than twenty-five years’ experience in API applications and over a sixtyfive year heritage in magnetic drive technology. It was the first pump manufacturer to develop a sealless pump. With stricter demands for the safety and welfare of both personnel and the environment being imposed, sealless pumps are playing an increasingly important role. Sundyne HMD Kontro is continuously developing and extending its range, as improved magnet drive technology enables ever more efficient and powerful pumps to be built, widening the application scope of this versatile pump format. A copy of the new GSPVS brochure can be downloaded from the Sundyne HMD Kontro website at www.hmdkontro.com. For more information contact Sundyne HMD Kontro Sealless Pumps, Eastbourne, East Sussex. Tel: +44 1323 452141 E-mail: vlee@hmdpumps.com Web: hmdkontro.com

NEW Wastewater iPad App from Grundfos Finding ways to demonstrate the operational benefits and attributes of any highly engineered equipment on the go has been unobtainable until quite recently. Today however, the advent of iPad Apps that uses 3-D graphics and augmented reality to demonstrate product features and deliver product attributes directly into your hands have changed this forever. Now the Grundfos Wastewater iPad App shows how Grundfos are once again leading the way in using new technology to deliver an App via a simple catalogue style view approach. Once linked the App allows access to the industry leading wastewater portfolio that also utilises augmented reality to enable you to explore relevant products. So if you want to be able to view a pump from any angle, examine exploded views or understand the benefits of internal technological advances, this is an App youâ&#x20AC;&#x2122;ll want to access. You will also benefit from being able to find detailed product information and performance curve information at any time and wherever you are. This technology is ready for you is access today. If you have an iPad 2+ simply visit the Apple App store and see the pump world open up in augmented reality. For more information or Literature request contact Grundfos Pumps Ltd, Leighton Buyzzard, Beds. Tel: 01525 850000 E-mail: uk-sales@grundfos.com Web: www.grundfos.co.uk

visit mipumps.co.uk/services for more information or call 01634 818503

3-Year Pump Protection Guarantee Protect your Pump with an ITT PumpSmart controller and weâ&#x20AC;&#x2122;ll GUARANTEE the pump against failure from process upsets for up to 3 Years... or the parts are on us. Also, ITT will warrant the PumpSmart controller for 3 years from shipment date. ITT Monitoring and Control presents the award winning PumpSmart PS200 variable speed drive. The PS200 is the powerful combination of a standard variable speed drive and over 150 years of pump hydraulic design and process knowledge. By leveraging information through the variable speed drive such as speed, power and torque, PumpSmart provides key pump performance indicators which maximises control and reduces energy consumption over a standard variable speed drive. Key features include: SmartFlow - Using speed and torque data from the motor and modelling the pump performance curve, PumpSmart can calculate the flow of the pump without any external instrumentation. Pump Protection - PumpSmart can alert an operator or fault the pump in the event of a process upset condition such as dry-run, dead-head, minimum-flow or run-out. Multi-Pump Operation - A properly controlled variable speed multi-pump system is one of the most efficient and flexible means to meet highly variable systems Cavitation Protection - By monitoring a suction pressure transmitter PumpSmart provides an active condition monitoring function to protect the pump from the onset of cavitation. VFD Platform The PS200 drive series is a microprocessor based Direct Torque Controlled (DTC) adjustable speed AC drive based on the ABB ACS800 drive platform. For more information contact Goulds Pumps, Axminster, Devon. Tel: 01297 630473 E-mail: goulds.axminster@itt.com Web: www.ittpps.com E-mail: lafertuk@lafert.com

ABB takes lead role in helping to build awareness of solutions for global water leakage issues ABB once again took a leading role in promoting awareness of the issues surrounding leakage and its prevention through its lead sponsorship of the Global Water Leakage Summit 2013. Held in London in mid-March, the two-day event was themed around how to design, manage and maintain water networks, pipes and infrastructure to prevent leaks being built in and continuously reduce leakage levels. The event featured representatives from water companies and other organisations, who explained their various initiatives and strategies to minimise leakage from water distribution networks to a large audience of other water operators, decision-makers and influencers from around the world. As a key supporter of the event since its creation in 2006, ABB exhibited alongside other organisations, this year ABB and it’s partner TaKaDu shared space and brought a combined approach in explaining and exploring new ways to find and fix leaks more quickly. A key aim of the event was to encourage the exchange of best practice examples between representatives for tackling water leakage. Day one... The first day of the event chaired by Tony Harding

BPMA News Enquiry Form May 2013 For more information about any item in this issue enter the relevant enquiry letters in the boxes below, then add the requested personal and company details and fax back to 01428 751199.

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

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

Executive Vice President, Suez Environment International, the question of whether enough is still being done to acknowledge and address water leakage. Sessions during the day focused on a broad range of topics, ranging from advice on how to win support within utilities companies for managing leakage and non-revenue water (NRW) through to suggestions for building intelligence into pipe networks in order to better identify potential and existing leaks. With Jack Carnell, former South Staffs water company CEO, chairing the afternoon session. Completing the first day sessions were two international case studies on implementing a nonrevenue water reduction strategy. In these sessions, Khut Vuthiarith, Deputy General Director for Phnom Penh Water Supply Authority, Cambodia and Mbalie Matiwane, Real Losses Manager for Johannesburg Water, South Africa, explained how their respective organisations have taken steps to reduce leakage through the introduction of the latest techniques and technologies. This first day was topped off with the Global Water Leakage Evening Gala Dinner. ABB’s Tim Door along with David Hillyard from WaterAid Lead the evening activities. As well as providing an excellent forum for

informal networking, the Gala Dinner also helped to raise £1,650 for the Water Aid charity, with various prizes being auctioned off, including iPad’s, Balloon Rides, Champagne and more. Day two... Day two was chaired by ABB’s Tim Door Global Product Manager- Water EMF, starting with a session on how to choose between Opex and Capex for infrastructure improvement. This session included discussions on using past data to guide future planning and investment decisions and using the latest technology to create truly autonomous water distribution networks. This session was followed up with a look at the issues relating to the use of plastic piping in water distribution networks, in particular how to prevent leakage through the use of quality polyethylene pipes and joints. An important aspect of the Global Water leakage Summit is its focus on innovation, both in terms of the application of technology and the creation of working partnerships between water companies and other third parties such as academic institutions. For more information about the Global Water Leakage Summit and its objectives or about the dates for the 2104 conference please contact the London Business Conference Tel: 0207 033 4970 or E-mail: info@london-business.-conference.co.uk

Efficient as standard: eCartex The new generation of the proven cartridge seal with the benefits of DiamondFace highperformance technology. Worldwide interest in energy-saving and environmentally friendly technologies has increased significantly. While the major pump manufacturers are following one trend worldwide, Europe already has guidelines for reducing the power consumption of the machines. With the new eCartex, EagleBurgmann now offers a technically perfected solution: a combination of the Cartex cartridge unit, proven by decades of use, combined with the innovative DiamondFace coating, especially characterized by its high dry-run capability and solids resistance. The eCartex utilizes DF-coated seal faces that stand for extreme hardness, resistance to wear, and excellent thermal conductivity. The results are high savings potential: Energy consumption is reduced by up to 80%, and the ultra-hard seal faces increase the operating period by up to 100%. What is the effect of such energy savings an example: A non-coated Cartex-SN/43 (SiC/SiC) with 8,000 operating hours per year consumes 3,200 kWh of friction energy. The same DF-coated eCartex saves approx. 2,500 kWh for the same period, which corresponds to approx 325 euros in industrial electricity prices, or the entire annual consumption of a two-person household. The eCartex is suitable for applications in the processing industry, in the chemical, petrochemical, pharmaceutical, cell and paper pulp, food, water and wastewater sectors, and offers enormous advantages in the initial installation, standardization, retrofits, and conversion of packing. The pre-installed cartridge unit makes it easy to replace a seal quickly and without problems. Since 2007 EagleBurgmann has been successfully providing the DiamondFace mechanical seal technology worldwide. During the DF coating

procedure, a microcrystalline layer with all the attributes of natural diamond is applied to the sliding surfaces by chemical vapor deposition in a vacuum furnace. The method combines thick layers with extremely flat and uniform sealing surfaces. More than 6,000 engineered EagleBurgmann applications show that, with DF-coated seals, extension to seal service life by a significant factor is achievable. This reduces unscheduled plant shutdowns and the associated production losses. Advantages of the eCartex: • Pre-installed unit • Tried and tested on thousands of applications • Compact Vastly extended MTBF/MTBR intervals and reduction of the associated costs

For more information please contact EagleBurgmann, Wedgnock Industrial Estate, Warwick. Tel: 01926 417600 Fax:01926 417616 E-mail: sales@eagleburgmann.com Web: www.eagleburgmann.com

If youâ&#x20AC;&#x2122;re looking for a reliable, energy efficient, quiet running sanitary centrifugal pump designed for CIP and SIP, look no further. AxFlow is introducing a brand new series of Waukesha Universal Centrifugal pumps. This range offers as many as 17 models with pressure and flow capacities to 15 bar and to 800m3/hr, and a number of optional features to customize the pump design to any pumping job. All pump models are 3A and EHEDG certified and offer easy and cost effective maintenance.

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

PumP

protection Reducing energy consumption is one of the main targets for improving efficiency in the process industries but pumps, which are required to perform so much work in process applications, are notoriously power-hungry devices. However, says Phil Burge, Country Communication Manager at SKF, improved condition monitoring techniques, better installation and setup, and upgrades to components such as bearings, seals and lubricants will make a big difference.

Process plant operators are under pressure to deliver higher throughput, which not only impacts on energy bills but also on pumps themselves. Higher throughput requires faster rotational speeds, leading to increased temperatures and vibration, while energy consumption, which typically accounts for up to 45% of operating costs, increases. The challenge must be met by improved condition monitoring techniques, and by capitalising on the best components when specifying bearings, seals and lubricants. For example, by using our Explorer class bearings, lubricant consumption, as well as vibration and noise levels, are all reduced, and when re-lubrication intervals are extended, maintenance and running costs are minimised. This is significant, because industrial pumps are typically hard to access and inadequate lubricant application is a common cause of premature bearing failure. One way to combat this problem is to install a fully automatic lubrication system. Another is to install pumps equipped with sealed, greased-forlife bearings that are considered to be maintenance-free.

total lifetime cost of your machinery with a pump action plan, which will take into account the efficiency and suitability of components such as bearings and seals. When it comes to bearing failures, we estimate that 80% are caused by contamination, lubrication or mounting issues and when bearings fail or require premature replacement, the result is reduced uptime, performance and service life, so the best possible bearing specification and installation is key to improving efficiency. Maintaining safety also protects profitability; pumps are required to function safely, without leaking lubricant either into the environment or into products, a factor that is critical for food and beverage manufacturers. The first thing to be considered by a strategic action plan is installation and specification. For example, pumps that are simply too large for a particular application are a common problem, typically in older plant, because it was once common practice to install a larger unit to cope with increased demand rather than risk lack of capacity. However, this no longer applies because modern pumps are designed to be run at high speed for long periods.

However, the capabilities and targets of each facility must be evaluated before bearing solutions and lubrication systems can be specified, and this can be a complex task. With a range of options to consider, efficiency goals are often best achieved by enlisting the services of an experienced engineering partner. By applying integrated pump solutions, businesses can be released from the burden of underperforming pumps that restrict potential and profitability. With reduced vibration levels, lower operating temperatures, and increased reliability, plant can be properly optimised with pumps that are working far more efficiently, whatever their duty.

Once installation and specification issues have been addressed, a pump action plan turns to maintenance. Poor maintenance may result in a loss of 10 to 15% pump efficiency so effective maintenance is critical to minimise life-cycle costs and machine downtime. An expert partner can assist with the integration of proactive reliability maintenance (PRM) and operator driven reliability (ODR) into your maintenance practices as well as providing upgrading services. Measured against the cost of unplanned stoppages to production schedules, return on investment is significant and once these efficiency programmes have been established the plant is much better placed to plan for, and achieve its long-term profitability goals.

Saving energy for greater efficiency

The bearing factor in performance...

The task of bringing efficiency to pumps is made easier by a pump upgrade service, which assesses the conditions and needs of a given facility and makes upgrade recommendations, with the target of using less energy to achieve more efficiency. True, pumps will always demand a lot of energy, however well specified and installed, but badly specified or poorly maintained pumps will demand a great deal more. Worse still, the expenditure on this wasted energy is not being pumped back into the business. Although the problem of taming the insatiable energy consumption of pumps seems unavoidable, you can significantly reduce the

Bearing performance is critical to achieving higher pump performance, by increasing pump flow and head. To stay competitive, manufacturers are now having to modularise pump design and reduce the number of different models while covering the entire flow and head demand. An expert partner can apply its extensive knowledge and considerable experience to performance-enhancing solutions and/or downsizing assemblies. Engineers can analyse all of the factors in an assembly - bearing arrangements, lubricants and other components - identify the pumps potential and support the plant to ensure the best results.

The right bearings can improve pump uptime, improve performance and reliability, reduce maintenance costs and offer longer lifespan than regular bearings. Energy efficient double row angular contact ball bearings (DRACBB) are typically used in pumps and are specifically engineered and manufactured to reduce frictional moment by at least 30% compared with standard bearings. This improved performance provides additional benefits including longer grease life and extended re-lubrication intervals, further reducing maintenance and running costs. By using pump solutions, you can rely on engineers to perform or arrange for all bearing rework, alignment and installations, as well as provide solutions such as automatic lubrication systems. Responsible providers will then supports the facility with a range of maintenance services, from basic condition monitoring to advanced maintenance reliability programmes. An integrated pump solution will also defend people and profitability by keeping pace with safety and environmental legislation. Pumping systems can often be responsible for the movement of hazardous materials such as flammable hydrocarbons, toxic chemicals and thermally reactive chemicals, and any leakage of such material could represent a serious risk for workers and the environment. Where pumping systems handle food, beverages or organic fluids in medical applications, there is a potential risk of serious contamination to the product itself, which could cause serious damage to the business and its customers. Industry standards and government legislation are becoming ever more demanding, which benefits safety but also puts a strain on businesses who must strive to provide components that can meet these demands in harsh, or hygiene-critical, conditions. However, the advanced technology and knowledge of an expert partner can help engineers in meeting these challenges with a number of proven solutions. There are many roads that lead to pump efficiency but the most direct route can often be to take an organised approach by investing in an integrated solution. By following a clear action plan and a scheduled condition monitoring and maintenance regime, you can run your pumps at the maximum level of efficiency. This will protect equipment, minimise maintenance, cut downtime and make the most of your energy bills. SKF (U.K.) Limited, Luton, Bedfordshire Can be contacted on: Tel: +44 (0)1582 496433 E-mail: marketing.uk@skf.com Web: www.skf.com

Process Industry Informer May 2013

FLUIDS & LIQUIDS HANDLING inc. pumps & valves ASCO Numatics introduces range VERSATILE VALVE & of energy efficient motorised POSITIONER PACKAGE FOR OPTIMUM CONTROL valves with stainless steel bodies Control valve specialists SAMSON CONTROLS is continuing its tradition of constant product development, combining innovation and technology as demonstrated by their Type 3291 valve and Type 3730-6 positioner. Although already well established, these products have been enhanced to provide additional features and added value. The Type 3291 Valve combines the proven V-port plug and clamped-in seat and is particularly suited for use under severe operating conditions, such as in the oil, gas and petrochem industries. The smooth interior surfaces of the valve make it hard for deposits to form so the potential for the valves clogging is minimised. The valve is easy-to-service as it can be disassembled and assembled using standard tools and Samson’s proven modular valve design makes it very versatile in use. For example, accessories such as flow dividers, perforated plugs, insulating sections, bellows seals, positioners, limit switches and solenoid valves can be easily mounted. The type 3730-6 positioner with HART® communication is a further development of the successful Series 3730 positioners. The standard version is supplied with the proven EXPERTplus valve diagnostics that allow the entire operating cycle of control valves used in throttling or on/off service to be monitored. Another feature is partial stroke testing (PST) that provides information on whether shutoff valves function properly on demand and can be started by hand or automatically. Diagnostic data can be read much faster thanks to the improved HART communication and emergency shutdown is guaranteed in accordance with IEC 61508 up to SIL 3 which eliminates the need for an additional solenoid valve. For more information and product literature contact: Samson Controls, Redhill,

Surrey Tel: 01737 766391 1 Fax: 01737 765472 wmb-606 qdos ad_Layout 16/01/2013 15:36 Page 1

E-mail: Sales@samsoncontrols.co.uk Web:www.samsoncontrols.co.uk

Series 290 motorised valves are compact and lightweight. Suitable for AC or DC operation they have a low power consumption of just 12W.

ASCO Numatics introduces a range of compact and lightweight motorised valves for applications where electric actuation is required. The new valves are quiet in use and can be operated by a 24V DC power supply or by AC voltages of 24 to 48 and 110 to 250 (50 or 60Hz). The low power design requires just 12W of power during opening/closing, compared with 40 to 50W for similar products. Available as G 3/8”, 1/2” and 3/4” body in stainless steel, the motorised valve is suitable for fluid temperatures up to 90°C and is rated to IP65, making it suitable for outdoor use without an enclosure. The angled seat design provides a high flow rate and testing has proved that the valves are reliable for more than one million cycles, reducing maintenance costs and downtime. With a fast response time of less than 2 seconds per cycle (open and close), they do not require a current to maintain position. Low operational power consumption enables cabling and power supplies to be minimised - saving cost and reducing footprint. LED’s indicate the status of the device and these are visible through 360° to aid installation and troubleshooting. The new valves complement ASCO Numatics’ range of pressure operated valves and share many of their industry proven characteristics. They have many applications in the water treatment industry, wine production plants, industrial heating and cooling systems, car wash equipment and on-board systems for vehicles. For more information contact ASCO Numatics Ltd, Skelmersdale, Lancashire. Tel: +44 (0) 1695 713600 E-mail: enquiries.asconumatics.uk@emerson.com Web: www.asconumatics.co.uk

Great news! Never use a diaphragm pump again • Reduce maintenance costs - no valves to gas lock • Slash chemical costs - accurate and linear flow 0-500ml/min • Cut installation costs - no additional ancillaries required and a competitively priced range 50 years of innovation in pump technology REVOLUTIONARY PERISTALTIC PUMPHEAD

Fully sealed for life, one minute, tool-free maintenance

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Process Industry Informer May 2013

FLUIDS & LIQUIDS HANDLING inc. pumps & valves NEW FULL-FLOW PTFE DIAPHRAGMS FOR HYDRA-CELL PUMPS New PTFE Diaphragm In Full Flow

AFTERMARKET PARTS that ﬁt AIR OPERATED DIAPHRAGM PUMPS

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Hydra-Cell pumps are now available with new style PTFE diaphragms that Wanner International claims will offer users full flow characteristics under flooded suction inlet conditions, when pumping the vast majority of aggressive chemicals The new diaphragms are available to fit Hydra-Cell G03, G04, P200 and P300 models and can be used in combination with plastic pump heads. “The use of full flow PTFE diaphragms dramatically increases the number of applications where these seal-less, hydraulically balanced, multi-diaphragm pumps are suitable,” said Nick Herrington, Marketing and Technical Support Manager. “Hydra-Cell pumps can now be used in a myriad of chemical metering, dosing and transfer applications with no sacrifice in performance when compared to pumps with elastomeric diaphragms.” The result of extensive research, development and field testing, the new PTFE diaphragms have been shown to provide over 4000 hours service life at 1000 rpm under the most arduous duty conditions. For more information contact: Wanner International, Fleet, Hants. Tel: +44 (0)1252 816847 E-mail: NHerrington@wannerint.com Web: www.hydra-cell.eu

Thinqk, YOUR NEW ONE-STOP SHOP FOR AFTERMARKET PARTS THAT FIT AIR OPERATED DOUBLE DIAPHRAGM PUMPS

www.thinqk.com Durable, seal-less pumps for high or low pressure duty When pumping applications involve corrosives, abrasives, slurries or non-lubricating liquids HydraCell seal-less, high-pressure diaphragm pumps are an ideal choice. Available from MICHAEL SMITH ENGINEERS, the Hydra-Cell range of pumps are suited to both high and low pressure applications and combine rugged durability with exceptional pumping accuracy. The range covers flow rates up to 140 lit/min at maximum discharge pressures between 70 and 170 Bar, depending on the model. The absence of seals, cups or packing eliminates the issues associated with seal failure and therefore lowers maintenance costs. They can also be run dry without damage. They have a compact, multi-diaphragm design which saves space and helps to reduce maintenance costs and also means that for most applications, there is no need for pulsation dampeners. They operate with true positive displacement for optimum energy efficiency (>85%), better than API675 for repeatability, linearity and steady state accuracy. Hydra-Cell pumps are available in a wide choice of liquid end materials ensuring versatility in their ability to handle most ‘challenging fluids’ along with the flexibility to be adapted to a wide range of pumping duties. They have a proven track-record of robust and reliable operation in applications such as; metering, dosing, injecting and spraying chemicals, solvents, acids, hydrocarbons, natural gas liquids, alkalis, polymers, aqueous ammonia, resins, slurries, recycled or dirty liquids. Find out more about the Hydra-Cell range of seal-less pumps at: http://www.michael-smith-engineers.co.uk/products/high-pressure-diaphragm-pumps/ hydra-cell.htm or Contact: Michael Smith Engineers Ltd, Woking, Surrey Tel: FREEPHONE 0800 316 7891 Fax: 01483 723110 E-mail: Info@michael-smith-engineers.co.uk

Thinqk Ltd is a complete One-Stop Shop for Aftermarket Parts that fit Air Operated Double Diaphragm Pumps . These Aftermarket Parts fit ARO®, Blagdon®, Depa®, Graco®, Sandpiper®, Verder Air®, Versa Matic® and Yamada®. Thinqk is also the first business of its kind where clients can simply order parts online at www. thinqk.com. All components are manufactured in Europe and United States to meet the highest quality standards in the industry. All our aftermarket parts are honoured with the same warranty as the OEM. Thinqk is committed to supply excellence, customer satisfaction and competitive pricing. Our Aftermarket Parts pricing is at average 25% below published OEM list price. Delivery times can be kept to a minimum because Thinqk keeps all components in stock and has also distribution centres in the Netherlands and Canada for supplying the European and North American markets respectively. For more information contact Thinqk ltd. Tel: +31 (0)499 55 10 08 E-mail: info@thinqk.com Visit our new website www.thinqk.com

Busch charms the market with COBRA The COBRA pump is described by Busch as being highly robust in construction and reliable in operation, while at the same time being energy efficient for the user. Featuring an asymmetrical screw profile and free gas outlet, the pump provides improved ability to handle liquid and dust carry-over. The optimised efficiency of the pump reduces thermal load, which in turn maximises the service life of the installation. Uniform temperature distribution gives high resistance to corrosion. Benefits include ATEX certification for categories 1, 2 and 3, fast access screws which allow for easy servicing and a vacuum capability of between 1 hPa (mbar) and atmosphere. Ideal for use in many industries including chemicals, pharmaceuticals, plastic extrusion, rubber, beverage, furnaces, drying and impregnation to name but a few. Other key features include single stage operation, homogenised temperature profile, low vibration and noise levels and the option of split body design is available if required. For more information contact Busch (UK) Ltd, Telford, Shropshire. Tel: 01952 677432 E-mail: sales@busch.co.uk Web: www.busch.co.uk

Process Industry Informer May 2013

NO COMPROMISE BETWEEN FREE PASSAGE AND HYDRAULIC EFFICIENCY

The S-tube impeller does not compromise free passage or hydraulic efficiency Efficiency: World class hydraulic efficiency without compromising free passage Free passage: Greater free passage means better solids handling and greater non-clogging capabilities Simplicity: A design as simple and robust as a tube results in longer lifetime and lower maintenance costs

Wastewater is not what it used to be. In fact, varying solids and water content in wastewater has always been a challenge. The S-tube from Grundfos is the only impeller that meets these challenges. The traditional trade-off between free passage and efficiency when pumping wastewater is no more â&#x20AC;&#x201C; now you can concentrate on maximising your up time and reducing your costs.

See more at grundfos.com/no-compromise

Pump efficiency is a payback not a technical issue January 1st 2013 marked the first stage in a revolution in the world of pumps, but it is a revolution which has, so far, been confined to pump manufacturers and distributors. Pump end users, the very people who will stand to benefit most from the replacement of fixed speed pumps with more energy efficient models, have remained largely in the dark. The revolution has been triggered by the European Union’s ErP Directive, which has required pump manufacturers to significantly increase the overall energy efficiency of their pumps in three stages.

The ErP Directive arrived on January 1st but many process engineers remain in the dark about the potential benefits of converting fixed speed pumps to more energy efficient models. Paul Crowe of AMS Pumps, part of BSS Industrial, an expert in industrial pumping solutions, argues that the focus must now turn to the benefits of proactive replacement.

For example, one application I was directly involved in, concerned a South East England based company which used copious amounts of water during the manufacturing process. Upon inspection we found that the pump user was operating with a single pump to supply all of the factory’s water requirements. What’s more, control of the pump was non-existent with the water was being return back to the tank via a pressure relief valve. In effect this meant that the pump was running uncontrolled 24 hours a day, 5 days a week for 50 weeks of the year, delivering a constant amount of water regardless of demand. The pump user was paying nine pence per kilowatt hour which equates to a running cost of over £28,000 per year, not including maintenance and repair costs.

Stage 1, which came into force in January 2013, has limited the value of the Energy Efficiency Index to 0.27 for new glandless circulator pumps installed outside the heat generator, such as a boiler.

The solution was to install three pumps, arranged as duty, assist and standby, controlled by an inverter whilst maintaining a constant pressure. The key to delivering the energy savings was to vary the pump speed in line with demand - when there is no demand the pump stops, rather than working continually.

In August 2015 the EEI limit will be reduced to 0.23 and the product category will be widened to pumps inside the heat generator and also solar stations.

In terms of savings, by utilising the principle of the three pumps and by controlling the system on constant pressure, the projected energy savings were in excess of £17,000 per year.

In the final implementation stage, from 2020, the Directive will also apply to the replacement of integrated pumps in heat generators, and all glandless circulator pumps in the heating, air conditioning and solar sectors. The truth is that many pump manufacturers, like Wilo and Grundfos, are well ahead of the implementation schedule and are already manufacturing pumps to comply with stage 2, due to start in 2015. However, the focus on manufacturer compliance has inevitably confined the debate to the technicalities of the ErP directive, in particular the process of implementation. This focus has failed to penetrate the thinking of process engineers, construction specifiers, maintenance and plant engineers who deal with pumping issues on a daily basis, and who are more concerned with benefits of the new pumps and potential cost savings. The result is that a new high efficiency pump is only installed when an older fixed speed pump is beyond repair and replacement is the only option. For pump users, the benefits of a more proactive replacement of non-compliant fixed speed pumps have not, as yet, registered. The key issue is that new pumps, which are compliant with the ErP Directive, can be up to 80 per cent more efficient than a standard fixed speed pump. With rising energy costs this can equate to a very significant saving on energy costs for an end user, savings which can be balanced against the cost of a new pump.

The proof is in the eating... Whilst all applications are different, typical payback periods on a non-domestic system, that is over five

years old, are less than two years. With older systems the timeframe can be even quicker.

A further example involved the use of a pump to deliver water to a cooling water system used to cool electrical equipment during test. The existing pump delivered 6,000 gallons per minute, but a projected increase in production was set to extend the flow rate to circa 8,000 gallons per minute. The existing pump was a long-coupled end suction pump with a 75 kilowatt motor, controlled by a variable speed drive. By utilising new ErP compliant pumps we were able to offer him a more efficient pump delivering the increased flow rate, whilst still maintaining his current motor size. A further benefit that pump users should take into account is standardisation of pumps around a specific manufacturer. Standardisation of pumps has additional benefits in terms of parts replacement. My advice to pump users is to consider a full-scale audit of your site’s pumps which should involve a full pump inspection. It is only when process and maintenance engineers are equipped with the full facts, including payback periods on the capital investment that the potential for more proactive replacement of pumps can be fully realised.

AMS Pumps, BSS Industrial, Leicester, Leicestershire Can be contacted on: Tel: 0116 262 3232 E-mail: Web: www.bssindustrial.co.uk

Process Industry Informer May 2013

FLUIDS & LIQUIDS HANDLING inc. pumps & valves EMERSON EXTENDS ALARM MANAGEMENT AND ACTUATOR CAPABILITY FieldQ™ diagnostics help simplify work practices and improve efficiency Emerson Process Management has released cost-saving new diagnostic capabilities in its FieldQ rack & pinion, fully integrated valve actuator and controls. The updated capabilities greatly simplify daily work practices with the release of FieldQ Foundation fieldbus Version 3, with device diagnostic alarm management in a flexible modular package. The enhanced diagnostic alarm tools enable users to categorise and prioritise device alarms based on the criticality of the device and the severity of the problem detected by the diagnostics. Alarm settings can be configured to alert appropriate plant personnel so they can take action without being distracted by irrelevant alarms. “Our device diagnostics can be tailored for maintenance and matched

to predictive routines. Users will see efficiency improvements in their daily maintenance and turnaround planning, which help to maximise uptime and reduce costs,” said Sue Ooi, Vice President, valve automation rack & pinion products, Emerson Process Management. The FieldQ product modularity further extends efficiency by offering plug-and-play modules for many requirements, including explosion-proof and intrinsically safe capabilities, as well as bus

communication options. In addition, control modules are available for diagnostics such as travel time, cycle counts, time in position, and module temperature. This capability enhances field services capabilities and makes user interface more cost effective. For additional information about the new diagnostic power and modularity of FieldQ, please visit www.emersonprocess.com/fieldq

Twin screw pump range PSG’s Maag Industrial Pumps, the global leader in positive displacement pumps and systems, is pleased to introduce its S Series line of twin screw pumps. The S Series screw pumps are part of Maag’s newly created Industrial Pumps platform, which also features both external and internal gear pump technologies. Maag Industrial Pumps will feature a new brand image and pump technologies targeting general industrial applications. Maag S Series pumps are ATEX-certified for use in explosive or dangerous environments.

Maag’s screw pump technologies address the difficult pumping challenges found in the Oil & Gas, Process and Marine industries. Maag S Series pumps will be able to provide solutions that can meet the toughest application challenges regardless of temperature, viscosity or pressure. To learn more about Maag, please go to www.maag.com. For more information on Pump Solutions Group (PSG®), visit www.psgdover.com.

Process Industry Informer May 2013

TANK CLEANING

EXPANDED TANK Mobile grounding The Grundfos CLEANING RANGE solutions Conlift gives

Nozzle and Spraying System specialists BETE Ltd have expanded their extensive range of tank cleaning products following a number of modifications and improvements to their main tank cleaning ranges. On-going product development and customer feedback has resulted in the following changes to their three key product areas. The HydroWhirl-S range of 316 stainless steel rotary tank cleaners have four new standard models added for increased versatility. HydroWhirl nozzles are designed to meet the exacting standards for effective cleaningin-place (CIP) and so are ideal for food, dairy, beverage, pharmaceutical and chemical industry cleaning applications. The HydroWhirl Poseidon range of PTFE rotary tank cleaners has a new lower flow rate model along with other modifications. This results in a slower rotation speed for increased dwell time and highly effective cleaning power for more challenging tank cleaning situations. The Hydrowhirl Orbitor range of high power impingement cleaners is designed to meet the most exacting cleaning and hygienic standards and options now include a new twin head, 8 nozzle variant for swift cleaning cycles as short as 5 minutes. This continued, customer driven, development reinforces BETE Ltd.’s position as the market leader in tank cleaning products and systems for the chemical, industrial and food processing sectors. For more information contact BETE Ltd, Lewes, East Sussex. Tel: +44 (0) 1273 400 092 Fax: +44 (0) 1273 401 220 E-mail: Ivan@bete.co.uk Web: www.bete.co.uk

During hazardous location tank cleaning, spill recovery and product delivery operations, vacuum trucks and bulk tanker trucks are regularly exposed to the ignition hazards of static electricity. Verified static grounding of vacuum trucks and tanker trucks ensures that electrostatic charges do not become a spark ignition risk. The award winning Earth-Rite® MGV is a truck mounted grounding system that enables HAZLOC operators and contractors verify a True earth ground for their truck prior to material transfer operations, reducing the risk of drivers connecting to unsafe grounding points that could result in high energy spark discharges. The OhmGuard® hose tester complements the Earth-Rite® MGV by ensuring the hoses to be used in the transfer operation have electrical continuity with the grounded truck. The rugged hose tester is easy to use and will rapidly identify breaks in continuity caused by mechanical faults like broken bonding wires.

For more information please contact Newson Gale, Nottingham Tel: +44 (0)115 940 7500 Fax: +44 (0)115 940 7501 E-mail: groundit@newson-gale.co.uk Web: www.newson-gale.com

you a lift

CONLIFT are pre-assembled lifting stations from Grundfos Pumps that have been specifically developed for condensate removal and operate automatically when condensate enters the collection tank. There are several variants available: CONLIFT1 and CONLIFT2 that are supplied with an integrated NC/NO contact and cable so that if the overflow switch detects a high water level this can be used to switch off the boiler. CONLIFT2 also includes an acoustic alarm in case of a high water condition. It also has a selector switch with additional options. The CONLIFT2 pH+ is the CONLIFT2 but with an additional neutralisation unit supplied for those applications where condensate has a pH value below 2.5. The granulate supplied will raise the acid condensate to a more neutral level. This will reduce the risk of acid corrosion of the underground drainage pipe work within the property. This range offers a wider choice of installation options and as these compact units can be installed as either floor standing or for wall mounting makes them suitable for many applications. Find out more about the Conlift family as well as many other exciting new developments from Grundfos by visiting www.grundfos.co.uk For more information or Literature request contact Grundfos Pumps Ltd, Leighton Buzzard, Beds Tel: 01525 850000 E-mail: grundfosuk@grundfos. com Web: www.grundfos.co.uk

RFID MISSION CONTROL

Find all product informati

on here

w w w.eCatalogue.H

ARTING.co.uk

Our RFID superheroes provide a complete overview Not just in steelworks but in a range of industrial applications - even in extreme environments. Find out more at www.HARTING-RFID.com HARTING Ltd I Caswell Road I Brackmills Industrial Estate I Northampton I NN4 7PW I Phone +44 (0) 1604 827500 I Fax +44 (0) 1604 706777 I gb@HARTING.com www.HARTING.com

Process Industry Informer May 2013

health & safetY Berson UV systems comply with iuva, awwa and dvgw guidelines for municipal water Users avoid expensive modifications to bring systems in line with current guidelines

RUPTURE DISC TESTED TO OVER ONE MILLION LIFE CYCLES Elfab’s Opti-Gard™ achieves another industry-first

The International Ultraviolet Association (IUVA) and the American Water Works Association (AWWA) working group has released a new communication related to low wavelength, medium pressure disinfection. Current users of Berson UV systems have found that their equipment is already in compliance, while other installations have selected Berson to help them avoid the uncertainty factors to account for low UV wavelengths. According to the document, legislators and engineers are now recommending the application of a correction factor for municipal drinking water medium-pressure UV systems to compensate for the effects of wavelengths less than 240nm. Pathogen surrogates used for testing have proven to react differently than actual target pathogens to these low wavelengths. Therefore, previous validation testing and modelling may have overestimated inactivation of harmful target pathogens. While Berson systems have always blocked wavelengths less than 240nm with the use of type-240 quartz sleeves, users of similar medium pressure systems not in compliance will be required to re-evaluate system sizing and possibly make costly modifications or purchase new equipment. Berson’s 240-type quartz sleeves also comply with DVGW (Germany) standards requiring low wavelength blockage to prevent nitrite formation. Since the Low Wavelength Document was published, Berson has won a number of new medium pressure UV system projects where owners are adding UV treatment for disinfection of cryptosporidium and giardia.

Pressure management specialist Elfab (www.elfab. com) has tested its Opti-Gard™ range of rupture discs to over one million life cycles. The new service life, over four times longer than previously achieved within the industry, is a significant improvement. Two years ago OptiGard™ became the first rupture disc to be protected by a three-year warranty. Since its launch in 2004, the range has proved so robust and reliable in operation that Elfab offers a three-year warranty as standard on Opti-Gard™ discs supplied after 1st January 2011. Opti-Gard™’s improved service life and three-year warranty now allow customers to more precisely calculate how long their discs will last in service and to better plan their maintenance schedules following product installation. Opti-Gard™’s three per cent performance tolerance has allowed the optimisation of process pressures for many of Elfab’s customers. Apart from lowering re-supply costs, this has reduced disc inventories by up to 65 per cent. The Opti-Gard™ system comprises a reverseacting rupture disc, a single-design holder with multi-flange compatibility and a non-invasive, ATEXapproved burst detector, Flo-Tel™+. Featuring an industry-leading tolerance of only three per cent across a wide range of burst pressures and a 95 per cent operating ratio, Opti-Gard™ offers the highest performance characteristics available for liquid, gas or vapour applications.

For more information contact Berson UV-techniek, PO Box 90, 5670 AB Nuenen, Netherlands Tel: +31 (0)40 290 7777 Fax: +31 (0)40 283 5755 E-mail: sales@bersonuv.com Web: www.bersonuv.com

For more information contact Elfab Ltd, North Shields, Tyne & Wear NE29 8SD Tel: +44 (0)191 293 1234 Fax: +44 (0)191 293 1200 E-mail: sales@elfab.com Web: www.elfab.com

FORTRESS DEVELOPS MODERN amGard Pro RANGE OF HEAVY DUTY INTERLOCKS Industrial safety specialist Fortress Interlocks has significantly developed its amGard range of heavy duty, safety gate switch interlocks to create amGard Pro. amGard Pro builds on the recognised modularity and robust design of the existing amGard range but with added features and benefits identified by market feedback. Some added features include forward and backward compatibility, stainless steel heads, emergency release options, anti-vibration parts and non-contact technology. The Pro range integrates modern technology to deliver new control functionality but still offers the option for traditional lockout retro-fitting, creating a variety of new configurations not previously available. amGard Pro has been tested to withstand up to 10KN retention force, making it Fortress’ strongest yet. Tony Baggott, Sales & Marketing Director at Fortress Interlocks, commented: “We have revamped the amGard range as part of a long term programme to ensure our products remain at the forefront of industrial interlock technology. amGard Pro builds on the success of amGard, and the new developments keep pace with changing technology while ensuring compliance with developing global standards. amGard Pro is the ideal safety interlock for safeguarding plant and personnel in heavy duty environments.” For more information about the new amGard Pro range contact Fortress Interlocks Ltd, Wolverhampton Tel: +44 (0)1902 349 000 Fax: +44 (0)1902 349 090 E-mail: sales@fortressinterlocks.com Web: www.fortressinterlocks.com

CHOOSING THE RIGHT SAFETY SHIELD IS NOW EVEN SIMPLER Preventing harmful spray-outs from failing pipe joints, especially where toxic, corrosive and other dangerous liquids are involved is acknowledged as a vitally important part of plant safety. Regrettably, accidents do happen and pipe joint failures have been responsible for a number of high profile industrial incidents around the world. Acid, oil and steam jet spray-outs have the potential to cause severe personal injuries, either directly or through consequent fires and explosions. Safety shields, or flangeguards, are recognised as being an effective ‘first line of defence’ and a dedicated website,flangeguards.com plays an important role in raising awareness of the dangers to personnel, plant and the environment. FlangeGuards.com aims to be the most comprehensive resource on safety shields, helping engineers to understand, specify and order the right

Process Industry Informer May 2013

safety shield for every application. Flangeguards.com has recently been upgraded with new features making the process of choosing the right safety shield even easier. For example, on-screen prompts enable users to select all the necessary options, such as materials, including; PTFE Safety, PTFE Clear, PVC and stainless steel, along with joint types and pressure ratings. Once the choice is made all the relevant technical information, specifications, ratings and costs are provided and users can order on-line, normally for next day delivery. Industry regulations such as; DSEAR, COMAH, SOLAS, IP15, REACH and MARPOL all recommend or suggest the shielding or shrouding of pipe flanges and other potential leak sources, to ensure the protection of operators and equipment along with the other objectives of minimising

downtime and reducing the risks of catastrophic incidents. Furthermore, spray control using safety shields has also been more recently employed by Process Engineers’ as an effective way of reducing the size of ‘zoned hazardous’ areas by limiting the potential spray to the area around the pipe joint. For more information contact FlangeGuards.com, Basildon, Essex Tel: +44 (0) 1268 526161 Web: www.flangeguards.com

Since the credit crunch began in 2008, when fossil fuels were inexpensive, the cost of energy, electricity, gas and the production of steam have steadily increased. For some companies, energy

Control the

- Steam trap monito

costs now amount to over 25% of their total operating costs. At the same time, within industry there has been greater emphasis on improving the environmental impact of production. Plants need to be much more energy efficient to ensure they comply with the EU 20/20/20 legislation. This requires industries within the EU to reduce their greenhouse gas emissions from 1990 levels by 20%, increase the amount of energy produced by renewable sources by 20% and improve energy efficiency by 20%.

Despite the EU legislation being in place there has been a very poor response from industry to help comply with these new guidelines. The lack of change was so significant that a new directive was created to support the original legislation and ensure the guidelines were met.The resulting Energy Efficiency Directive (EED) requires industries with an energy consumption of over 50MW to comply within the next 18 months. The need for plants based in the EU to minimise energy consumption and maximise energy efficiency has therefore never been higher. For refineries, chemical, petrochemical and other heavy industries, this will present significant problems.The average plant was built between 20-30 years ago at a time when the cost of fossil fuels was low. This meant that the need to design a highly energy efficient plant was far less important than it is today. In addition, plant emissions were also far less of a concern than they are now. Significant changes will therefore be required to enable plants to comply with the new directive. Of course many plants have already started working to save energy and reduce their carbon footprint, but together with carbon trading becoming more expensive and the rising demand for energy, the EED has really created a sense of urgency to make rapid improvements to enable compliance. Industrial automation companies such as Emerson Process Management are helping industries achieve the improvements they need, such as reduce CO2 emissions, increase plant efficiency and reduce energy consumption to ensure they meet the EU directives. Some of the key areas to focus on are steam traps, compressed air stations and Pressure Relief Valves (PRVs).

Steam traps When steam leaves the boiler it has almost 100% quality (fraction of a saturated mixture that is steam). As it is distributed throughout the plant, heat is lost and some of the steam condenses and is collected in low points within the distribution network. Condensate forming within steam pipes can produce water hammer effects, which can cause costly damage and present safety issues. To prevent this problem steam traps are installed to remove condensation and enable the steam to flow freely. Steam traps play an important role in helping to: • Improve safety for plant personnel and equipment • Increase plant throughput and product quality • Reduce maintenance costs • Reduce energy consumption, lowering fuel costs • Meet environmental standards and goals Steam traps failing in the closed position allow condensate to collect within the steam line. This build up can prevent steam from passing, with eventually slugs of condensate producing the “water hammer” effect. This can cause damage to the pipework and fittings. Where condensate is not removed, high velocity steam can entrain small droplets to cause an erosion effect on valves, elbows and tees. Unlike water hammer, this erosion is silent and largely goes unnoticed until pipework is destroyed. Fortunately, steam trap blockages and failures in the closed position tend to be identified through operating problems and are therefore promptly repaired.

Failed open steam traps However, this is not the case for steam traps which have failed in an open position. Apart from unusual heating patterns or noticeable sound, there are generally no external signs to indicate a defective steam trap which has failed in the open position.

Increased fuel costs Steam traps failed in an open position do not pose a direct threat to the process or safety of plant personnel. But there is a significant financial impact on the bottom line of the facility. When steam traps fail in the open position, they allow steam to pass through continuously. Each steam trap has an internal orifice that limits the amount of steam/ condensate that it will pass, but devices installed on large, high-pressure steam lines can pass more than 270 kg/hr of steam. Depending on the cost of generating steam at a facility, this can cost the plant upwards of A25,000 per year in wasted energy.

Increased boiler load When a plant ages, the number of leaks increases and overall plant efficiency decreases. This loss of energy is often referred to as the “phantom” load. One executive at a major refining company estimated that 20% of his boiler steam production went to this phantom load with the majority of being lost from failed steam traps. Unless a plan was produced to reduce losses from the steam distribution system, a major investment would have been required to increase the capacity of the boilers or even the possibility of having to add another boiler. Because of the potential safety and process issues caused by failed steam traps in the closed position, many operators choose to open the bypass of failed cold steam traps. While this reduces both the safety and process impact of the failure, it increases the amount of fuel consumed by the boiler and eats in to any excess capacity. This has both a financial impact on the fuel bill and increases the impact on the environment from burning additional fossil fuels.

Steam trap failure rates When talking about failure rates it is useful to consider the underlying failure rate, or the rate at which your steam traps are actually failing. Ageing plants may appear to have a higher failure rate from years of not identifying and/or replacing failed traps. Process plant operators report that in annual audits they experience upwards of 35% failure rates. This is usually an indication that failed traps are mounting and not that the underlying failure rate is actually that high. An initial plant-wide survey found that, of 887 traps tested, 12.4% were defective and more than A320,000 worth of steam was being lost annually as a result of the failed traps. It is more likely that the underlying failure rate of steam traps is closer to a generally accepted 15% - 20% per year.

Manual steam trap audits - creating a false sense of security Many operators only perform steam audits once a year. Failed steam traps can therefore go unnoticed for long periods. This can leave the plant exposed to the safety, process and financial impact of failed steam traps. By increasing the insight into the health of steam traps,

Process Industry Informer May 2013

e cost of energy

oring using wireless technology By Danny Vanderput, Wireless Business Manager, Emerson Process Management maintenance can be better managed, helping to reduce the impact of failures and improve the efficiency of the plant. The best manual steam trap audits use testing devices that monitor flow (usually through acoustic noise) and temperature. Technicians must walk through the plant performing analysis on individual steam traps one at a time. For the test to be reliable, trap type, size and operating pressure must be entered into the monitoring equipment to enable actual readings to be compared with the ideal parameters. Some testing devices used are able to make this comparison in as little as 15 seconds. However, a 15-second test interval only allows a maximum of two cycles to be completed of a steam trap operating normally. In many cases, the noise caused by the flow will vary enough, even in a blow-through steam trap, to trick the testing equipment into believing that the trap is operating correctly, even if it has failed. Another problem is that steam traps are only in service if the sections of the steam distribution system where they are installed are being utilised at that time. During an annual audit, only those traps which are in service can be checked. This can mean that as many as 30% of traps are not analysed during an audit. The next audit may be 12 months away and even then, the particular trap might be offline again.

Distribution of steam trap sizes In order to implement a continuous monitoring programme it is important to know where the largest impact is on the process.The factors that decide where the impact is include both the size and failure rates of steam traps, their location in the plant and the important plant equipment they are protecting. Knowing the status and condition of every steam trap could enable a 20% reduction in steam loss that would contribute to A4 million a year saving in lost energy. Automated monitoring systems are available to enable operators to continuously monitor steam traps, helping to reduce the impact of failures. However, large plants can have hundreds, if not thousands of steam traps installed. It is therefore not economically viable to add monitoring to every trap. Operators must identify those steam traps whose failure would have the most impact and then apply the automated systems to these devices. Steam traps vary in shape and size. The flow through a traps orifice is dependent on both the pressure of the steam and the size of the trap. Although each plant has its own design, we can generalise on the overall number and size of steam traps installed in a plant. To simplify things further, we can concentrate on the financial impact of a failed trap.

Figure 1 shows the financial impact of all failed steam traps in a typical refinery. The majority of failed steam traps have a relatively low financial impact of less than A5000 a year. Those that create greater losses, should they fail, are referred to as “high value” steam traps. The average annual failure rate of high value steam traps is 10-15%. Financial impact is just one consideration when identifying high value traps. Energy loss is actually one of the least important impacts of a steam trap failure. Operators must consider high value steam traps to be those that: • Protect important plant equipment • Would have a large impact on plant processes if they failed • Are located on larger, higher pressure steam lines • Have a known high failure rate

Real-time automated steam trap monitoring Once high value steam traps have been identified then it is a question of adding new automated equipment to monitor these devices. Adding new networks and cable infrastructure to support these systems can often be cost prohibitive. Steam traps can be spread across a very wide area and located in hard to reach parts of the plant. Adding new cabling can be difficult, time-consuming and expensive. With the advent of wireless transmitter technology, continuously monitoring the health of the highest value

Figure 1.

Process Industry Informer May 2013

steam traps is now cost-effective. The widespread adoption of WirelessHART technology within process plants presents the ideal solution. WirelessHART networks are reliable, quick and easy to install, and provide a low cost way of adding new instrumentation across a plant. Taking advantage of this capability, Emerson Process Management’s Rosemount 708 Acoustic Wireless Transmitter monitors acoustics and temperature and transmit data using WirelessHART communications are used to identify failing and failed steam traps in real time.

Case study A large refinery that has recently installed 50 steam trap monitors was skeptical about the ability of a permanently installed real-time monitoring system to be more accurate than their current method of an annual manual audit of steam traps. The manual system was believed to be 95%-97% reliable. The refinery initially installed a real-time steam trap monitoring system on 24 steam traps, which had recently been audited and were found to be in good working condition. Of these 24 steam traps, 16 immediately indicated a failed condition. To check the validity of the results an independent company was asked to check the valves to see whether they had failed. All 16 of the steam traps were confirmed to have failed. The financial impact of the 16 failed traps was estimated to be A500,000 per year, if they had not been identified and repaired.

Emerson Process Management, Stockport, Cheshire Can be contacted on: Tel: +44 (0) 870 240 1978 E-mail: uksales@emersonprocess.com Web: www.EmersonProcess.co.uk

pROCESS CONTROL

Wonderware InBatch 2012 R2 Software Unifies Manufacturing Process Management Integration with ArchestrA System Platform drives real-time performance optimization Invensys Operations Management, a global provider of technology systems, software solutions and consulting services to the manufacturing and infrastructure operations industries, has released a new version of its Wonderware® InBatch software. Used to manage complex batch processes that require maximum flexibility, InBatch 2012 R2 software is integrated with the company’s ArchestrA® System Platform software to provide a unified application and information environment across the complete manufacturing process. By making batch management data available to users and systems throughout the plant, the software increases operational effectiveness and enables better levels of business optimization in real time. With more integration, InBatch 2012 R2 software makes equipment and phase information quickly available and useable with the company’s other offerings, including its Wonderware Historian, MES, Corporate Energy Management and ArchestrA Workflow software. This end-to-end approach to production management helps streamline processes, provides complete traceability and genealogy and improves collaboration across systems and people. Additionally, the software provides new recipe version history and comparison functionality based on XML documents, leveraging the World Batch Forum’s Batch markup language standards. Wonderware InBatch software is control system independent and consistent with the ISA-88 standard on batch control. Its capabilities include recipe management, batch execution management, equipment history, material genealogy, stringent security, webbased reporting and the ability to facilitate the design and implementation of systems that are compliant with FDA 21 CFR Part 11 regulations. For more information, please visit http://global.wonderware.com/EN/Pages/ WonderwareInBatchSoftware.aspx.

EMERSON CERTIFIED FOR PROCESS SYSTEMS CYBER SECURITY Wurldtech Security Technologies’ Achilles® certification recognises best practices to protect process control equipment against evolving cyber security threats Emerson Process Management’s DeltaV™ digital automation system and its project and engineering support services have successfully passed annual best practice standards set by Wurldtech Security Technologies, a world leader in protecting mission-critical connected systems and devices. Emerson has taken a leading role in responding to increased global cyber-security threats by providing cost-effective, easy-to-use protections to its DeltaV digital process automation system. Because of the dynamic nature of cyber security threats, manufacturers participating in Wurldtech’s Achilles Practices Certification programme must re-certify every year. Annual audits help participants improve their cyber security processes and practices, development, testing, commissioning, maintenance and support throughout an automation system’s lifecycle. Building on industry security requirements set by the International Instrument Users Association (WIB), Wurldtech created its programme to proactively and independently certify that manufacturer policies and practices meet and exceed these requirements. “Wurldtech set the bar for device manufacturer cyber security,” said Emerson Process Management’s chief strategic officer Peter Zornio. “Now, with the Achilles Practices Certification they’ve expanded coverage to the entire control system and its lifecycle. This certification is just one testament to Emerson’s on-going commitment to helping process industries meet current and emerging international cyber security standards and regulations, and most importantly, protecting their process and assets.” “We congratulate Emerson on this achievement,” said Wurldtech CTO and founder, Nate Kube. “By certifying its DeltaV system and its service practices for project engineering and support, Emerson can better meet cyber security expectations through globally recognised standards.” For more information E-mail: InfoCentral@EmersonProcess.com or visit www.EmersonProcess.com

Honeywell strengthens its OneWireless network capabilities with over-the-air device provisioning, other features OneWireless Release 210 Makes Wireless Technology Easier and Less Costly to Deploy in Large Capital Projects and Monitoring-Only Applications Honeywell (NYSE:HON) recently announced the availability of OneWireless™ Network Release 210, which incorporates several new features that make wireless technology easier to deploy and operate, and result in lower deployment and operational costs. New features in Release 210 include over-the-air field device provisioning and a Gateway General Client Interface (GCI) made possible by the ISA100 standard; and native integration of OneWireless field networks into Honeywell’s Experion® Process Knowledge System (PKS). “Wireless technology is transforming the industrial landscape and we are trying to make it even easier for end users to deploy and use,” said Ray Rogowski, global marketing director, Wireless, Honeywell Process Solutions. “With OneWireless Release 210, users can benefit from the flexibility and scalability offered by the ISA100 standard while maintaining high performance and reliability.” With the over-the-air provisioning feature, field devices can now be configured and commissioned without having to invest in handheld devices or needing to perform provisioning locally at the device. The result is faster and less costly deployment and improved worker safety. The GCI feature, enabled by the ISA100 standard, allows operations to continue using legacy protocols and proprietary applications while making it easier to wirelessly expand those applications throughout the plant. For further details of Honeywell’s range of OneWireless industrial wireless network solutions visit the website at www.honeywellprocess.com.

Rockwell Automation Launches New Configuration Tool to Simplify Machinery Safety-System Design Rockwell Automation Safety Automation Builder tool helps automate safetysystem development and save machinery design time Rockwell Automation recently announced the release of a new configuration and design tool to help machinery automation system engineers save time when designing safety systems. The Rockwell Automation Safety Automation Builder (SAB) configuration software helps users navigate the safety-system design process and apply global best practices. The SAB tool is available as a free download from the Rockwell Automation website. It guides engineers through the safety-system design process by providing options for layout, safety Performance Level (PL) analysis and product selection using AllenBradley products. The PL analysis uses IFA’s SISTEMA software tool (Safety Integrity Software Tool for Evaluation of Machine Applications) which is based on the globally accepted standard EN ISO 13849-1. “Our recent 2016 global market research outlook study on machinery safety found Rockwell Automation to be the leading global supplier of safeguarding solutions,” said Sal Spada, research director, ARC Advisory Group. “Rockwell Automation continues to support this leading market position with the launch of new safety tools. Its new Safety Automation Builder tool provides safety-system design guidance using the world’s broadest safety-automation portfolio, giving customers a single trusted source for the safety expertise they need.” The SAB software can be downloaded on the Rockwell Automation website. To get the most from this new tool, users should also download and run SISTEMA for PL calculations and Rockwell Automations Proposal Works software for product selection and bill of material output. For more information contact Rockwell Automation Ltd, Milton Keynes, Bucks Tel 0870 242 5004 Fax 01908 839696 E-mail: ukmarketing@ra.rockwell.com Web: ra.rockwell.com

Process Industry Informer May 2013

Saving Energy with Tailored Drive Solutions By Michael Müller (48) Business Manager for the drive, safety technology and switchgear areas at Rockwell Automation in Germany.

The reality of global climate change means that production and manufacturing techniques must become more modern and sustainable. The EU has already set the 20-20-20 goal as part of its Europe2020 strategy, with the objective of reducing carbon emissions by 20 per cent, lowering energy consumption by 20 per cent, and increasing the proportion of renewable energies by 20 per cent, all in order to curb climate change. From the manufacturing perspective, the term ‘sustainable production’ includes technologies able to make products with no greenhouse gas emissions, no non-renewable or toxic materials, and no waste - all while optimising profits and supply chain integrity. The manufacturing industry is responsible for 33% of total energy consumption. A reduction of just 1% would be equivalent to saving about 55 million barrels of oil a year - a value of about a billion dollars. For a manufacturing company, saving energy brings significant advantages. Lower energy consumption translates to lower production and operating costs and makes the company more competitive. In addition, it helps companies cope more easily with energy price rises. And last but not least, a company that actively saves energy scores points in the area of environmental commitment.

processes do not need a pressure or flow rate of 100 per cent, which is the case with most pump and fan control applications. Many are still direct-drive applications - in other words, their motors are running at the maximum power levels. However, most of these applications are characterised by variable or regulated speeds that are often controlled by valves and dampers. This mechanical regulation offers a lot of potential for saving energy. A car is a good example of this, as no driver would slow the car down using only the brakes if the engine was still running at full speed. Regulating pump and fan control applications can easily be performed with the addition of an AC drive. Unlike valves and dampers, the pressure or flow is changed by regulating the motor speed, and this in turn has a considerable effect on the power consumption of the motor. Energy savings are equivalent to the reduction in speed cubed (n3), resulting in significantly lower energy consumption. For example, reducing the speed of an application with variable torque by just 20 per cent would achieve energy savings of up to 50 per cent!

When companies look at specific applications, the electric drive system is a focal point due to its energy consumption. The ZVEI, the German electrical and electronic engineering industry association, reports that two thirds of all electrical energy consumed in the industrial environment is used for driving machines with motors (published in Motoren und geregelte Antriebe,April 2010). Pump and fan control applications are to be found in manufacturing companies and make up about 55 per cent of motor applications. This is where significant energy savings can be made, especially if production

Process Industry Informer May 2013

As mentioned earlier, there are tools available that can give an overview of potential energy savings within an establishments facilities that allows manufacturers to use mobile devices or computers to calculate potential savings derived from variable frequency drives for power pumps and fans. Manufacturers can use these tools online or as is the case of the Rockwell version, please forgive the “commercial” (http:/www.rockwellenergycalc.com/) download them to their iPad, iPhone, Blackberry or Android device. Modern drives are well suited to pump and fan control applications. They provide multiple control, communications, safety and hard ware options. Some now cover a power range of up to 1500 KW in the 400/480V and 600/690V areas which allow them to be used in ever more diverse and flexible applications. Finding the right drive is about more than performance, it’s about scalability and ease of integration into existing systems. Certain drives are based on a common platform with the same supply and control structure, extending their power range and providing a constant user experience. The best drives are also scalable, if more power is needed, the appropriate drives can be added.

Companies wanting to save energy can analyse a whole production or manufacturing process, or start by looking at individual applications. There are various online tools available, like the Rockwell Automation Energy Evaluator, that give a manufacturer a complete analysis of its current water, air, gas, electric and steam (WAGES) management performance. These tools also deliver a clear understanding of how its operating strategies compare with its peers in the same industry and in other sectors. The tool provides a 20-minute online assessment to generate a real-time report outlining a facility’s competitive WAGES management baseline. The results allow employees at all levels of the business to identify and implement strategic changes and to set improvement goals - both for individual facilities and across their entire organisation.

lower power consumption by almost 50%. Without taking flow conditions or other parameters into account, this reduction would enable the factory to save approximately a135,000 per year.

Many pump applications are suitable for this type of regulation, including main pumps for factory water as well as dosing, circulation, booster, cooling water, cooling tower and process pumps. In addition, as the motor is started and stopped by the AC drive, there is less mechanical stress on the motor, pump or fan, valves, tubes etc. This extends their lifecycle and allows for more efficient operation, providing further possible savings on maintenance and operating costs.

Seamless integration into the control environment facilitates and improves application development and diagnostics. Add-on profiles and embedded motion commands help to reduce development time and the associated costs, while optimising the configuration, control and collection of data. An additional function contributing to increased productivity for the best drives is the automatic device configuration whereby the controller automatically detects a replaced drive and downloads all configuration parameters onto it.

The following calculation is an example of possible cost savings that could be made by replacing mechanical with electrical regulation. A factory is using an older 250kW motor to drive a pump. The flow is regulated using a damper. Let us assume it is operating under the following conditions: three-shift operation, six days a week, with energy costs at a0.15/kWh including taxes. With the cubic formula mentioned above, an average speed reduction of 20% for this pump application would

Rockwell Automation Milton Keynes, Buckinghamshire Can be contacted on: Tel: 0870 242 5004 E-mail: ukmarketing@ra.rockwell.com Web: www.uk.rockwellautomation.com

4-6 June 2013, NEC, Birmingham

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