Process Industry Informer May 2014

PROCESS INDUSTRY INFORMER.

MAY 2014 Volume 10 No. 3

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

· www.flexim.com

Non-invasive Gas Flow Measurement In this issue...

• Air Compressor Focus • Process Measurement Special • In total 13 Editorial Articles • Plus News & Applications • Product Introductions

We value your valves, discuss why Coriolis is a ‘mass’ for flow measurement, learn how recovering your heat can save energy, why it’s ‘Logic’ to safeguard your management system, give your boiler house a boost and explain why the latest IEC guide is more static than you think

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

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CONTENTS News & Events 4

EDITORIAL FEATURES Boosting boiler

Compressors & Compressed Air 39

house performance 8 Process Measurement Special

Applications 5-7

– Temperature, Flow & Pressure

Air Control Products 39

1. The Changing Face of Temperature Control 11

Process Measurement & Instrumentation 7-13 + 18

Calibration 39

BPMA News from The British Pump Manufacturing Association 19-30

Array Spectrometers 39

Fluids & Liquids Handling inc. Pumps & Valves 31-35

Infrared Thermometers 40

2. Why Choose a Coriolis? 14 3. The pressure to conform 16/17 VALVES – when to repair or replace? 32 Guarding your plant automation assets 37 Compressor Special

Turbidity Monitoring Systems 34

Network & Communications 40

Solids Handling & Processing 36

Health & Safety 43

1. A third way to better compressor efficiency 38 2. Reducing costs by recovering energy from compressors 41 3. Saving waste from compressed air supply systems 42

Sieves & Sieving 36

Heat Transfer & Energy 43

Weighing 36

Product & Services Directory Inside Back Cover

Avoiding hazards due to static electricity 44/45 Process Industry Marketing 46

Maintenance 36

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

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NEWS & EVENTS

Sponsored by

Axion exhibits full range of WWEM 2014 services at PRE Show in Telford Exhibition Almost Full Resource recovery specialist Axion will be showcasing its polymer products derived from ELV, plus processing engineering, training and laboratory services from both its Consulting and Polymers divisions at the PRE Show, 18/19 June at the Telford International Centre.

Of particular interest to visitors will be sales of its high-performance polymers derived from end-of-life vehicles; process design services, such as plant design and optimisation and laboratory testing services.

Derived from end-of-life vehicles (ELV), Axpoly r-PP51 is a black polypropylene (PP) polymer for use in closedloop applications in new automotive-related products, such as the BMW Mini air vent component, plus wider manufacturing industries. Axion will also be launching a new styrenic polymer grade at the show.

“There is tremendous scope for re-using recycled polymers sourced from old vehicles entering the UK’s

scrap car ‘graveyard’ back into new motor vehicles’ components and other plastic goods; thereby stimulating a circular economy for these sustainable materials,” comments Axion Director Keith Freegard.

Axion specialises in resource recovery engineering, designing and commissioning innovative processing plants and plant modifications for other companies in the resource recovery sector.

It also has expertise in setting up collection trials and schemes for particular industry waste material streams.

As well as the plastics sector, Axion’s expertise also covers designing plants for resource recovery of a variety of waste streams including metals, end-of-life vehicles (ELV), aggregates and solid recovered fuel (SRF).

For more information contact Axion Consulting, Bramhall, Cheshire. Tel: 0161 426 7731 Fax: 0161 426 7732 E-mail: info@axionconsulting. co.uk or visit our Website: www.axionconsulting.co.uk

AIR TREATMENT EQUIPMENT PRICES REMAIN UNCHANGED FOR 4TH CONSECUTIVE YEAR Having built-up a reputation for high performance, energy efficient products, Hi-line Industries Ltd now also confirm that prices for their range of air treatment products will be held unchanged for the 4th consecutive year.

Their product range includes adsorption, refrigerant, desiccant and membrane dryer technologies for general commercial and industrial applications. Specialised requirements for medical, dental and breathing-air operation are also covered with their Hi-Zorb point-of-use desiccant dryers incorporating both filtration and energy control technologies. Adsorption dryers in their range include the HBP-ZL heat regeneration units with zero airloss qualities. These offer touch-screen control with -70°C and -40°C dewpoints, while also providing heat recovery and heat-of-compression energy-saving options. Their HPSA (heatless pressure swing adsorption) dryers offer -70°C, -40°C and -25°C dewpoints with AEMS dewpoint control and approval of food industry applications.

Their membrane technology dryers do not require an electrical supply, ideal for remote site applications where clean, dry air can be provided in the absence of a power supply. Their latest Tundra range of refrigerant air dryers incorporate direct energy technology delivering a constant +3°C dewpoint. An efficient single cell heat exchanger and zero loss condensate removal ensures minimum running costs.

Both in-house and mobile service and maintenance facilities are also available on a nationwide basis, covering both Hi-line and other manufacturers products, utilising ACRIB registered engineers approved as ‘safe refrigerant handlers’ and operating to higher than F-Gas Regulations.

For more information contact Hi-line Industries Ltd, Burton-on-Trent, Staffs Tel: 01283 533377 Fax: 01283 533367 E-mail: enquiries@hilineindustries.com Web: www.hilineindustries.com

PII to EXHIBIT at FlowEx 2014 CHINA This will be a “first” for us, and probably the first UK process title to do so.

FlowEx, co- located with Aquatec China takes place at the Shanghai World Expo Exhibition & Convention Centre over June 25 – 27 and is the most important event of its kind in East China.

With an expectant footfall of 23,000+ visitors, including 2000 from overseas, in an arena covering 30,000 square meters it will no doubt be an interesting and eventful experience for us.

Exhibitors from overseas include those from Germany, USA, Japan, Taiwan and South Korea and the UK.

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The exhibition that will run alongside WWEM 2014, the international Water, Wastewater and Environmental Monitoring conference, is now almost fully booked with just a handful of spaces remaining. “As WWEM 2012 approached, we were forced to refuse the later applications to exhibit, and it looks like this situation will be repeated, despite the fact that we have expanded the floor space considerably,” says WWEM organiser Marcus Pattison. “In order to create the extra space, we have moved the Conference into an adjacent Hall with access via the Exhibition.”

WWEM 2014 (www.wwem.uk.com), the 6th in a series of highly successful environmental monitoring events, will return to the Telford International Centre in the UK on the 5th and 6th November.

The event will include conference speakers and exhibitors from all over the world, providing delegates with access to a broad selection of conference presentations, workshops and demonstrations.

The event will seek to provide delegates with the latest information on the techniques, technologies, methods, standards and regulatory requirements that relate to the monitoring which takes place both on-site and in the laboratory, covering sampling, field analysis, gas detection and continuous water and wastewater monitoring applications.

WWEM delegates include anyone with a professional interest in environmental monitoring; including regulators, industrial process operators, water utilities, accreditation organisations, commercial laboratories, instrument manufacturers, consultants, analytical service providers, researchers and academics.

CPD points will be awarded to Conference delegates and the cost to attend will be £55 per day. However, registration for the event is free of charge and preregistered visitors are provided with free access to the exhibition and to the workshops, in addition to free on-site parking, and complimentary lunch and refreshments.

For more information please visit WWEM 2014.

Exhibition Opening Hours 9.30am - 5.00pm Wednesday 5th of November 2014 9.30am - 4.30pm Thursday 6th of November 2014

PROCESS INDUSTRY INFORMER May 2014

APPLICATIONS

A clearly better treatment There are many different demands facing businesses in the UK today.

This includes the dairy sector that is keen to improve standards whilst driving down costs and reducing their carbon footprint.

This was the case for BV Dairy in Dorset who operates as an independent manufacturer of top quality dairy produce and who is committed to ensuring they employ the latest and best in manufacturing technology. Two years ago this ambition, in collaboration with their project partner Clearfleau, was successfully realised with the installation of an efficient, innovative anaerobic digestion plant that came about as a result of a Government initiative.

Grundfos Pumps worked with Clearfleau to provide a range of pump solutions that operate integrally within the Clearfleau’s liquid digestion process. These included a booster set, as well as a number of specialist Grundfos TP circulators, members of the SEV submersible range, a Hygia II sludge pump and a CM3 that operates as a permeate transfer pump as well as members of the Grundfos Digital Dosing family.

The results have been excellent and being able to generate renewable energy from co-products will also provide the ideal solution in many similar situations in the wider food and drink processing sectors. Add to this the ability to integrate these systems within new or existing effluent treatment plants and it is clear why Grundfos pumps and Clearfleau are the obvious choice for delivering a novel, effective anaerobic digestion process.

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

PRECIA-MOLEN MAXIMISE THE BEER DUTY REFUND FOR MARSTON’S Marston’s a West Midlands brewery has started to ensure that they minimise their beer duty by claiming a refund on the ‘dregs’ from their returned kegs and casks.

Known as ‘ullage’, this is often only thought of as a beer unfit for consumption but has quite a wide definition. With duty being paid on all beer leaving a brewery it seems sensible to reclaim any duty on beer which is returned.

Before sterilising the casks and kegs prior to being filled with fresh product, any beer remaining in the container is emptied and collected in a trade approved (ullage) vessel. This procedure then allows the weights, and therefore the volumes to be recorded and any beer duty previously paid can then be re-claimed.

With a current maintenance and calibration contract in place with Precia-Molen, Marston’s placed an order for them to upgrade the current system.

Precia-Molen supplied a new stamped ullage ‘return’ vessel and replaced all the indicators on the holding vessels. A platform scale was also supplied to compliment the ullage vessel.

The Marston ullage vessel is basically a tank on load cells which is calibrated for trade use and recalibrated on a regular basis under the contract previously mentioned. Precia-Molen redesigned this vessel to incorporate four load cells, and oversize foundation plates which facilitate the regular use of a force calibration rig to recalibrate and complete the reverification of the vessel for trade use. A model I200 weight indicator was also supplied to complete the installation.

For more information contact Precia-Molen UK Ltd, Redditch, Worcs.

Tel: 01527 590320 Fax: 01527 590301 E-mail: sales@preciamolen.co.uk Web: www.preciamolen.com

PROCESS INDUSTRY INFORMER May 2014

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APPLICATIONS

SEALLESS, MAG-DRIVE PUMPS SOLVE REFRIGERANT RECYCLING PROBLEM Minimising the potential for chemical and environmental hazards by eliminating pump leaks, reducing downtime and extending service intervals were the important challenges in a fluids recycling application at a leading refrigeration company. In this situation, the use of magnetically coupled vane pumps supplied by pumping specialists MICHAEL SMITH ENGINEERS has proved successful in eliminating the contamination threat, reducing downtime and repair bills.

The Problem As part of the reflux process at the refrigeration company, a range of refrigerants including HFCS’s (Hydrofluorocarbons), propane and butane needed to be transferred to the top of a distillation column. Previously, a mechanically sealed cast iron gear pump had been used for this stage of the process. However, there were problems with seal leakages, process liquid contamination and reduced capacity due to excessive slip caused by the low liquid viscosity of 0.2 cp.

The Solution The decision was taken to install an M Pumps magnetically coupled vane pump from Michael Smith Engineers, model VM-15 with variable speed drive. M Pumps Vane series are capable of flow rates up to 3000 lit / hr at up to 12 bar differential pressure and at temperatures up to 200 deg C. They can pump liquids with viscosities up to 10,000 cSt and are suitable for system pressures to 25 bar for the standard design, or 150 bar for the

high pressure version. The pump was installed in late 2012 and has been running for over a year without problems.

The Result and Benefits The combination of the magnetically coupled, sealless design and a stainless steel pump head has provided excellent corrosion resistance and effective containment of all the process fluids.

There are no rotating seals to fail, so leak-free pumping is assured and consequently the refrigeration plant is benefitting from a reduced environmental hazard and no repair costs associated with the seal failures of the previous pump. The extended pump operation between servicing also means reduced downtime. The user also appreciates the compact, close-coupled design which has freed up plant work space and the variable speed drive feature which provides the flexibility for them to pump at different duty points, depending on the refrigerant being pumped.

M Pumps VM Series ATEX certified pumps are one of a wide range of mag-drive, sealless pumps available from Michael Smith Engineers which provide an ideal solution to pumping aggressive, corrosive or high purity liquids.

For more information contact Michael Smith Engineers Ltd, Woking, Surrey Tel: FREEPHONE: 0800 316 7891 Fax: 01483 723110 E-mail: Info@michaelsmith-engineers.co.uk Web: http://www.michael-smithengineers.co.uk/products/vane-pumps/vanepumpsproducts.htm

MICRONICS CLAMP-ON FLOW METERS PROVIDE COST EFFECTIVE SOLUTION TO IMPROVE FLOW MONITORING AND EFFICIENCY In any manufacturing process guess work has to be kept to the absolute minimum. Scott Bader is a multinational chemical company manufacturing polymer, polyester and resins and their business depends heavily on precise measurements for manufacturing efficiency and cost minimisation. The company uses reactors and blenders which require cooling at different stages of production and it is crucial to know precisely the flow rate through heat exchangers of variable pumps which run at different speeds.

Atiq Malik, Scott Bader’s Process Improvement Engineer needed to know the exact flow rate through cooling coils in order to estimate the overall cooling load and time in reactors and blenders. He had little confidence in the existing electromagnetic flow meters on 2 vessels. The other 3 were fitted with Micronics 220A and 220B, portable flow measurement and recording systems which allow simple, accurate flow measurement from outside the pipe giving non-invasive measurement of liquid flow.

An interactive QuickStart menu simplifies installation at any suitable location, together with minimal set-up requirements, means that the system can be installed and brought into service very quickly. Furthermore, the application parameters for a particular site can be saved

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to non-volatile memory and instantly recalled if a site is revisited for monitoring at a later time – further reducing the set-up time.

Mr Malik was satisfied with the quick and accurate flow measurement and easy to follow menu and simple set up which provided for minimum downtime. This in turn meant time and cost savings so he had no hesitation in recommending that the remaining 2 vessels were fitted with the Micronics meters.

Micronics were selected to supply the meters due to Scott Bader’s existing experience with the clamp-on, ultrasonic, flow measurement technology. It was an easy decision to make due to the considerable cost reductions and the competitive pricing in comparison to similar technology solutions or alternatives which would have required significant installation and set up. Mr Malik is certain that there will be numerous opportunities throughout Scott Bader to benefit from the confidence the Micronics flow meters provides.

Going underground – NOV Mono helps keep rail tunnel project on track Outstanding build quality, reliable performance and an ability to withstand demanding applications helped five NOV Mono E Range pumps to be selected for difficult mine dewatering duties in Hong Kong. They replaced the original submersible pumps which were expensive to operate and subject to frequent damage.

The Mono™ high pressure pumps are now being used to on the construction of two new express rail tunnels, Shek Yam and Pat Heung, on the Hong Kong’s Mass Transit Railway system. They were chosen for their ability to withstand the high volume of drill cuttings, mud and concrete found in the fluids they are pumping.

In the eighteen months since they were installed, the pumps have run for more than 4,800 hours without the need to change any parts. The pumps on the sludge transfer duties have operated for 24 hours per day without any problem.

“The Mono pumps run at 10 bar pressure and handle an average of 20 litres per sec of fluid,” says Derrin Cikoja of the tunnel construction site management team, who worked closely with the Mechanical Superintendent, Paddy Gallagher. “They are providing us with a high dollar-to-dewater ratio and that is helping to reduce their whole-life costs. We would definitely look at using more Mono pumps on future projects.”

For more information contact Nov Mono Ltd, Audenshaw, Manchester Tel: +44 (0)161 339 9000 Web: www.mono-pumps.com

Available on iPhone and Android devices

For further information on this project or the Micronics range contact Micronics Ltd, Loudwater, Bucks. Tel: +44(0)1628 810456, or visit Web: www.micronicsflowmeters.com

PROCESS INDUSTRY INFORMER May 2014

APPLICATIONS

Archco-Rigidon Protects Injector Spools, Pipework and Vessels Painting and Labour Ltd of Immingham are long-term users of Winn & Coales (Denso) Ltd’s ArchcoRigidon 403D and 503D glass flake vinyl ester coatings. The company has been regularly contracted to line internal surfaces of pipework, tanks and vessels and also injector spools with these specialist interior protective coatings, following shot blasting to the Swedish Sa 21/2 standard near white metal.

Cristal Pigments, also of Immingham, is also a leading customer for services for protection of injector spools, pipework and process tanks. Pretreatment and ArchcoRigidon application of injector spools and pipework was carried out at Painting and

Labour’s workshop.

Painting and Labour also lined two small receiver vessels onsite at Cristal Pigments – one of them only required coating with Archco-Rigidon 403D on the bottom dish end after blast cleaning. The full vessel specification was: blast cleaning to Sa 21/2 followed by multiple brush applied coats of Archco-Rigidon 403D to achieve l000 microns overall thickness. On completion of lining both vessels were checked for film thickness and Holiday detection readings.

For more information contact Winn & Coales (Denso) Ltd, London Tel: 020 8670 7511 Fax: 020 8761 2456 E-mail: mail@denso.net Web: www.denso.net

PROCESS MEASUREMENT & INSTRUMENTATION Latest Hansford Sensor provides vibration monitoring to customers with limited space

Hansford Sensors, the leading European manufacturer of industrial accelerometers, has launched a new accelerometer, designed for use in engineering applications where space and access is limited. The new HS-420S vibration sensor provides customers with a low cost on-line means of monitoring fans, pumps, motors and a wide range of process equipment, with the capability of interfacing directly to PLC, BMS or any 4-20mA input module.

The development of the HS-420S vibration sensor meets high customer demand for a low profile and cost-effective industrial accelerometer that is ideal in a wide range of applications where space and access to apparatus is limited. Weighing just 170 grams, and measuring 25mm in width and 35mm in length, the HS-420S vibration sensor can also be used for offline applications using commercially available data collectors. The base isolated vibration sensor ensures that problems are detected early enough to allow planned maintenance intervention to be carried out with minimal disruption and cost.

For more information contact Hansford Sensors Ltd, High Wycombe, Bucks.

Tel: +44(0) 845 680 1957 Fax: +44(0) 845 680 1958 E-mail: sales@hansfordsensors.com Web: www.hansfordsensors.com

PROCESS INDUSTRY INFORMER May 2014

Vega Pressure Transmitters: World First For Temperature Compensation Among the new VEGABAR 80 series family of pressure instruments, VEGA has innovated a revolutionary new feature: A fast thermal reaction and shock compensation system, which is the first of its kind in the world.

Most pressure users could practically write a book about thermal shock. In the past, after being exposed to extreme temperature fluctuations, it often took many minutes, sometimes longer, for pressure transmitters (especially flush diaphragm types) to recover and deliver sensible measurements. At worst, it goes unnoticed that a sensor is experiencing thermal shock and transmitting incorrect readings. These errors can be much greater with ‘differential systems’, for level in pressurised vessels, with ‘top and bottom’ transmitters. However, this new technological breakthrough for temperature and thermal shock compensation, consigns these problems to history. The fast thermal reaction on this flush-mounting CERTEC® ceramic cell maintains stable and correct measured values, even with very rapid temperature changes.

This technical innovation is a patented design, which utilises the elegant solution of mounting a temperature measurement element directly in the back of the diaphragm (see fig. 1).

This complements the temperature sensor at the heart the CERTEC® cell which is, by nature, slower to react. By being on the diaphragm itself and so close to the process, even the tiniest temperature change it is immediately detected, this means any thermal shock that occurs is quickly and fully compensated. All Fig 1: VEGABAR 82 CERTEC the transmitters in the cell with fast thermal reaction – VEGABAR 80 series a clever yet simple innovation can also be used in an – the undulating line is electronic differential the temperature element pressure configuration. which delivers high reliability So, for example, in a even with sudden temperature pressurised vessel jumps level measurement, with both measuring cells able to do this, resulting in a high stability and accuracy is maintained through all process temperature stages such as CIP cleaning or rapid cooling. This innovation also offers

the possibility to measure both process pressure and product temperature via a single device and process connection.

VEGA has conducted extensive tests on the new system with thermal shock change (<4°C / >95°C) and compared the performance of other ceramic measuring cells with the new one of VEGABAR 82 (see fig. 2) The result: convincing proof that the new CERTEC® ceramic pressure cell easily handles sudden, large jumps in temperature. This advance with VEGA pressure sensors using the established, modular plics® system, now ‘leap frogs’ many other pressure cell technologies in stability and reliability for rapid temperature changes and process measurements.

Fig 2: Result of the thermal shock test (<4° C / >95° C): In green: deviation of the new fast thermal reaction CERTEC® ceramic measuring cell of VEGABAR 82 compared with previous ceramic cell in red dotted line.

For more information contact VEGA Controls Ltd, Burgess Hill, West Sussex Tel: +44 1444 870055 Fax: +44 1444 870080 E-mail: info.uk@vega.com Web: www.vegacontrols.co.uk

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Boosting boiler

house performance and safety today The evolution of steam generation and control technologies has produced safer and more energy efficient steam systems for today’s processing applications. Paul Mayoh, Technical Manager for Spirax Sarco UK, discusses the regulations governing boiler operations and looks at some of the technologies available to reduce energy consumption in the boiler house.

Arguably, the most important change in recent years for boiler operation and management came in the form of new guidance document ‘Guidance on the Safe Operation of Boilers’, or BG01, introduced in October 2011. Drafted by the Combustion Engineering Association (CEA), the Safety Assessment Federation (SAFed) and the Health and Safety Executive (HSE), BG01 runs in parallel with the Health and Safety Executive’s Safe management of industrial steam and hot water boilers (INDG436).

BG01 replaced the old PM5 and PSG2 guidance notes from the HSE and SAFed respectively. Rapidly evolving control technology was one of the big drivers for changing the guidance.

Why bother?

Although BG01 (like PM5 before it) is guidance, not legislation, with the weight of the HSE behind it, you’d need a pretty good reason not to follow the best advice around. It’s a great way for steam-using organizations to show regulators and insurers that they’re committed to best practice. Furthermore, operating a boiler safely and efficiently can boost productivity and cut energy consumption, keeping costs down. So there is a range of benefits for boiler operators that comply with BG01.

Ultimately, however, the biggest reward is a safer and healthier working environment.

The latest training courses will ensure boiler managers and operators are compliant with the guidance, but there are also changes that can be made around the boiler house that will improve the safety and efficiency of most steam systems.

Bring down boiler costs with blowdown A good example is boiler blowdown, probably one of the least understood areas of boiler operation.

Necessary to ensure that the boiler can deliver clean, dry steam to the system, blowing down a boiler is potentially wasteful of energy when performed manually and the water removed is just dumped to drain. Tremendous cost savings can be achieved with the latest automatic blowdown control systems.

Payback times of only a few months are possible.

So what does BG01 mean for people working with steam and hot water boilers? In terms of equipment, it’s the wider range of control options that probably marks the biggest change. In terms of making sure that personnel are up to scratch, it’s the minimum recommended qualifications that come under scrutiny.

Advanced boiler house controls help ensure boiler operations are kept at peak operating efficiency and in compliance with the latest safety guidance Blowdown is essential to control boiler water contamination and is performed by drawing off boiler water, which is then replaced with clean water from the feedtank to reduce the concentration of contaminants.

The amount of energy contained in water taken out of a boiler during blowdown can be considerable. Blowing down a 10,000 kg/hr boiler running at 10 bar g can produce an energy flow rate of up to 240 kW.

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Why install heat recovery?

Without heat recovery, the energy in the blowdown water would be wasted, but with proper heat recovery about 80% of this energy can be recaptured. The savings are considerable with the system paying for itself within months.

As blowdown water is drawn off it flashes to low pressure steam, which can be captured by a flash vessel. This separates the flash steam from the condensate. From here, the flash steam is fed to the boiler feedtank to heat the feedwater, while the remaining hot condensate is passed through a heat exchanger. The heat extracted from this is also used to pre-heat the make-up water, as every kilogram of flash steam used in this way is a kilogram of live steam which does not need to be supplied by the boiler. Finally, the cooled condensate can be discharged to drain.

It’s not just heat, recover more condensate Next to steam, condensate is the most valuable resource available to any steam system operator. While almost every steam system used to heat a building and its hot water is likely to have some kind of condensate recovery system in place, the financial benefits of upgrading the system are too good to miss Condensate contains about 25% of the energy of the steam from which it came, which is why most steam system operators recognise condensate as being a particularly valuable resource. In reality, many UK sites already have condensate recovery systems in place, although nearly all could be enhanced by the latest techniques.

For BG01, correct training of boiler operators and managers is essential. The document even names a specific qualification for the first time. It recommends that personnel should be qualified under the Boiler Operation Accreditation Scheme (BOAS), with Certified Industrial Boiler Operator (CertIBO) training for operators and a Diploma in Boiler Plant Operation Management (DipBOM) for managers.

Correct training of boiler operators and managers is essential. BG01 recommends that personnel should be qualified under the Boiler Operation Accreditation Scheme (BOAS)

Much better is to install an automatic blowdown control system. This ensures the minimum blowdown rate is achieved. Not only does this minimise energy loss from the boiler, but it also eliminates the need for skilled boiler operators to be tied up performing this tedious task.

So it is important to ensure that a boiler is not subjected to an excessive blowdown rate, which is typical with manual blowdown routines. Manually controlled boiler blowdown entails the boiler attendant opening the boiler’s blowdown valves at set intervals during the day. The drawback is that, almost invariably, operators will err on the side of caution and a much larger volume of water will be drawn off than is necessary, wasting energy and water treatment chemicals.

Most systems could be achieving a condensate recovery rate of 75-80%, so returning condensate to the boiler can save thousands of pounds per year in energy alone. Using hot condensate to heat the boiler feedwater means the boiler has less to do in converting the water to steam. In other words, less fuel is needed to produce steam from hot water rather than from cold water.

Additionally, condensate returned to the boiler feed tank reduces the need for blowdown and helps to reduce the energy lost during the blowdown process.

Any condensate not re-used must be replaced with fresh water. This top up will incur additional water charges. Re-using as much condensate as possible also minimises the use of costly chemicals to treat raw water from the utility.

Many of these technologies may require some upfront investment, but they will pay for themselves in a matter of months. Ensure your boiler operations are operating at peak efficiency and aim to keep up with the latest developments not only in boiler technologies, but legislative and guidance documents as well. If in doubt, be sure to contact your local steam systems specialist.

For further information, contact Spirax Sarco UK on 01242 521361 or ukenquiries@spiraxsarco.com

PROCESS INDUSTRY INFORMER May 2014

PROCESS MEASUREMENT & INSTRUMENTATION

New Guide INNOVATIVE TEMPERATURE helps to MEASUREMENT simplify Pressure Transmitter selection ABB’s latest ‘How To’ guide, ‘How to select the right pressure transmitter for your application’ covers the key factors to consider when choosing pressure transmitters and ancillary equipment.

Written by ABB’s pressure measurement experts, the guide highlights the differences between transducers and transmitters and explains the sorts of application to which each type of device is best suited. The guide looks at the different types of transmitters available, each of which uses different techniques to transmit a signal.

Advice is also provided on the factors to consider where pressure transmitters are part of a Functional Safety system. The guide concludes with a look at the benefits of using multivariable transmitters in applications involving the measurement of gases or fluids subject to rapid density changes.

Endress+Hauser now has the most complete, modular thermometer portfolio for all hygienic and aseptic applications. Designed for use in the food & beverage and life sciences industries, the innovative iTHERM TM4xx thermometers comply with the highest quality standards to improve plant safety, end product quality and operating costs.

Technical innovation has led to the development of two new sensors, or inserts. The new iTHERM QuickSens insert offers the fastest response times worldwide, with high-precision measurements for maximum process safety and process control. The iTHERM StrongSens insert offers unmatched strength with a vibration resistance greater than 60g, reducing life cycle costs and increasing plant availability.

Calibrating the instruments is easy, as the new iTHERM QuickNeck allows removal of the insert without tools, minimising plant downtime and eliminating the possibility of wiring errors.

The stainless steel head offers optimal access to the terminals due to a low housing edge, reducing installation and maintenance costs. Thanks to the IP69K protection class water ingress is avoided, even if high-pressure cleaners are used.

For more information contact Endress + Hauser Ltd, Floats Road, Manchester Tel: 0161 286 5050 E-mail: info@uk.endress.com Web: www.uk.endress.com/TM4xx

A copy of the guide can be obtained by sending an email to moreinstrumentation@gb.abb.com, ref. ‘Pressure Guide’.

KC CONTROLS ANNOUNCE NEW PARTNERSHIP KC Controls are pleased to announce that they have been selected as the sole channel partner for Slick Sleuth, the revolutionary oil on water early warning detection system.

“We are very proud to have been selected as the sole providers and support company for the UK” stated Mark Howarth, KC Controls Managing Director “This leading product provides early warning of oil and hydrocarbon leakage saving companies money and ensuring environmental protection.”

Using fluorescence technology, the Slick Sleuth can be used up to 30 metres from water surfaces to detect oil sheen; providing users with alarms should oil leak into discharge and outlet channels to allow early corrective actions. The product is also used worldwide by environmental compliance authorities to ensure the health of waterways, wetlands and coastal areas.

With applications in a number of industries including ports, harbours, power generation, petrochemicals, tank farms and many more, KC Controls see Slick Sleuth as world leading technology and essential in cost saving and ensuring compliance.

For more information contact KC Controls (UK) LLP, Crawley, West Sussex Tel: 01293 538 940 E-mail: sales@kccontrols.co.uk Web: www.kccontrols.co.uk

PROCESS INDUSTRY INFORMER May 2014

9

PROCESS MEASUREMENT & INSTRUMENTATION

Workshops combine latest measurement technology knowledge with invaluable hands-on experience HBM are offering a series of workshops at the Williams Conference Centre in Oxfordshire on the 11th, 12th and 26th June. This represents a wonderful opportunity for engineers to deepen their knowledge on new measurement technologies and quickly learn how to use modern systems effectively and safely.

Topics include installation of strain gauges including optical gauges; Professional measurement software; Practical use of modern data acquisition; Efficiency testing on electric drive trains and Optimising production capabilities in weighing applications.

Each of the seminars contains significant practical elements enabling delegates to undertake a variety of exercises on specially equipped workstations while benefiting from expert advice.

Delegates will also be given a chance to go on a tour of the world’s largest collection of Grand Prix Formula 1 racing cars and there will be many opportunities to network and share ideas with colleagues from different areas of engineering.

HBM’s team of highly trained facilitators will conduct the workshops and seminars and further information can be found on HBM’s web site.

For more information contact HBM United Kingdon Ltd, North Harrow, Middlesex Tel: +44 (0) 208 515 6100 Fax: +44 (0) 208 515 6149 E-mail: info@uk.hbm.com Web: www.hbm.com

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Call us now or visit our new website www.ukflowtechnik.com For more information contact UK Flowtechnik Ltd, 1 Central Park, Lenton Lane, Nottingham NG7 2NR Tel: 0800 433 4770 / 0115 900 3550 Fax: 0115 970 5597 E-mail: sales@ukflowtechnik.com Web: www.ukflowtechnik.com

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10

PROCESS INDUSTRY INFORMER May 2014

The Changing Face of Temperature Control

By Ian Collins – Product Manager, West Controls Solutions Ltd Industrial temperature controllers have changed considerably over the last fifty years. This paper looks at how the development of technology has reacted to the changing demands of its customers to create powerful new solutions. products, graphite electrodes. However, the ideal system could not be realised with a standard controller; any upgrade would require a more sophisticated model with, for example, sequence management, but one that would also be easy to operate.

The problem was that a graphite electrode needs to be evenly heated throughout, but a gas burner may heat areas of the oven at different rates and intensities. This can result in expensive wastage if electrodes are damaged through either over heating or because they have not been heated evenly.

The solution arrived at featured a special combination of a gas burner system and a method of heating the oven with pure gas, using enhanced oxygen control. Our KS98-1 temperature controller, a compact mini PLC (Programmable Logic Controller) and DIN controller, perfectly fitted the existing ? DIN housing, and came with all the necessary I/O options already on board. For example, the KS98-1 provides a comprehensive function library containing tested PLC and maths functions that are not normally available in a DIN controller.

In early 1960s, moving coil full DIN (192 x 192mm) temperature controllers were an industry standard but the adoption and progression of electronics would soon change the way controllers were designed and manufactured. Open frame PCB controllers were first introduced incorporating On/Off or proportional control, set by dials on the controller.

Proportional control was the most accurate type of control at that time and was achieved by providing a reduced power output around set-point. The proportional output around set-point minimised temperature overshoot. The biggest draw-back of proportional control was that the temperature would stabilise at a temperature slightly above or below set-point. – known as an offset error.

Analogue controllers continued to reduce in size during the 1970's from ? DIN (96 x 96mnn) to 1/16 DIN (48 x 48mm) with little change in functionality. In fact, analogue controllers today have not progressed in technology from controllers in the late 1970's. However, the introduction of digital controllers in the 1980's represented a major step change in temperature control technology. The guesswork that had previously been involved with setting controllers was eliminated as dials were replaced by pushbuttons and digital displays. It was now possible to have P.I.D. (Proportional Integral Derivative) capability in controllers, achieving more accuracy due to the development of microprocessors. In addition to proportional control, the integral term removes offset, while the derivative term helps reduce temperature overshoot and changes response to disturbances.

However, although the benefits in terms of temperature management are good, manual setting P.I.D. control can be time consuming and require a skilled engineer. Thankfully, P.I.D. auto-tune is now available in most of today’s controllers. Using the P.I.D. auto-tune feature, a controller will calculate the optimum P.I.D. values for any given application.

As an example, the easy-to-use CAL 3300 from West Control Solutions offers integrated PID auto-tune. This means users do not have to set these parameters manually, a task that requires a certain amount of technical knowledge, and can reduce set up time to a few minutes. The PID facility is further enhanced by a unique dAC (Derivative Approach Control) function, which prevents temperature overshoot by increasing the proportional band temporarily during warm-up.

One of the other advantages of modern electronics is that manual interaction in a process can be reduced, hence minimising errors. Automatic variation of temperature during a procedure can be achieved by using a controller with temperature profiling. Programs can be created with temperature ramps rates, soak/dwells, steps, and loops to accurately achieve the required temperature profile for an application. To save time in setting up a machine, programs can also be stored and called for different process 'recipes' as needed.

In some applications (for example, extruders) temperature does not fall quickly enough when power is removed from the heating load. Assisted cooling is therefore required to achieve better temperature control. A heat-cool feature is available in some controllers which means that a single unit can be tuned for governing both heater and cooling loads as required to achieve improved control.

Integration of functions within controllers has become more common in recent years to simplify wiring and reduce installation times. Some medium to high end controllers offer integration of co-working control elements; this is achieved by supporting programming of logic capability around the core process control element of the device. And with a single HMI as the interface used for the complete system, this offers the end user increased efficiency and functionality with easy controllability.

As a case in point, a major component manufacturer in Germany required a new temperature control solution for the special oven they used to heat one of their core

PROCESS INDUSTRY INFORMER May 2014

A standard DIN controller normally has one control loop, sometimes two, but no kind of sequence mechanism or PLC logic function. The KS98-1 offers this functionality, but all within a DIN housing. And because it is still a DIN controller and not a PLC, the set-up of the process is more cost-effective. The customer’s problem could have been solved with a PLC, but this would have also required the expensive services of a high-end PLC programmer with a lot of knowledge.

Like many other devices, communications have changed the way that controllers are integrated as part of a system. Temperature and process controllers have generally been used as a discrete device within a machine. With communications options, monitoring and supervisory control are now possible directly from a PC or via a PLC system. Many generic SCADA (Supervisory Control And Data Acquisition) packages or specialist monitoring software products are available for data-logging, charting, configuration and management. In particular, PC based data-logging has grown over the last decade as more companies require data records for quality control purposes.

For instance, one of our customers, Solent Scientific, produce the 37° Incubation Chamber, an acrylic enclosure integrated with a powerful microscope used to conduct prolonged studies of living human cells, usually involving time lapse image capture.

Using the process monitoring software for real-time logging of CAL controllers, Solent Scientific could prove that the temperature within their chambers was kept to + or - 0.1°C over long periods of time, which is well within the tolerances required for the application.

It was also a solution that avoided the considerable cost and development involved in employing SCADA packages.

Although temperature controllers are much more advanced in functionality and accuracy, simplicity in setting up has been retained through features such as auto-tuning. Controllers are now also much smaller in size, making it much easier to integrate temperature control to a machine.

So how will temperature control change in the future?

The need to expand the capacity for gathering process information, provide simplicity of use for the operator, and integrate co-working control elements, is driving the development of solutions that offer single display, such as HMIs, operator panels, or the routing of information back to a PC. This means that the controllers of the future will increasingly become a single product rather than individual devices, bringing to the user the benefits of better application and control functionality, in addition to the monitoring of enhanced system data.

The trend is towards new levels of controller customisation, in which the operation of the device is tailored to the application. The latest display and programming technologies allow the controller to use terminology used by the operator, gain easy access to data, and ensure process changes are optimised for efficiency.

There’s also the potential for controllers to integrate with a wider network. The use of Ethernet communication is simplifying integration, with standard cabling and ‘nonengineering-based’ connectivity, further enhancing the powerful blend of easy operation and increased control capability that continues to enhance temperature control.

One thing’s for sure; as the above examples illustrate, industrial temperature controllers are continuing to react to the changing demands of customers, creating powerful new solutions that improve efficiency and quality for a diverse range of applications.

West Control Solutions Ltd, Brighton, East Sussex Can be contacted via: Tel: +44 (0) 1273 606271 Fax: +44 (0) 1273 609990 E-mail: UK@West-CS.com

11

PROCESS MEASUREMENT & INSTRUMENTATION

6 KEY FEATURES TO LOOK FOR WHEN CONSIDERING A GUIDED WAVE RADAR TECHNOLOGY SOLUTION All process industries today require the ability to safely and accurately measure level in critical applications. This task, however, can be complicated by a variety of factors, including process media that are very low dielectric or those that contain corrosive vapors, foam, steam, buildup, agitation, bubbling or boiling.

Guided wave radar (GWR) technology, which is the operating principle used by the Eclipse® Model 706 transmitter from Magnetrol®, provides true level and interface control for applications

Flow metering & instrumentation solutions for all industrial applications Call for more information, pricing, technical support & to receive our extensive catalogue.

across many process industries, including petroleum refining, electric power generation, chemical manufacturing, water and wastewater, pulp and paper, pharmaceutical processing and food and beverage. To ensure that you implement an optimal solution for your company, it is important to learn about some of the innovative features that the most reliable GWR solutions offer. The remainder of this post will discuss 6 features that you should look for when you are considering GWR technology as a possible solution for level measurement.

Signal Performance While many GWR options on the market today promote the amplitude (size) of transmitted radar pulse, a far more important parameter for reliable level measurement in difficult applications is the overall signal-to-noise ratio (SNR).

The ECLIPSE Model 706 features an innovative (patent-pending) design concept (called Diode Switched Front End) that can dramatically reduce the impact of noise and increase overall GWR transmitter performance. This new circuit design completely isolates the transmit path from the receive path, thereby maximizing receiver sensitivity and impedance matching.

0800 433 4770

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

New

Complete Line of Probes

The type of probes that a GWR solution offers is another key consideration.

Look for a GWR transmitter that offers an extensive line of dedicated coaxial, single and twin rod probes to handle a variety of level challenges.

Some GWR devices feature probes that have a transition zone at the top where interacting signals can affect the linearity of the measurement or result in a loss of signal.

The ECLIPSE Model 706 offers overfill safe probes which have a predictable and uniform characteristic impedance across the entire length of the waveguide. This allows the GWR to measure accurate levels, to within specification, all the way up to the process flange without any non-measureable zones at the top of the probe.

Advanced Diagnostics Look for those GWR transmitters on the market that offer advanced diagositc capability, such as having the ability to save echo curve and diagnostic information based on Time (using an on-board clock) or a key Event (such as Loss of Echo or Low Echo Strength). The transmitter should have the ability to store a number of echo curves in its on-board memory, which can then be downloaded for troubleshooting.

Newer GWR devices also meet the NAMUR NE 107 standard. This relatively new standard allows the user to categorize diagnostic indicators in a way that suits their specific needs. The more advanced GWR transmitters incorporate this diagnostic scheme to allow much greater flexibility for the sophisticated user.

Output Types Typical GWR devices provides an analog 4-20 mA signal with HART, or FOUNDATION fieldbus digital communication output. The GWR solution you are considering should accommodate both HART® and FOUNDATION fieldbus™ communications protocols.

Convenient Pre-Configuration

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. in control u o y dBi – The new range of puts t Intelligent Transducers. a h

as Level me

nt t e m ure

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

www.pulsar-pm.com 12

Some GWR transmitters can be supplied “pre-configured” from the manufacturer. One step closer to plug-and-play, a pre-configured device allows you to virtually take the transmitter out of the box, apply 24 VDC to it and walk away, thereby greatly reducing installation time. Look for the manufacturer that offers this service at no additional cost.

Advanced Installation Capabilities While most GWR transmitters are mounted directly onto the probe, some can be remote mounted up to 12 feet (3.6 meters) away from the probe to meet the needs of applications that may involve high temperature or vibration – or to simply increase ease of viewing for technicians. Some GWR units, like the ECLIPSE Model 706, also offer a quick-disconnect probe coupling that eases installation and servicing by allowing full 360° rotation of the transmitter housing. To orient the transmitter, the user simply selects the desired transmitter position, tightens the coupling and completes the wire terminations.

For more information contact Magnetrol UK Ltd, Burgess Hill, West Sussex Tel: 01444 871313 E-mail: sales@magnetrol.co.uk Web: www.magnetrol.com

PROCESS INDUSTRY INFORMER May 2014

PROCESS MEASUREMENT & INSTRUMENTATION

Non-intrusive flow measurement in harsh, corrosive environments The FLUXUS F705 and G705 ultrasonic liquid and gas clamp-on flow meters allow for an inherently precise bi-directional, highly dynamic flow measurement of volume and mass flow rates of virtually any gaseous and liquid media – even at wet gas applications (up to a Liquid Volume Fraction of 5%) or liquid media carrying high contents of solids.

FLUXUS F/G705 ultrasonic clamp-on With the transmitter being ATEX, IECEx gas and liquid flow me Zone 2 and FM Class I, Div. 2 certified – transducers for ATEX, IECEX Zone 1 and FM Class I, Div. 1 are available - it is also the ideal flow meter for hazardous areas. Moreover, with its stainless steel enclosure (316L / 1.4404) it is highly corrosion resistant and especially suited for applications Offshore.

IF YOU NEED A METERING OR FLOW MEASUREMENT SOLUTION FOR YOUR PROJECT: ■ Heat & Energy Meters ■ LPHW, DHW, Chilled or Potable

Water Meters ■ Standard in-line or clamp-on ■ Fixed or portable

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Non-contacting ultrasonic measurement specialists Pulsar Process Measurement of Malvern have launched a new range of self-contained two-wire powered transducers, which feature a choice of either HART Version 7 or Profibus PA version 3.0.2 Fieldbus protocols. The dBi Intelligent Transducer range are both available in three sizes, covering a measurement range from 125mm through to 15m.

Pulsar’s dBi Series Transducers feature Pulsar’s world-leading DATEM echo processing system for robust and reliable measurement. Integration with plant systems and other equipment is straightforward, dBi Transducers supporting a full range of industry standards. It is easy to configure and calibrate the devices using standard PLC/HMI industry protocols, Pulsar’s own software or on site multi-drop set up, with options to program the transducers using either a standard interface or using Pulsar’s programming parameters. A standard HART or Profibus modem allows the units to be set up from a PC if required, or proprietary hand held calibrators will also perform the function.

The dBi range is low-power, with rapid response times that make them perfect for wide scale monitoring or overflow, such as CSO, applications. Powerful crystal arrays make the dBi series suitable for use in either solids or liquids applications, and can be specified with a full range of options; PTFE coating for corrosive chemical applications; flange options, front threads or brackets for ease of mounting; submergence shields to keep the transducer face dry in applications where it may be covered from time to time and more. For solids applications the dBi transducer can be fitted with a foam face for more power and mounted on an aiming kit.

The transducers feature, in each case, the latest version of the digital protocol. In particular, Pulsar are early adopters of the Profibus PA 3.0.2 system.

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For more information please contact Pulsar Process Measurement Ltd, Malvern, Worcestershire. Tel: +44 (0) 1684 891371 Fax: +44 (0) 1684 575985 E-mail: keithf@pulsar-pm.com Web: www.pulsar-pm.com

PROCESS INDUSTRY INFORMER May 2014

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13

Why choose

Coriolis?

Many industrial processes depend on the mass, rather than the volume, of the materials reacting together. Yet in the case of reacting liquids and gases, most flowmeters don’t measure mass flow rates. Only one kind of flowmeter directly measures mass flow rates of both liquids and gases – the Coriolis flowmeter. Les Slocombe, for ABB’s UK Measurement Products business, explains why Coriolis flowmeters are increasingly the device of choice in a growing range of flow measurement applications.

Commercial Coriolis flowmeters are a relatively recent innovation, having emerged in the midto-late 1970s. Steady technical improvements since then have greatly increased their accuracy and acceptance in the process industries. Today, direct mass flow measurements account for up to 20 percent of worldwide flowmeter applications.

How they work

With zero flowrate, the two sine waves from the pickups are exactly in phase since the fluid’s angular momentum remains constant and no twist occurs. As flow increases, the phase difference between the two sine waves also increases. This phase difference is the measure of the mass flow rate through the Coriolis flowmeter. The greater the mass flow, the greater the twist, and the greater the measured phase difference.

A Coriolis flowmeter requires a force acting on a tube carrying a flowing fluid. This force actually deforms tubes through which the fluid flows. The amount of deformation depends directly on the mass flow rate through the tubes. Signals from sensors measuring this deformation provide a direct indication of the mass flow rate.

Most often Coriolis flowmeters incorporate identical dual tubes oscillating in opposite directions. The flow from process piping splits in two as it enters the flowmeter. This provides a more balanced design, making the meter more resistant to external vibrations and temperature swings. Sensors mounted on the tubes measure their relation to each other rather than to a fixed plane.

In Coriolis flowmeters the concept of angular momentum comes into play. Angular momentum is a function of the point’s radius from the axis, the mass at the point, and its speed. The further the mass from the axis, the faster its rotational speed and the greater its angular momentum.

Straight tube designs operate in a similar manner. The vibrating tube is fixed at its ends, creating two rotating reference frames. The rotations at the inlet and outlet sides are in opposite directions, creating opposing Coriolis forces that distort the tube.

This is demonstrated in the diagram below, which shows a counter clockwise rotating carousel viewed from above. The length of the arrows indicates the relative magnitudes of velocities of the points on the diameter.

If you’re at the edge of the moving carousel, your speed is relatively high compared to standing anywhere nearer to its centre. For example, if the carousel has a radius of 10 feet and it makes one revolution in five seconds, then you move 20 feet (about 63 feet) in five seconds (or about 12.6 feet per second relative to a person standing off the carousel. Any point nearer to the centre represents a smaller radius and a slower rotational speed.

If you (the mass) start to walk towards the moving carousel’s centre, decreasing your radius from the axis, your rotational speed slows. Your angular momentum also decreases.

Conversely, as you walk away from the centre, your angular momentum would increase.

Coriolis flowmeters take advantage of this change in angular momentum as a fluid flows away from and back towards an axis of rotation.

Coriolis flowmeter construction When this principle is applied to measuring process mass flow rates, the flowmeters must rotate the fluid. In practice they rotationally oscillate the fluid, which produces equivalent Coriolis forces. Tube designs are U-shaped, S-shaped, or straight.

In U-shape or S-shape tube designs, the fluid moves away from and back towards the axis of oscillation, resulting in a changing angular momentum of the fluid. As the tube oscillates up, the fluid mass flowing into the U-tube will resist its increasing angular momentum (because of the inertia of the fluid mass) and push down against the tube. As the fluid moves back toward the axis, it resists its decreasing angular momentum, pushing up on the tube. These opposing forces depend on the fluid’s mass. They deform the U-shaped tube with a twisting action.

The two opposing forces twist the tube first one way, then the other, with each oscillation cycle.

Waveform outputs from the pickup sensors are sine waves, reflecting the oscillation frequency.

Measuring the magnitude of this deformation amounts to measuring the mass flowrate.

14

Benefits of Coriolis flow measurements The Coriolis metering principle is independent of the fluid’s density, temperature, viscosity, pressure, and conductivity, making it independent of Reynolds number. It’s also independent of the upstream and downstream flow velocity profiles. Consequently, a Coriolis flowmeter does not require straight runs of piping on either side of it, making it suitable for asymmetric velocity profiles.

In addition, in most designs, the tube oscillates at its resonant frequency. This frequency depends on the meter tube geometry, the characteristics of the flowmeter materials, and the mass of the fluid in the meter tube. With knowledge of these properties, this frequency provides a bonus measurement of the fluid density within the tube. Separately, the flowmeter includes a thermal sensor to account for dimensional and elasticity changes of the tube with fluid temperature.

Flowrate calibration may be done with any convenient liquid or gas, such as water or air. To calibrate for density, the tubes may be simply filled with fluids of known densities to note the resonant frequencies attained.

Today’s Coriolis flowmeters are highly accurate. Accuracies of our new CoriolisMaster flowmeter models, for example, range from 0.1 to 0.4 percent of reading for liquids and 0.5 to 1 percent of reading for gases. High accuracies make Coriolis flowmeters obvious candidates for custody transfer applications. They also fit applications such as material balances and blending by weight. Since these meters can monitor a variety of different fluids, they also suit batch operations and tanker truck loading and unloading.

Summary The Coriolis flowmeter makes it possible to simultaneously measure the mass flow rate, fluid density, and temperature. Other measurement values can be derived from this information, such as the volumetric flow rate and percent concentration. Coriolis flowmeters are a good choice for a variety of flow measurement applications in the oil and gas, chemical, power, and food and beverage industries.

ABB Measurement Products UK, Warrington, Cheshire Can be contacted via: Tel: 0870 600 6122 ref. ‘Flow advice’ E-mail: moreinstrumentation@gb.abb.com Web: www.abb.co.uk/measurement

PROCESS INDUSTRY INFORMER May 2014

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The pressure

~ Pressure measurement and differential pre The early 1960s was a period that featured some significant engineering advancement. In the UK, the Forth Road Bridge was opened to link Fife and Edinburgh, the British Motor Corporation launched the Austin 1800, which went on to become European Car of the Year, and Dorothy Crowfoot Hodgkin became the first and only British woman to win a Nobel Prize in Chemistry for her work using X-rays to determine structure in biochemical substances.

16

Meanwhile, in Japan, global automation business Yokogawa was developing its first pressure transmitters, which represented a significant step forward in pressure and differential pressure measurement. Here, Andrew Fenn, the company’s UK product specialist for transmitters and flow, explains how the technology should be specified by a process engineer.

Accurate pressure and level readings are essential to the safe, reliable and profitable operation of your plant. Both are key process variables, alongside considerations such as flow, temperature and liquid interface. The pressure under which a material is held can severely impact ultimate product quality by increasing variance and reducing efficiency.

Crucially, accurate pressure measurement is also a key component of an effective health and safety strategy. For example, maintaining proper boiler pressure by controlling the inflow of air used in combustion and the outflow of exhaust gases is crucial in preventing boiler implosions that can clearly threaten the safety of workers In my experience, accurate pressure measurement is critical in batch chemical and oil and gas applications in particular, as well as the pharmaceutical sector.

However, it’s fair to say that it’s hugely relevant across the process industries, from food to plastics and from metals to cosmetics.

Differential pressure transmitters compare two pressures and transmit the difference to a control unit, performing multiple functions. For instance, by applying Bernoulli's equation, differential pressure transmitters can be used to infer the flow of fluid through a pipe.

In fluid dynamics, Bernoulli's principle states that for an inviscid flow, an increase in the speed of the fluid occurs simultaneously with a decrease in pressure or a decrease in the fluid's potential energy.

Differential pressure monitoring applications include filter monitoring and feed pressure monitoring in liquid or gaseous media, density and flow measurement, measurement of aggressive or viscous media, flow measurement of gases and vapours, level measurement of aggressive or adhesive media, measuring liquid in pressurised vessels and interface measurement.

Defining our terms Because of the pressures we all face as engineers, it isn’t uncommon for a non-specialist to come across problems in specifying pressure transmitters as the result of loosely defined technical terms. We all know our own sectors backwards, but who can honestly say they understand the engineering and design requirements of every product further up or down the chain?

Transducer accuracy refers to the degree of conformity of the measured value to an accepted standard. It is usually expressed as a percentage of either the full scale or of the actual reading of the instrument. In case of percent-full-scale devices, error increases as the absolute value of the measurement drops.

Repeatability refers to the closeness of agreement among a number of consecutive measurements of the same variable.

Linearity is a measure of how well the transducer output increases linearly with expanding pressure.

Finally, hysteresis error describes the phenomenon whereby the same process pressure results in different output signals, depending on whether the pressure is approached from a lower or higher point.

PROCESS INDUSTRY INFORMER May 2014

e to conform

essure measurement in the process sectors ~ Choosing a pressure transmitter In choosing a pressure transmitter, it’s important to take into account the key benefits it can provide.

The market for this kind of product is extensive and includes many grey market devices that can negatively impact on product quality or health and safety.

Digital precision is an essential element in this choice, something which goes hand in hand with a high level of repeatability. This also removes the possibility of errors in the analogue to digital conversion process.

In choosing a differential pressure transmitter, one should ensure that it provides the ability to measure differential pressure and static pressure in a single instrument. This kind of versatility is essential in the modern, highly adaptive process environment. In such a product, over pressure protection is also essential to obviate the possibility of damage to the device.

In all pressure transmitters, a high level of accuracy, repeatability and stability is essential, as is a robust and reliable design, particularly in hazardous environments.

Weight may also be a consideration, depending on the application, and easy maintenance almost certainly is. This is particularly true in batch chemicals, oil and gas, where factors such as validation and traceability, lack of access to remote applications and the hazardous nature of the environment mean that maintenance opportunities have to be carefully scheduled.

Similarly, in these sectors it’s essential that the manufacturer you choose to partner with can provide a range of materials for wetted parts to cater for aggressive process media.

The most advanced pressure transmitters on the market use silicon resonant sensors, fabricated from a single crystal, using proven 3D semi-conductor micromachining techniques.

In these cases, two "H" shaped resonators are patterned on the sensor, each operating at a high frequency output. As pressure is applied, the bridges are simultaneously stressed, one in compression and one in tension. The resulting change in resonant frequency produces a high differential output (kHz) directly proportional to the applied pressure. This simple time-based function is managed by a microprocessor.

The net effect of silicon resonant technology is that temperature effects are reduced to less than 1/10th of other silicon technologies (10 ppm/deg C), making these sensors extremely stable in the most demanding process applications.

The output produces a much higher signal to noise ratio than traditional analogue sensors and, compared to piezoresistive silicon sensors (the silicon resonant sensor's immediate predecessor) the output is at least four times greater. Errors resulting from temperature and static pressure are thus insignificant in relation to total output.

PROCESS INDUSTRY INFORMER May 2014

Finally, one should ideally consider advanced digital diagnostics to help avoid unpleasant surprises and minimise downtime. Other essentials are mass flow output direct from the transmitter, without the need for a flow computer, thus minimising cost, as well as technology to reduce process leak paths.

Common application problems One frequent application issue is impulse line blockage. Common differential pressure sensor configuration includes impulse lines that couple the sensor to the process fluid or gas to be measured. The impulse lines are typically small bore lines filled with a fluid. This fluid provides pressure coupling between the sensor and the process.

Dirt in the process can settle in these lines causing blockages to form. Typical blockages include solid depositions, wax depositions, hydrate formation, sand plugging, gelling, frozen process fluid plugs and air or foam pockets. All of these blockages can cause errors in measurement.

The impulse line condition can be detected by extracting the fluctuation component from the differential pressure and static pressure signals. The extracted component of the process fluctuation is used to determine the amount of impulse line blocking. The ability to detect the early signs of instrument impulse line blockage problems is a key requirement of an advanced differential pressure transmitter. While this isn’t by any means a common function of even the most advanced products currently on the market, it is very useful.

Standards and accreditations As with most equipment used in the process sectors, it’s essential for the pressure transducer you choose to provide the appropriate accreditation to the most relevant industry regulations and standards.

Typically, these would include hazardous area accreditation such as ATEX (Appareils destinés à être utilisés en ATmosphères EXplosibles) and testing-house approvals from accreditation agencies like FM Approvals and CSA, as well as the IEC (International Electrotechnical Commission). One might also expect marine certificates, CE marking, GOST for transportation into the Soviet Union, PED (Pressure Equipment Directive) compliance and SIL2/3 capability (Safety Integrity Levels determined

by TUV Nord and certified to IEC61508) as standard.

To give you a clue of scale, extremely high power water jet cutters might operate at 100,000 psi, the pressure on the hydraulic system of an Airbus A380 is around 5000 psi and the blood pumping through your veins while you read this is probably somewhere between 1.55 psi and 2.35 psi.

The demand we face as manufacturers of pressure transmitters is the continually developing requirement for even higher pressure measurement than is currently offered to the market place. While we provide this, we have to also maintain our high standards of accuracy, stability and repeatability along with robust construction, low maintenance and suitability for the application.

Pressure measurement has certainly come a long way since Yokogawa introduced its first products in this sector in the early 1960s. However, just like the Forth Road Bridge, many of our oldest technologies are still relevant today and, in the spirit of Dorothy Crowfoot Hodgkin, we are still committed to continuous innovation and product development.

Whether we will need to work on a 200,000 psig application in the near future is very much in doubt, but what is certain is that we are relied upon in thousands of process industry applications across the world.

What does the future hold?

Generally in industry, pressure exceeding 1,000 psig (pounds per square inch gage) is considered to be high pressure. However, due to advancements across the sector, there are now devices that can measure high pressure up to an incredible 200,000 psig or more.

Yokogawa UK, Runcorn. Cheshire Can be contacted on: Tel: +44 (0) 1928 597100 E-mail: simon.rogers@uk.yokogawa.com Web: www: www.yokogawa.com/uk Twitter: https://twitter.com/Yokogawa

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PROCESS MEASUREMENT & INSTRUMENTATION From ordering, a level or pressure instrument, to delivery can take ages ...

... or be there before you know it.

The easy-is-better principle from VEGA.

VEGA has thought through the “easy is better” principle right down to the last detail.

The instrument platform plics® solves any measuring task related to level and pressure, and has been doing so for 10 years.

9 instrument selection

9 quick setup

9 fast delivery

9 reliable operation

9 easy installation

9 fast service

www.vega.com/plics

Bronkhorsts CORI-FILL System goes from Strength to Strength

Bronkhorst back in 2009 introduced CORIFILL technology for its Coriolis product portfolio and after five years this technology is now a standard feature and growing in its uses and applications.

CORI-FILL is suitable for a whole range of batching, blending, dosing, filling a sterilization applications. The market place this is aimed at is vast and as we have found over the years it is being used from very low dose amounts to high volumes.

With the conventional methods of using a mass/ volume flow meters, separate shut off valves and batch controllers or gravimetric processes using weighing scales where fluids are dosed one by one this can be time consuming, sometimes inaccurate and costly as there also is some need for engineering experience to tune the system correctly.

Using the Bronkhorst CORI-FILL system which is very much a plug & play type system this can make life for the end user so much simpler. Using one of our Coriolis instruments with a close coupled pump or valve the CORI-FILL system is neat and compact so requires little installation space. What this means is that the pipe lengths from raw ingredients to the process can be kept short to ensure the optimum condition of fluids. The CORI-FILL system uses Coriolis technology which measures the true mass passing through the flow tube. The flow measurement is independent of the fluid properties and this in turn means that it is possible to use the instrument on various fluids at any one time and still have very accurate dosed quantities. The CORI-FILL system can offer to the end user an improved accuracy of dosing and this can also bring shorter production times.

The CORI-FILL system can dose from 0.1 g/hr and up to 1000 kg/hr.

Over the years we have gained experience and as the technology used in the system also has improved the systems capabilities to control dosing down to <0.3secs using shut off valves and for longer periods either a proportional control valve or pump if the fluid is not stored in a pressurised vessel has improved. One of the strengths of the CORI-FILL system is that it has a dedicated output for either a valve or pump control which means that this can be used with any valve or pump technology. The flowmeters on board PID controller can be used for optimising the control to offer down to +/-0.5% accuracy or better. A key feature of using Coriolis technology is that through the digital outputs the end users can measure the density and temperature of the fluid passing through. The CORI-FILL systems also have a self learning functionality and the ability to be first time right. Within the software package supplied free of charge the end user has the capability to adjust the method of dosing from fast dosing with a reduced slope at the end to a slow dose from start to finish. Another very powerful feature is the alarm functionality. The system can give you minimum, maximum or response alarms so for example if the fluid vessel is empty you can have an alarm output signal. This could also save other high cost machinery.

Even if the environment is aggressive we are still able to supply the CORI-FILL system.

The CORI-FILL system uses our Coriolis instruments and these can be ATEX Zone 1 or 2 rated or IP65. We can also integrate these with pumps and valves that are ATEX rated too so the CORI-FILL system can be used for any application. With demand from the field the CORI-FILL system can also come in various wetted parts materials so if the fluid is aggressive a solution can be found.

The CORI-FILL system has the ability for multiple controllers to be networked together via a fieldbus connection so if you were looking for an accurate way to blend ingredients then this would be very suitable. With the flowmeter being independent of fluid properties this system can be used on various fluids so after one recipe is done and cleaning is undertaken then the system can be used again on different fluids. The net result will be a cost saving of capital equipment. Also with the fluids being able to be directly injected to the process with no need for a weigh scale there is a reduction in health & safety challenges through open containers not being in the working atmosphere.

We recently supplied the CORI-FILL system to an end user who needed to update and automate the dosing for colour and flavour in to their process line. The previous system needed a lot of maintenance and man power. Using the CORI-FILL systems powerful feedback and outputs to the control station the end user is now able to control the process better and improve the quality of the end product.

For more information contact: Bronkhorst (UK) Ltd, Newmarket, Suffolk.

Tel: 01223 833222 Fax: +44 1223 837683 E-mail: sales@bronkhorst.co.uk Web: www.bronkhorst.co.uk

18

PROCESS INDUSTRY INFORMER May 2014

A golfing theme or is it!!!

It’s good to see that this edition of the “News” has much to bring to your attention from the association

NEWS

MAY 2014

Motors | Automation | Energy | Transmission & Distribution | Coatings

Optimum control and performance with WEG Pump Genius software

and that there is a healthy increase in the number of member organisations participating – could it be that the economy is becoming a driving force!!

For whatever reason this May edition has much to inform and interest

readers

with

articles

covering the report in April that suggests that, despite of some concerns from “holes” around the country showing concern, that the potential economic benefits – but then you can’t please all of the people all of the time – ultimately it will be “time” that tells…

No

matter

what,

it

fuels

discussion and conversation and with another article saying that the North Sea is not yet “dry”, or should I say “watered down” there is still good times for the pump industry.

With an item about the Energy Efficiency Directive included it’s worth turning the pages to find out who were the winners of our recent BPMA Golf Day held at the famous Celtic Manor Resort – happy smiles all around. If you would like to join “the club” why not register for next years’ round – there are full details inside.

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.

Pump Genius WEG, a global leader in automation and control technologies, has launched Pump Genius process control software enabling engineers to optimise their pumping systems so that they run more efficiently. The software is designed to reduce pumping system operation and maintenance costs whilst increasing process accuracy and protection.

Working with WEG’s popular CFW11 inverter drive Pump Genius can be applied to any system that requires constant flow or pressure and can manage up to six pumps in a coordinated system.

For more information, visit www.weg.net

1

NEWS BYTES   BPMA

Golf Day  Getting

The famous Celtic Manor Resort in the Usk Valley was the venue this year for our annual Golf Day which was held on 8 May. 16 teams took part in a “Texas Scramble” and despite the terrible weather forecast, the rain held off and everyone reported having a great time.

Our usual well deserved dinner in the evening concluded with the prizegiving.

Winners this year were Sulzer with Smedegaard ‘B’ team coming second and WEG Electric Motors ‘B’ team third.

Peter Miller of Smedegaard ‘B’ team won Sulzer Team L to R the “longest drive” competition with Steve – Sandeep Sharma, Hall (ITT ‘A’ team) winning the “nearest Mark Teale, Tim Francis the pin”. and Captain Dave Drewe Congratulations to all!

A special thanks to our sponsors this year:

Energy Efficiency Directive



By 30 April 2014, and every three years thereafter, Member States will have to submit their National Energy Efficiency Action Plans (NEEAPs) to the Commission. Once received, the NEEAPS will be published on the Commission’s website.

A public consultation to seek the opinions of the general public and all stakeholders on the issues related to energy efficiency policies and measures for 2020 and 2030 was open until 28 April. The replies submitted to this consultation will provide important input to the review of progress towards the 2020 energy efficiency target under Article 3(2) of the Energy Efficiency Directive 2012/27/EU. As a reminder, by May 2014 the the EU Member States must prepare schemes for their energy companies to deliver annual energy savings of 1.5% as part of the Energy Efficiency Directive. The Review of the progress towards meeting the 2020 energy efficiency target, as well as the EED review is foreseen in June 2014.

In the context of energy efficiency investments, DG Energy has published a new study of the Energy Efficiency Financial Institutions Group (EEFIG), entitled ‘Energy Efficiency – How to drive new finance for energy efficiency investments’.

At the end of 2013, EEFIG was asked by the European Commission and the United Nations Environment Programme Finance Initiative (“UNEP FI”) to bring together their experience to address the need to increase the scale of energy efficiency investments across the EU. This study is the interim report of EEFIG and represents the consolidated consensus and shared views of its expert members.

The report states the EU is at risk of missing its targets as insufficient public and private investment is flowing into energy efficiency at present. Energy efficiency investments should increase. EEFIG members believe energy efficiency investments produce multiple benefits for multiple stakeholders and increase energy security, which makes the case for using public funds to blend with private sector investment to address risks and achieve the scale of financing needed.

According to the report, in order to achieve this outcome a historic level of publicprivate collaboration will be required.

2

ready for shale gas

– supply chain estimated to be worth billions as new environmental measures announced A shale gas supply chain report published on the 24th April 2014 showing huge potential economic benefits to the UK economy and measures to minimise the environmental impacts of shale gas have been announced by the Government.

Business and Energy Minister Michael Fallon: • welcomed an EY shale gas supply chain report that estimates a potential £33 billion benefit to the UK economy and over 64,000 jobs; • fully accepted the recommendations of the MacKay/Stone report to monitor the carbon footprint of domestic shale gas; and • announced £2 million competition by the Technology Strategy Board to support innovative ideas to produce or explore for shale gas, particularly focused on projects reducing environmental impact.

Shale gas supply chain Shale gas could create a new onshore supply chain market for equipment, services and skills across a number of industry sectors worth up to £33 billion by 2032, creating over 64,000 jobs, according to the EY report published today by trade body United Kingdom Onshore Operators Group (UKOOG).

The UK could also lead the way in technology and skills across Europe, a significant and untapped market, adds the report, commissioned by UKOOG and part funded by the Department for Business Innovation and Skills.

The report sets out UK industry sectors that could benefit from UK shale development include: • Specialised equipment and skills for hydraulic fracturing operations worth £17bn; • Waste management, storage and transportation requirement of £4.1bn; • Steel requirement of £2.3bn; and • New rig manufacturing industry worth £1.6bn.

The report projects that a flourishing shale gas industry in the UK would lead to the employment of over 64,000 people at peak employment, most of them in the supply chain.

A key part of the Government’s long-term economic plan to secure Britain’s future is to back businesses with better infrastructure. That’s why the Government is committed to shale - it will mean more jobs and opportunities for people, and economic security for our country.

Business and Energy Minister Michael Fallon said: “This report shows the huge prize at stake for the UK in terms of jobs and manufacturing in the supply chain for our onshore oil and gas industry.

“Shale gas has the potential to kickstart a whole new industry, building on the world leading expertise the UK already has in the energy sector.

There will be significant opportunities across the steel, manufacturing and engineering industries as shale develops.

“This government is fully committed to ensuring the UK not only benefits from the energy security shale gas could provide but also maximising the economic benefit across the country. It’s time to get ready for shale.”

NEWS BYTES   North

Sea still attractive for oil and gas industry

DECC’s latest offshore oil and gas licensing round, which closed for applications on Friday 25 April, has received a strong response with 173 applications from industry for around 370 blocks.

Energy Minister Michael Fallon said: “It’s 50 years since North Sea licensing began and there remains an extraordinary level of interest which is excellent news for industry and for the UK economy.

“We have committed to implementing all of Sir Ian Wood’s recommendations to help maximise recovery of North Sea oil and gas, and the Chancellor is reviewing the tax regime.

“Making the most of Britain’s home grown energy is crucial to keep job and business opportunities, get the best deal for customers and reduce our reliance on foreign imports.”

The department will scrutinise applications over the coming months and aims to start awarding acreage in the autumn.

The UK’s oil and gas sector still provides almost half of the country’s energy and is by far the largest single industrial UK investor. Directly and indirectly it supports around 450

Major milestone reached for new nuclear in Cumbria A major step was taken on 1st May 2014 towards a new nuclear power station at Moorside, West Cumbria, that will create at least £10 billion worth of investment and thousands of jobs.

The Nuclear Decommissioning Authority has agreed key commercial terms with Toshiba and its partner GDF Suez to extend a land option agreement that reaffirms the consortium’s commitment to build three reactors at Moorside.

The reactors, to come online from 2024, will deliver 3.4GW of new nuclear capacity, enough to power up to 6 million homes.

It is estimated that the project will result in 14,000 of jobs over the construction period for the three reactors, including peak on-site employment of more than 6,000 people. In the operational phase the three reactors will sustain around 1,000 permanent jobs over the course of the reactors’ lifetimes.

The Prime Minister David Cameron said: “Today we can announce the huge investment being made by Toshiba and Westinghouse – over £200 million – into the rebuilding of the British nuclear industry, specifically in the North West of our country, in a project that could provide as many as 14,000 jobs during the construction phase, and many thousands of jobs ongoing, as well as providing low-carbon, base load electricity for Britain. This is a symbol of the growing relationship between Britain and Japan.”

Energy and Climate Change Secretary Ed Davey said: “This is an important step forward in the plans for a new nuclear power station at Moorside – a plant that will generate enough clean electricity to power around 6 million homes.

“Moorside means outstanding opportunities for Britain – thousands of jobs during construction and billions of pounds of investment in Britain’s booming energy sector. The new nuclear programme is a core part of our drive to build a new, clean energy sector in Britain to tackle climate change as the same time as we deal with a legacy of underinvestment in Britain’s energy sector, ensure we remain among the most energy secure countries in the world.”

NDA Chief Executive Officer John Clarke said: “This is a significant step forward for the plan to establish new nuclear in West Cumbria. Together with our nuclear partners we are seeing the emergence of West Cumbria as a centre of nuclear excellence across the whole span of the industry from new build to decommissioning and waste management.”

Golf @ Glorious Goodwood Player Registration Company......................................................................

The 2015 BPMA Golf Day will take place at one of the UK’s premier sporting venues, ‘Goodwood Park’, Nr. Chichester. A great venue for you to entertain your clients and employees alike.

Thursday 14th May 2015

Goodwood Park Hotel & Kennels (Downs Course) 09:00 - 10:30 Registration - ‘Goodwood Bar & Grill’ 09:00 - 10:30 Coffee and Bacon Rolls - ‘Goodwood Bar & Grill’ 10:30 18 holes Texas Scramble on the Downs Course, 4-Ball with Buggies 16:00 - 18:00 Card return & Bar - ’Goodwood Bar & Grill’ 19:30 Drinks Reception - ‘Cedar Suite’ 20:00 Dinner and prize giving - ‘Cedar Suite’

Friday 15th May 2015 Goodwood Park Hotel Breakfast & Departure

Special Room Rates Available for 13th & 16th Where Required

Amazing value at just

I/we would like to reserve .......... places at the 2015 BPMA Golf Day. At a rate of £220.00 + VAT per player. I/we understand that invoicing will take place in January 2015 for immediate payment.

Name............................................................................

Signature.......................................................................

Date..............................................................................

Please return your completed form to Jeanne at the BPMA offices.

Contact: Jeanne Page 0121 601 6691 j.page@bpma.org.uk

£220.00 per player + VAT

Places are limited so register now to avoid disappointment Please complete the registration form attached.

3

NEWS BYTES  ATEX

Directive

Directive 2014/34/EU on equipment and protective systems intended for use in potentially explosive atmospheres (ATEX), as aligned with the New Legislative Framework (NLF), was published in the EU Official Journal on 29 March 2014.

The essential health and safety requirements to ensure protection against the hazards which result from the use of equipment and systems in potentially explosive atmospheres are set out in Annex II of the directive. As a result of the

NLF alignment, manufacturers need to ensure that the products they place on the market bear the specific marking of explosion protection and also that the use of equipment and protective systems in a potentially explosive atmosphere is clearly stated.

Member States need to transpose this directive into national legislation by 19 April 2016.

Up to that date both directives (the old and the new one) will exist in parallel, whereby the 94/9/EC will be the one which has to be referred to until the new one comes into force. All certificates and declarations of the manufacturer have to refer to 94/9/EC until 2016.

Europump

2014

Sponsored by WEG Electric Motors, BPMA hosted the 2014 Europump Annual Meeting at St Andrews over the period 22-24 May 2014 at the Fairmont St Andrews Resort. Some 150 attended the event which provided updates on all technical, marketing and commercial matters currently pertinent to European and American pump companies.

A fantastic partner programme was arranged,

including lunch at the famous St Andrews Seafood Restaurant, a visit to the Hill of Tarvit and a Falconry display.

Additionally, following the meetings, many of the delegates took the opportunity to participate in a WEG Electric Motors sponsored golf competition on of the resort’s championship courses.

The whole event was marked on the final evening by a Gala Dinner at the Fairmont.

Pump Technology Training Remaining Courses held throughout the year at the National Metalforming Centre and dates fixed for 2014 are as follows:16 June 2014 – Module 007, Pump Testing 17 June 2014 – Module 008, Pump Systems 23 June 2014 – Module 009, Hydraulic Design of Centrifugal Pumps 28 October 2014 – Module 001 Part 1, Pumping Fundamentals 29 October 2014 - Module 001 Part 2, Pump Selection For further details on costs or availability please contact Jeanne Page at j.page@bpma.org.uk

CPSA

Training

The BPMA Certified Pump System Auditor Scheme (http://www. bpma-cpsa.co.uk) has established BPMA as THE body to train and certify personnel who undertake “Pumping System Assessments” as referenced in UK Government Energy Strategy documents.

BPMA will again be offering the opportunity to attend a four–day residential course culminating in certification and eventual personal ID “Certified Pump System Auditor” status following approved audits.

The next course will take place in the Autumn (dates to be confirmed) at the National Metalforming Centre, West Bromwich.

Delegate fees £1,500 + VAT (BPMA Members) £1,750 + VAT non-members (includes accommodation for 3 nights (b&b) at the Rezidor Park Inn Hotel) To register your interest please complete and return the form right E-mail: goulds.axminster@itt.com

4

Tear off

I am interested in attending the CPSA Course to be held in October 2014 Name:............................................................................

Company:......................................................................

Email:.............................................................................

Phone:............................................................................

Please return to either by post to Jeanne Page, BPMA, The National Metalforming Centre, 47 Birmingham Road, West Bromwich, West Midlands B70 6PY or j.page@bpma.org.uk or by completing the form on-line at www.bpma-cpsa.co.uk For further information contact Steve Schofield, Director on 0121 601 6350.

Making low flow more efficient Sundyne HMD Kontro has designed its new GSPLF (LF for Low Flow) pump to fill the gap in the market for a low flow sealless pump with a relatively high head capability.

Combining the proven technologies of Sundyne Barske Wheel hydraulics with the HMD Kontro sealless magnetic drive, the GSPLF meets the requirements of API 685 and is fully ATEX compliant, making it ideal for oil and gas installations, plus chemical and petrochemical applications.

Sundyne has many years’ expertise in offering Barske Wheel pumps, designed to provide efficiency in the low specific speed regime i.e. low flow, high head applications. These pumps have an open impeller with straight blades and a tapered conical diffuser to produce the desired performance. Development and testing demonstrates that this combination produces a head factor (ratio of developed head to theoretical head) considerably higher than that of swept-back vane impellers.

By combining Barske Wheel hydraulics with the HMD Kontro sealless magnetic drive, reliability and efficiency is further optimised, ensuring trouble-free plant operation.

An additional advantage of the GSPLF is the flexibility inherent in the diffuser and impeller, which can easily be upgraded should the duty need to be changed without replacing the pressure casing.

Sundyne HMD Kontro has more than twenty-five years’ experience in API applications and over a sixty-five year heritage in magnetic drive technology, being the first company to develop a magnetic drive sealless pump.

With stricter demands for the safety and welfare of both personnel and the environment being imposed, Sundyne HMD Kontro sealless pumps are playing an increasingly important role.

Further information, including a copy of the GSPLF brochure can be seen and downloaded from the Sundyne HMD Kontro website at www.sundyne.com/hmdkontro.

Alternatively, please telephone +44 1323 452141 or email vlee@sundyne.com

by Pumping Technology

is available as:

SPILLPRESS ECO ELITE Smedegaard offer what is Probably the most comprehensive range of Pressurisation equipment in the UK. With full WRAS approval pending, the GaardPress Range is the Pressurisation set of choice for discerning engineers.

Pumping Technology

www.smedegaard.co.uk info@smedegaard.co.uk Tel: 01278 458686 • A KSB Company

E-mail: info@smedegaard.co.uk

5

The 2014 Pump Industry Awards The 2014 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, Tomlinson Hall & Co, SPP Pumps, AESSEAL, WEG Electric Motors, Process Industry Informer, KSB, John Crane & ABB plus leading industry publications Process Industry Informer and World Pumps the 2014 event has been heralded as ‘the best PI Awards yet.’

Held at the Chesford Grange Hotel in Kenilworth on Thursday 27th March the gala awards evening was attended by over 220 pump industry professionals who raised over £2,000 for WaterAid, the BPMA’s chosen charity.

Entertainment was provided by Jeff Probyn, the ex England and British Lions rugby player who recounted numerous tales from his playing days and as always the evening encouraged a great deal of networking in a competitive but friendly atmosphere, where the 2014 winners were revealed by celebrity compère, ITV Presenter Helen Fospero.

★ Meet the Winners ★ The awards focus on key areas of manufacture and supply, including innovation and achievement, energy saving, engineering excellence, customer care and employee motivation.

On the night, six companies and two individuals were awarded, and a fantastic night was had by all!

• Technical Innovation – Products Sponsored by: World Pumps Winner: KSB SALINO® Pressure Center

KSB’s SALINO® Pressure Center revolutionises and reduces the cost of seawater desalination. The four main components of a Reverse-Osmosis system; high-pressure pump, energy recovery, booster and motor – are replaced with a single compact unit. As a result, it has the best energy efficiency and lowest life cycle costs in its class. KSB is the first manufacturer to supply this type of compact system for RO processes and is ideal for small and medium-sized systems.

• Technical Innovation – Projects Sponsored by: Tomlinson Hall & Co Winner: Wilo UK for Palm Papers Newsprint Factory

Palm Papers has recently built a new plant in Kings Lynn for its work in the UK and Ireland. It’s one of the world’s largest and most efficient newsprint paper mills producing 400,000 tonnes of newsprint a year. The total pump infrastructure in the building has been supplied by Wilo. Heating, cooling, water supply, sanitation.

This integrated pumping system delivers lower bills and lower maintenance costs along with lower life cycle costs.

• Environmental Contribution of the Year Sponsored by: SPP Pumps Winner: Xylem Water Solutions UK for Veolia Water

Xylem Water Solutions worked in partnership with Veolia Water to deliver an engineering solution with benefits of 25% combined savings (£239K Per Annum).

Ongoing blockages were causing pump failures: Experts from Xylem re-engineered one of the pump lines (560kw) with a tandem set of Flygt N3400 250kw pumps.

The self-cleaning N-technology of the Flygt N-Pumps reduced blockages to virtually zero, achieving sustained station performance. Veolia’s environmental risk was reduced dramatically and sustained efficiency was achieved.

6

• Manufacturer of the Year Sponsored by: AESSEAL 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 more technical expertise, experience and approvals than our competitors. We are organised 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: WEG Electric Motors Winner: Tomlinson Hall & Co

Tomlinson Hall are shortlisted for Distributor of the Year for the eighth consecutive year, an acknowledgement of the Teessidebased distributors’ technical experience and knowledge combined with speed and quality of service to facilitate the production of customised solutions for their worldwide clients. They have continued to extend both their geographical market and number of OEM’s for whom they act without losing the attention to detail that has been the foundation of their success.

• Supplier of the Year Sponsored by: Process Industry Informer Winner: ABB

ABB is one of a few companies that can provide variable-speed drives and electric motors, perfectly matched for pumping systems. Part of ABB’s R&D investment has resulted in a dedicated pump-specific drive, the ACQ810, the UK’s largest range of electric motors and the world’s first IE4 synchronous reluctance motor and drive package. About one-quarter of ABB’s drives are used in pumps; the energy savings from these drives amount to an estimated 11 billion kWh per year.

• Engineer of the Year Sponsored by: KSB Winner: Jamie Lightly, SPP Pumps

Due to his leadership skills overseeing many projects, his hard working and reliable nature, and the enthusiasm with which he takes on extra roles to improve his company’s overall productivity.

Lifetime Achievement Award Sponsored by: BPMA Winner: John Veness, ITT Goulds Pumps

Due to his full participation in BPMA activities through the BPMA Technical Committee, BPMA Council and his two terms as the BPMA President. Currently a Director of BPMA, Chairman of the Europump Marketing Commission, member of the Europump Council and as such a very active in supporting and directing BPMA activities. John has been extremely influential in the pump industry for almost half a century!

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 2015 event please contact Andrew Castle on andrew@touchwavemedia.co.uk.

Nov Mono makes its mark at IFAT 2014 static mixer, which delivers a high degree of mixing in turbulent flow applications. It also creates a low pressure drop through the mixing element to boost the overall energy efficiency of the process. Alongside this was the Chemineer model 20 HT/GT mixer, fitted with an RL-3 Ragless impeller to create the ideal

This year’s IFAT exhibition gave visitors the opportunity to discover the wide range of solutions available from the leading global manufacturer of progressing cavity pumps, NOV Mono, which offers products for all types of sewage, water and raw material handling applications. The exhibition was the first time the company displayed standard and custom Chemineer™ fluid agitation equipment, following its acquisition of Robbins and Myers and its associated businesses in 2013.

New dosing duty solution Underlining MonoTM’s dominance in the waste water industry was a model of the company’s newly launched dosing pump.

This provides a reliable, lowmaintenance solution for low flow, dosing applications, with a smooth, non-pulsing action. It is a costeffective alternative to expensive gear pumps.

Maintain-in-place Mono’s revolutionary EZstrip™ transfer pump was also displayed.

This can be ‘Maintained-in-Place, disassembled, de-ragged and maintained without disconnecting suction or discharge pipework, thus reducing a typical day-long maintenance operation to just a 30-minute job.

Protective equipment The EZstrip™ CT201 Muncher on display can offer various cutter stack size options to create the optimum particle size and protect downstream equipment from blockages. A quick-release inspection cover allows the cutters to be replaced with the unit in-situ.

Universal Parts Mono also promoted its high quality Universal Parts. Manufactured by Mono, these can be fitted to many other brands of progressing cavity (PC) pumps, thus offering a reliable solution which helps reduce equipment downtime.

Mixing Solutions Mono’s expertise was reinforced by its Chemineer™ standard and custom fluid agitation equipment and systems. These included the compact Kenics™ UltraTab™

wastewater plant mixer.

For more information contact Nov Mono Ltd, Audenshaw, Manchester Tel: 0161 339 9000 Web: www.mono-pumps.com Web: www.chemineer.com

Meet the family the fast way.

All our Eta pumps at a glance.

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

Etanorm

Etaline

Etabloc

Etanorm SYT

Our technology. Your success.

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AESSEAL® now offers a full range of ATEX products and services After recently achieving ATEX certification of the LabTecta® bearing protection products, AESSEAL® have now successfully completed ATEX certification of their standard mechanical seal product range. The products are certified to comply with ATEX directive 94/9/EC, and are complimented by an ATEX assessment and support service, which is included at no additional charge to the customer.

Demonstrating commitment to delivering market leading customer service, AESSEAL® have invested not only in product certification and accreditation to ISO 29001, but also in providing the technical expertise, experience, and know-how to assess ATEX applications and ensure compliance. In addition, AESSEAL® is actively involved with various industry bodies ensuring that the mechanical seal industry properly advises its users in hazardous area applications.

The AESSEAL® range of mechanical seals and seal support systems are suitable for a wide range of industries including: Oil & Gas, Mining, Water & Waste Water, Power, Pharmaceutical, Chemical and Food & Beverage. Through investment in modular design and some of the most advanced manufacturing equipment AESSEAL® provide a value for money solution and the best on-time delivery performance in the industry.

For more information contact AESSEAL Plc, Rotherham, South Yorkshire.

Tel: 01709 369 966 Fax: 01709 720 788 E-mail: marketing@aesseal.com Web: http://www.aesseal.com

Grundfos extends MAGNA3 range When Grundfos Pumps introduced the updated MAGNA3 range of commercial circulators in 2012 the family was quickly recognised as offering ‘best in class’ in terms of energy efficiency. This new generation of state-of-the-art circulator pumps built on the excellent reputation that MAGNA established when it was introduced in 2001.

Today the extended range offers an extra 25 models, meaning that the MAGNA3 offers a circulator range that can support light, medium and large commercial heating, air conditioning and cooling systems, domestic water systems, ground-source heat pump systems and solar heating systems.

With its simple installation wizard the MAGNA3 has been designed for easy and intuitive installation. It comes with a high-resolution colour display and once the pump is turned on, the Assist™ software immediately guides the installer through set-up. With many integral features including AUTOADAPT that helps optimise energy usage in conjunction with the FLOWADAPT and FLOWLIMIT control features that allow a maximum flow limit to be set, which means the pump continuously monitors the system.

Offering complete control over every aspect of the pumps performance, Grundfos developed the innovative Grundfos GO control software. From the user-friendly interface on a smart phone or iPod Touch, you can monitor, set and control MAGNA3 as well as other Grundfos e-pumps.

With so much attention on both the bigger and smaller details, this pump family is an important step forward in pump engineering. A point that has been proven by the MAGNA3 winning a series of design and engineering awards.

For more information contact Grundfos Pumps Ltd, Leighton Buzzard, Buckinghamshire.

Tel: 01525 850000 E-mail: grundfosuk@grundfos.com Web: www.grundfos.co.uk

Isolated Systems Ltd specialise in the design, manufacture and installation of industrial noise, vibration and thermal management products. Our services include global support of our products comprising comprehensive site surveys, full installation and commissioning of our systems from our qualified team of site engineers that extends to offshore facilities.

Spring & Rubber Mounts

Multi-Layer Seals & Expansion Compensators

Packaged Skid Units & Inertia Bases

Silencers/Attenuators

Thermal Jackets

Louvres

Enclosures

Isolated Systems Ltd, Adams Close, Heanor Gate Industrial Park, Heanor, Derbyshire, DE75 7SW T +44(0)1773 761226 F +44(0)1773 760408 E sales@isolatedsystems.com www.isolatedsystems.com E-mail: sales@isolatedsystems.com

8

SPP

strengthens team with Major Projects Business Development Manager

SPP Pumps, leading manufacturer of centrifugal pumps and systems, has appointed Ian Burrows to take up the position of Business Development Manager for Major Projects.

The announcement comes following a recent double award win for SPP at the 2014 Pump industry Awards, and demonstrates the company’s commitment to providing the best solutions to customers, when and where it really matters. The result is finely-tuned, bespoke-engineered units that precisely meet the performance specifications each project requires.

Ian Burrows brings with him a track record of 30 years in the pumping industry and experience of managing business development programmes in the UK and Europe, and Russia. His key expertise is in the oil & gas and offshore sectors.

At SPP, Ian will be responsible for expanding the company’s portfolio of projects in the oil & gas markets. He comments: “I am excited to be joining the team at SPP. It is a company focused on providing the best quality, most efficient pumping solutions to customers, and it has an excellent reputation in the offshore business already for the supply of Fire and Seawater Lift pumps – I’m sure it will be an exciting challenge to broaden SPP’s scope and activity. I’m really looking forward to it.”

Bob Tichband, SPP Sales Director, said: “I’d like to welcome Ian to SPP. As part of our commitment to providing the very best services and solutions to customers, we need to recruit the best people – and Ian certainly fits this bill. We wish him a long and prosperous journey with SPP.” For more information contact SPP Pumps, Reading, Berkshire.

Tel: +44 (0) 118 932 3123 Fax: +44 (0) 118 932 3302 E-mail: solutions@spppumps.com Web: www.spppumps.com

Shard climbs to new heights Just a couple of months after The Shard’s official opening the 1020ft/310m vertical city received a huge accolade when it was announced as the project of the year at the recent Building awards. The development is perhaps the most ambitious development to date in London and has been the subject of much debate from both advocates and detractors alike.

It was designed by the architect Renzo Piano who compared his slender, spirelike design to “a shard of glass” a nickname that stuck. The building incorporates a wide range of restaurants, retail space and a spa; as well as a five star Shangri-La Hotel, all of which are open to the public. Additionally the development provides luxury residential accommodation and a significant amount of office space. There is also a multi-storey viewing gallery that in its own right is proving to be a real tourist draw and one that is expected to attract 2 million visitors each year.

Behind the scenes and keeping such an iconic building operational are a small army of Grundfos pump solutions. Grundfos were selected because of the combination of their experience in supplying to skyscraper projects in London – in particular Canary Wharf - coupled with their track record in successfully delivering complete and complex pump solutions. Other aspects that helped to secure this landmark project were Grundfos’ reputation, and the reliability and breadth of their product portfolio.

Whenever you see a silhouette of the London skyline, it is clear to see The Shard standing proud and pointing towards the future.

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

The Wilo Way: Customised solutions with personal commitment.

Goulds Pumps ISO Process Pumps now come with a 5 YEAR WARRANTY What would give to spot a pump failure sooner? With the Goulds iFrame you could.

The iFrame features on Goulds ISO and ANSI process pumps, incorporating the iAlert, vibration and temperature are constantly monitored on your pump to ensure your process runs at its optimum condition with strong visual indication in the form of three flashing LED’s, its never been easier to see how a pumps performing.

When the iAlert is first activated at startup it sets an operating benchmark for temperature and vibration of your pump, with any change in either of these conditions outside of acceptable limits the iAlert notifies you by green flashing LED’s turning red. So when you’re on the morning walk around the plant it couldn’t be easier to see how things are running.

As the iFrame with iAlert is fitted to Goulds ANSI and ISO process pumps which come with a 5 year warranty you’d have to ask yourself, why not? We just believe it’s better.

For more information contact Goulds Pumps, Axminster, Devon Tel: 01297 630473 E-mail: www.gouldspumps.com/Contact-Us Web: www.gouldspumps.com

Water Management by Wilo – that’s more than innovative technology and long-term expertise. The Wilo Way rather means making your working life easier by providing you with all the information you need – exactly when you need it. This includes planning tools, documentation and personal assistance in every project phase. That is how we live our promise “Pioneering for You”.

So how can Wilo support you? www.wilo.com/WaterManagement

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9

EasyClean™ from AESSEAL ®, helping improve hygiene standards in the food, beverage and pharmaceutical industry AESSEAL® is pleased to announce the launch of the patent pending EasyClean™ seal support system.

EasyClean™ is a unique, cost effective solution to improve hygiene standards in the Food, Beverage, and Pharmaceutical industries.

Despite the requirements of these industries to maintain a high level of hygiene in the production lines and throughout their factories, it is frequently the case that the seal support systems harbour dirt and bacteria on the interior of the main vessel. This is due to their inherently enclosed design, which makes them difficult to inspect, clean and maintain high levels of hygiene.

The EasyClean™ vessel, developed by AESSEAL®, is the ideal solution for industries, which require more control over the level of hygiene in their plants. EasyClean™ has a detachable lower section, which enables the vessel to be taken apart for inspection and cleaning. This removable lower section, offers manufacturers the opportunity to quickly inspect and clean their systems without severely impacting on costs, production or product quality, whilst also eliminating the harmful build up of dirt and bacteria.

Leading the market in ease of use and affordability, EasyClean™ sets new standards in support system capabilities. EasyClean™ is both a convenient and cost effective solution allowing manufacturers to further reduce the risk of product contamination in industries where a high standard of cleanliness is essential.

For more information contact AESSEAL Plc, Rotherham, South Yorkshire. Tel: 01709 369 966 Fax: 01709 720 788 E-mail: marketing@aesseal.com Web: http://www.aesseal.com/latestnews.aspx

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

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

INSERT REPLACEMENT Can be replaced without moving the associated machines

Rely on John Crane for lower cost of ownership, guaranteed reliability and improved productivity.

To learn more, please contact us at: John Crane UK Ltd, 31 Nash Road, Trafford Park, Manchester, M17 1SS. Tel: 0161-872-2484 Email: enquiries@johncrane.co.uk

®

www.johncrane.com E-mail: enquiries@johncrane.co.uk

10

Booster sets welcomed to Boss range BSS Industrial, supplier of heating and pipeline solutions, has added a range of one and two pump BOSS™ Booster Sets to its industry-leading, ownbrand range of products.

The BOSS™ Booster Set range (with WRAS approved pumps and components) are suitable for a wide variety of system requirements, including potable water supplies. Supplied fullyassembled to ensure ease of installation, BOSS™ Booster Sets have a compact design, produce minimal noise and provide constant pressure using an inverter with duty assist and duty stand by modes.

Ed Kendall, Project Category Manager at BSS Industrial, said: “This is a valuable addition to the BOSS range of products. The complete BOSS™ Booster Set range is stocked at our Magna Park National Distribution Centre, meaning we can provide unrivalled availability whilst our AMS Pumps team can commission the set for customers. Combined, this means we can provide a product and service package to make customers lives as simple as possible.”

The range consists of six, one pump variable speed booster sets and six, two pump variable speed sets for duty ranges between 0.4l/s and 7l/s.

For more information on BSS Industrial and to find your nearest trade counter, please visit www.bssindustrial.co.uk or call 0116 262 3232.

Follow BSS on twitter @BSSIndustrial.

New Contract Win Points to a Bright 2014 for SPP Pumps SPP Pumps, leading manufacturer of centrifugal pumps and systems, has won a new contract for energy assessment services at a large pumping station for Northern Ireland Water.

The company kicked off the year with its first order from Northern Ireland agent P A Quinn Energy and Graham Construction for Northern Ireland Water.

The project at the Sydenham Waste Water Pumping Station in Belfast involves a full pump system assessment of four 36” Weir Harland MSz vertical turbine pumps, each producing 2,273 litres/second at 7.6m.

These critical storm water pumps are amongst Northern Ireland Water’s most sensitive locations in the heart of Belfast.

SPP Energy will be working in partnership with its Belfast Service Centre during the assessment, demonstrating SPP’s seamless service. The assessment will provide Northern Ireland Water with essential energy consumption and flow profile information, for future development of their Flood Defence System and Water Discharge Control.

Chris Rose, Business Manager at SPP Energy comments: “Within Industry in the UK, there are over 11 million motors with a total capacity of around 90GW. However for every 100KW generated for a pumping system, around 90.5% is lost through inefficiency. A system assessment like the one we’re conducting for Northern Ireland Water can identify potential savings to companies, where it really matters to them – on their bottom line.”

SPP’s pump system assessment expertise provides the critical data and analysis, which is needed to ensure the plant equipment is updated to meet its operating requirements in an efficient manner.

Paul Quinn from P A Quinn Energy adds: “SPP proved themselves right from the start, through their dedicated expertise and the way they effectively collaborated between their field assessment team and their local service centre, right here in Belfast. It’s great to be working with such a dedicated and experienced team on such a critical project.”

For more information contact SPP Pumps, Reading, Berkshire.

Tel: +44 (0) 118 932 3123 Fax: +44 (0) 118 932 3302 E-mail: solutions@spppumps.com Web: www.spppumps.com

‘ONE-NUT’ ease of maintenance and electronic rupture protection secure 3-A accreditation for new Flotronic pump Specialist air-operated doublediaphragm pump manufacturer, Flotronic Pumps Limited, have secured 3-A accreditation for their brand new ‘H’ series pump. Among a number of critical design features, Flotronic’s innovative ‘ONE-NUT design, which allows rapid pump disassembly and straightforward cleaning in place, was crucial to the success of the ‘H’ series’ 3-A application. The ‘H’ series’ electronic rather than pneumatic rupture protection system was also a deciding factor.

3-A Sanitary Standards Inc is an independent not-for-profit corporation dedicated to advancing hygienic equipment design for the food, beverage,

and pharmaceutical industries. It sets high standards for cleanability of equipment as well as for the provenance of the parts and raw materials used and the pump’s ability to shut-down immediately to avoid contamination in the event of a problem.

“Ease of cleaning and robust rupture protection and associated alarm systems are vital for 3-A accreditation,” says Flotronic Chief Engineer, Peter Wheal. “We were confident that our ‘ONE-NUT’ design would completely satisfy 3-A cleaning and maintenance demands.

“We also knew that we needed to find a cost-

effective alternative to our pneumatic rupture protection system,” says Peter. “The result is an electrical unit connected to sensors in the pump’s air domes. The presence of any leakage is immediately detected avoiding the need for any secondary chamber, with a control unit shutting the pump down when activated.”

Flotronic designed the ‘H’ Series not only to meet 3-A’s stringent criteria but also with the US market particularly in mind. Meeting the high standards demanded by 3-A is a requirement of many US companies, especially those in the food processing industry.

For more information contact Flotronic Pumps Ltd, Haywards Heath, West Sussex. Tel: 01444 881871 E-mail: sales@flotronicpumps.co.uk Web: www.flotronicpumps.co.uk

Adhesive specialist switches from progressive cavity pumps to peristaltic pumps • Peristaltic hose pumps solve downtime issues • Three Bredel 80 models chosen for their low maintenance costs • Single wearing component offers superior chemical resistance Incessant wear, clogging and seal changes that resulted in high periods of downtime have seen Polandbased adhesive manufacturer Zakład Chemiczny Paweł Paprocki switch from the use of progressive cavity pumps in its production processes, to peristaltic hose pumps from Bredel.

Screw pump frustration

Zakład Chemiczny Paweł Paprocki is one of the largest manufacturers of adhesives and raw materials for the production of glue and paint in Poland. The company produces more than 30,000 tons of raw material every year. The company uses pumps for metering products, such as Caviol® or Winakar® PW-50, with viscosities varying from a few to tens of thousands millipascal-seconds (mPas). However, chemical compatibility between the constituent parts of the adhesive were causing the company’s pumps to wear, resulting in clogging and production downtime. Additionally the frequency of seal changes became problematic.

As a result, the decision was taken to change the progressive cavity pumps to Bredel 80 peristaltic hose pumps due to their significantly lower maintenance and spares costs. These seal-less, valve-less hose pumps offer highly accurate, reliable, low maintenance metering, dosing and transfer capability - right across the full range of viscosities.

The inherent design of Bredel hose pumps means there are no intrusions in the flow path, eliminating any risk of blockages.

The pumped substance only contacts the reinforced, chemical-resistant hose, making

them particularly suitable for handling problematic fluids such as those with a high viscosity and fluids containing abrasives or with high solids content, for example.

Rigorous trials

Before purchasing the pumps, immersion tests were performed with the Bredel hose. The tests lasted 168 hours, and confirmed that the hose materials were resistant to the chemicals found in the fluids which Zakłady Chemiczne Paweł Paprocki intended to meter.

160 x 110 advert 2_Layout 1 09/05/2014 15:55 1 for Next, Watson-Marlow provided a Bredel 80Page pump

on-site trials, to check flow rates, pipe runs and pressures in the process. The trial led to the purchase of three Bredel 80 models.

“If we are confident that a pump will perform in a specific application we often agree to on-site trials by the client since it is the best proof of quality and performance,” concludes Rafał Łydziński, Sales Manager at Watson-Marlow in Poland.

For more information contact Watson-Marlow Pumps Group, Falmouth, Cornwall.

Tel:01326 370370 Fax: 01326 376009 E-mail: info@wmpg.co.uk Web: www.wmpg.co.uk

Why not join the growing list of companies that use ?

Market-leading software designed for your business!

“

EMIR is an ideal tool for us because it is already perfectly suited to the pump and motor industry. We have been able to use it with minimal customisation and it is quick to learn and logical to use. The fact that a single system can cover everything from customer contact information through ERP and include accounts cuts out significant additional work.

The scalability and the additional modules also make it attractive for businesses that are expanding.

The support from Solutions in IT has been exceptional, with them working as a true partner to us. Customisations have been fast and painless.

Working with Solutions in IT has been the best supplier service that I have ever experienced. I would personally recommend EMIR as an excellent solution for other Electro-mechanical businesses.

”

E-Commerce

Web-CALS

Stock

Purchasing

Quoting

Finance

Motor Management

Time & Attendance

Web Job Tracker

EMIRPDA

Labour Scheduling

CRM

Winding Details Database

Annette Boulter, Commercial Manager, Hidrostal Ltd.

Tel: 0845 009 4588 www.solutionsinit.com email: info@solutionsinit.com

Product discounts for all BPMA members E-mail: info@solutionsinit.com

11

When Pressurised just call Smedegaard the Pressurisation system experts Smedegaard Pumps limited manufacture and supply what is ‘probably’ the largest range of pressurisation equipment for LTHW, MTHW and CWS systems.

The standard ECO and Elite pressurisation units are primarily designed for commercial systems and are used with Expansion Vessels. The units can be free standing or walls mounted, and are Category 5 compliant. Elite units are fitted with system ‘safe fill’ packs allow the units to fill the closed loop system.

For applications such as very large volume, high rise, higher temperature systems or where the final working pressure of the system must be similar to cold fill pressure then the SpillPress units offer the ideal solution. The compactness of the SpillPress units may also be a great advantage where the available floor space is limited. SpillPress tanks are designed to accept the full expansion of the system; level control is fitted as standard. All tanks have an overflow and spill over weir to give a WRc Category 5 compliant type AB air gap.

A full digital control panel is fitted to the unit which gives an audible and visual alarm indication with mute, password protection and hours run log and

has volt free contacts for BMS connection.

SpillPress are split into three distinct ranges each providing the optimum engineered solution.

SPILLPRESS COMPACT

The ‘Compact’ range consists of the pump and control module mounted together with the spill tank on a common base plate. Peripheral turbine pumps in twin configuration are normally used in the range. However, other pumps can also be offered to suit specific requirements. The spill tanks are available in three sizes to accept 400 litres, 600 litres or 1000 litres of expansion. Solenoid valves are utilised as spill valves on this range.

BPMA News Enquiry Form May 2014

SPILLPRESS MODULAR

The ‘Modular’ range consists of the pump and control module on a common baseplate and the spill tank supplied loose. Usually two vertical multistage pumps are fitted but there is the option for a third pump. Self acting spill valves are utilised with this range but solenoid valves can also be fitted to this

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Company:..........................................................................

Address.............................................................................. .......................................................................................... ................................County:................Postcode:..............

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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

SPILLPRESS BESPOKE

The ‘Bespoke’ range is designed and engineered for larger projects which exceed the capability of both the ‘Compact’ and ‘Modular’ packages. The ‘Bespoke’ sets are designed and built to the client’s specific specifications with the aid of our in house expertise. The accompanying picture shows a ‘Bespoke’ custom built pump and control package.

Spill tanks with a capacity of 53,000 litres were provided with this package.

High Temperatures Applications

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

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

range. ‘Modular’ packages can accept expansion of up to 11875 litres and is suitable for use with boilers of up to 12000 kW at 90°C.

When operating the system above 95°C higher pressures will be required to eliminate vaporisation.

Additionally intermediate cooling buffer vessels may be necessary. As the SpillPress for these applications is customised to specific needs, please contact the Smedegaard technical team for assistance when dealing with these system types.

Smedegaard Pumps Limited, Bridgwater, Somerset Tel: 01278 458686 Fax: 01278 452454 E-mail: info@smedegaard.co.uk Web: www.smedegaard.co.uk - or enter U on ENQUIRY COUPON (See back page)

Wernert submersible pumps for chemical effluent transfer Wernert vertical VKPF50-250 pumps are proving to be a great success for transferring chemical effluent from collection tanks to a treatment/neutralisation facility at a chemical processing plant in the north of England.

Sometimes referred by to by Wernert as the ‘forget me pumps’ because of their reliability, AxFlow now has five variable speed vertical, cantilever shaft pumps handling a mixed acidic solution. The chemical plant produces refrigerants/propellants and because of the highly corrosive and hazardous nature of the effluent, the pump shaft in the liquid area is protected by a plastic sleeve whilst the bearing in the thrust bearing lantern is protected from aggressive vapours and gases by a PTFE radial shaft seal ring.

First installed in 2010 and added to in 2012, all five

pumps were required in order that the plant could comply with new emission controls. It is important that the continuous transfer of the chemical effluent is done reliably in order to prevent an overflow that could result in an emission to the local waterway. The Wernert pump is capable of handling this challenging application as it is especially suited to pumping liquids that are contaminated with solids.

This type of pump is not provided with any sealing against the pumped liquid because leakages flow out above the impeller through lateral openings in the delivery suspension pipe.

For more information contact AxFlow Ltd, Ealing, London. Tel: 020 8579 2111 E-mail: info@axflow.co.uk Web: www.axflow.co.uk - or enter V on ENQUIRY COUPON (See back page)

FLUIDS & LIQUIDS HANDLING INC. PUMPS & VALVES

NOV MONO MAKES ITS MARK AT IFAT 2014 This year’s IFAT exhibition gave visitors the opportunity to discover the wide range of solutions available from the leading global manufacturer of progressing cavity pumps, NOV Mono, which offers products for all types of sewage, water and raw material handling applications.

The exhibition was the first time the company displayed standard and custom Chemineer™ fluid agitation equipment, following its acquisition of Robbins and Myers and its associated businesses in 2013.

New dosing duty solution Underlining MonoTM’s dominance in the waste water industry was a model of the company’s newly launched dosing pump. This provides a reliable, low-maintenance solution for low flow, dosing applications, with a smooth, non-pulsing action. It is a cost-effective alternative to expensive gear pumps.

Maintain-in-place Mono’s revolutionary EZstrip™ transfer pump was also displayed. This can be ‘Maintained-in-Place, disassembled, de-ragged and maintained without disconnecting suction or discharge pipework, thus reducing a typical daylong maintenance operation to just a 30-minute job.

Protective equipment The EZstrip™ CT201 Muncher on display can offer various cutter stack size options to create the optimum particle size and protect downstream equipment from blockages. A quickrelease inspection cover allows the cutters to be replaced with the unit in-situ.

Universal Parts Mono also promoted its high quality Universal Parts. Manufactured

by Mono, these can be fitted to many other brands of progressing cavity (PC) pumps, thus offering a reliable solution which helps reduce equipment downtime.

Mixing Solutions Mono’s expertise was reinforced by its Chemineer™ standard and custom fluid agitation equipment and systems.

These included the compact Kenics™ UltraTab™ static mixer, which delivers a high degree of mixing in turbulent flow applications. It also creates a low pressure drop through the mixing element to boost the overall energy efficiency of the process. Alongside this was the Chemineer model 20 HT/ GT mixer, fitted with an RL-3 Ragless impeller to create the ideal wastewater plant mixer.

For more information contact Nov Mono Ltd, Audenshaw, Manchester Tel: 0161 339 9000 Web: www.mono-pumps.com Web: www.chemineer.com

PROCESS INDUSTRY INFORMER May 2014

31

VALVES - when to repair or replace?

When it comes to process, pilot and actuation valves, the question of whether it is advisable to repair or replace a worn or intermittent unit is worth considering, regardless of the type or the size. Tom Carnell, Systems Applications Manager, from valve manufacturer Bürkert UK gives his advice as a basic guide.

Starting with the smallest of solenoid-controlled valves, which are a relatively low cost item, it would usually be beneficial to replace the valve with a new component which carries the manufacturer’s warranty. Outside influences, beyond the design parameters of a system however occur more often than we would like to think. With some processes costing thousands of pounds per hour of downtime, a straight replacement can often be a default choice in this situation.

In contrast, large-scale butterfly and ball valves, which have seen little advance in design over the years, just in materials technology, would often see repairs carried out with many serviceable parts available. These tend to be used in applications dealing with dirty or aggressive media and the bodies can be worn down by the passage of abrasive particles. The larger the valve, often the more economic a repair can be.

Usually, valve seats, seals and stem seals are available as a service kit which provides a known maintenance cost for budgeting purposes. Aggressive materials can often perish soft seals and seat materials. Valves should be specified very carefully based on the medium they carry, but in many cases simple age can result in seals and seats requiring replacement in an otherwise perfectly healthy valve.

Potential downtime is a major issue and a distress situation, can affect the decision, as can issues of cleanliness and meeting ‘as new’ material specifications; especially in food, aerospace or medical applications. Often valves used in hygienic applications have recommended service intervals which are dependent on their position within the manufacturing process. This planned maintenance schedule often prevents unwanted valve failures which can cause substantial production losses.

When it comes to process valves, the medium tends to be less aggressive or at least more consistent. In this instance each component is replaceable, so valve seats and seals would be available as well as components for the pilot valves. In this case you would expect the valve body to remain serviceable, unless it has received physical damage, and then a replacement is usually the only option.

Repair or replace – an important consideration…

Upgrades are also a crucial aspect of the decision to repair or replace, it may be that a different type of valve can replace a series of older valves and therefore prevent the requirement for further replacements; TakeBurkert’s Robolux series as an example. This multi way valve can potentially do away with more than one valve and several pipe sections and bends. Modern design techniques allow this valve to be customised to incorporate mixer and diverter valves, or to integrate sensors into the valve block. Crucially, the number of potential leak paths is greatly reduced and with the valve delivered pre-assembled, the installation time is also reduced.

Control is also a key decision, as the development of automation marches on, the repair or replacement of a valve might present an opportunity to increase the control and visibility of an application. There are products which can be applied to create an intelligent field device from an existing valve, providing information on status and allowing external actuation in an application that previously relied on pressure or manual actuation.

When assessing control valves, there can be strong benefits in upgrading equipment due to the new technology which is evolving in this area. Older systems can be upgraded to provide faster response times with the use of 4-20mA

32

converters and also to provide diagnostic information on valve performance. This information can be very valuable when trying to pinpoint areas for concern and resolving performance issues.

The after sales department of the supplier should inspect any returned valves to help in understanding failure modes and so improve installation and reliability.

However, many of these valves perform as required when tested; further investigation with the customer can help in determining any reduction in plant performance.

In many cases it transpires that the valve was incorrectly specified by the process design engineer - an issue which can be easily resolved in the future by asking for expert help from the valve manufacturer.

A typical example is using the Kv value for a valve as the flow rating - a common mistake which does not take into account the differing pressures through the valve or the viscosity of the material under control. By making use of expert advice, production control systems can be designed to use the most efficient and appropriate equipment to ensure reliable performance.

There are cases where we have received a 25 year old valve returned for its first service, but unfortunately the parts may no longer be available. In such cases, we would look at the application and the process as a whole and make suggestions as to the most efficient way forward. This could include integrating new technologies and reducing the total number of valves in the process. Each case is different and our engineers have the expertise to understand the requirements of each client and to give advice on the best course of action.

After all…

The bottom line is that prevention is better than cure. Good maintenance practice and ensuring that the control devices are providing reliable efficient service is crucial. Replacement of valves may entail higher initial costs, however, additional benefits such as increased diagnostic and communication ability as well as product warranty, all lead to improved productivity in the long term. Where possible, consult with expert engineers, whose experience can be used to benefit the design and operation of the control system.

Process control technology has made huge advances in recent years and when an opportunity arises to assess a production system with a view to upgrading, operations managers should consider their options carefully and work with a provider that has experience of process control systems and that their expertise can be used to help all customers ensure that their application is designed, installed and operated in the most efficient and reliable manner possible.

Bürkert Fluid Control Systems, Cirencester, Gloucestershire Can be contacted via: Telephone: +44 (0) 1285 648 720 Fax: +44 (0) 1285 648 721 E-mail: aftersales.uk@burkert.com Web: www.burkert.co.uk

PROCESS INDUSTRY INFORMER May 2014

FLUIDS & LIQUIDS HANDLING INC. PUMPS & VALVES

Compact turbine PRECISE, FAST RESPONSE CONTROLLING pumps for smooth, WHEN LARGE VALVES long life performance When pumping applications present the challenges of low flows at high pressures, very low NPSH for high temperatures or low vapour pressure liquids, the smooth and balanced performance of MTH regenerative turbine pumps will be appreciated.

Available from fluids handling specialists PUMP ENGINEERING, the MTH range of pumps is ideally suited to applications such as boiler feed, high pressure cooling, refrigeration and CIP process. These compact pumps, which are available in direct drive, bareshaft, magnetic drive and canned rotor options, can replace multistage pumps, generating high heads in only a single stage. This design allows the pump to handle hot liquids, refrigerants, liquefied gases and liquids with entrained air, for example gas dissolution systems, where the pump will self-vent carrying air bubbles with the fluid to the discharge port.

The regenerative turbine pump is characterised by its unique impeller, which has a large number of blades machined into both sides of its periphery. Fluid enters the impeller at its outside diameter and is accelerated as it passes from blade to blade exiting the pump, at the same radius as the inlet. The row of blades located on each side of the impeller minimizes axial thrust; in effect, it is two impellers in one, operating within identical channels on the casing and the cover which allows the impeller to float freely and find its own equilibrium.

Another important advantage of the regenerative turbine pump is its ability to generate a very steeply rising head curve between minimum and maximum flow ensuring accurate flow control and very stable operation.

The standard range of MTH pumps includes models which cover capacities from 1 to 500 lit/min and pressures up to 70 bar. Construction materials include iron, bronze and 316 stainless steel.

Where process control systems require larger valves it can sometimes be difficult to achieve the required levels of accuracy combined with fast positioning. Larger valves, for example where flow rates require valve sizes of 200mm and above enabling flows in excess of 200 m3/h, tend to be fitted with pneumatic actuators which provide significant positioning forces.

In these situations the positioning of the valve is achieved by filling the actuator with the corresponding amount of air, or by venting from the actuator. However, the air output capacity required to achieve fast positioning in larger actuators (with diaphragm areas of 1400cm2 up to 2800cm2) is simply too much for normal positioners and accuracy can be compromised.

An added complication in these situations is that the positioner controls a volume booster which results in a much higher air capacity than the positioner and this can lead to an overshoot on responding to small signal changes.

To overcome these problems control valve specialists SAMSON CONTROLS have developed a control valve positioner package which ensures precise positioning with fast response times, over the entire operating range, for example strokes of 60mm and greater. The package consists of a positioner and a special hook up of several volume boosters with different air output capacities which perform this task.

Closing and opening times of less than two seconds can be achieved over the entire positioning range.

The flow control applications where the Samson package has been successful is for compress or bypass valves (anti-surge valves) as well as in petrochemical applications involving adsorption processes in moving-bed adsorbers.

For more information contact Samson Controls, Redhill, Surrey E-mail: sales@samsoncontrols.co.uk Web: www.samsoncontrols.co.uk

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

AIR ACTUATED STAINLESS STEEL BALL VALVES COMBINE QUALITY WITH ECONOMY Thorite has launched a new range of economy stainless steel, pneumatically actuated ballvalves from leading Italian manufacturer Bonomi, each designed to offer rugged performance in a wide number of general-use industrial process applications.

Thorite is the UK’s biggest independent distributor of pneumatic products and process systems and has selected these Bonomi ball valves to provide customers with quality units at super-competitive prices.

The new ball valves are available with 2 and 3 piece, direct-mount stainless steel valve bodies, with single or double acting aluminium actuators and can be specified in port sizes from 1/4” to 4” BSP. All valves are supplied complete with the quality, tried and tested Bonomi aluminium air actuators which also have position sensing ports for signal outputs and Namur valve interfaces.

Customers can get full product details, prices and discuss specific model recommendations by callingThorite’s Technical Department on freephone 0800 0345850.

The new ball valves are just part of Thorite’s £3million+ stockholding, which can be ordered from any of Thorite’s 10 regional Sales and Service centres or direct from Thorite’s National Distribution Centre for next day delivery.

For more information contact Thorite, Bradford, West Yorkshire Tel: 01274 663471 E-mail: ross.gowler@thorite.co.uk Web: www.thorite.co.uk

PROCESS INDUSTRY INFORMER May 2014

AFTERMARKET SERVICE | UPGRADES | SPARES

Valve overhaul or upgrade during scheduled shutdown On-site repairs anywhere in the world for unplanned outages Fast-track OEM spares service

Talk to us today to get expert advice on your aftermarket requirements.

Koso Kent Introl Limited, Armytage Road, Brighouse, West Yorkshire HD6 1QF

T. +44 (0)1484 710311 E. info@kentintrol.com W. kentintrol.com

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FLUIDS & LIQUIDS HANDLING INC. PUMPS & VALVES

ARI ZETRIX® - Completely tight, versatile, durable, SAFE!

ARI-Armaturen are proud to promote the recent launch of their new process valve, the ZETRIX® an innovative triple off-set process valve, designed specifically for challenging applications.

The ZETRIX® design was developed to be a premium triple offset valve, suitable for liquids, gases and vapours that will outlast and outperform other valves on the market.

Permanently leak-proof, durable and versatile for guaranteed isolation and control, even in the harshest industrial environments, the ZETRIX® has been developed and tested using high precision technologies and quality German engineering.

ZETRIX® utilises the benefits of a metal-seal process valve with all the advantages of a butterfly design.

Along with compact dimensions and light weight material, this cutting-edge valve is very easy to handle.

Adapted to a range of applications and available in both cast and stainless steel, this extremely versatile and durable product will assure you the ultimate reliability and efficiency.

For more information contact ARI-Armaturen UK Ltd, Tewkesbury, Glos.

Tel: 01684 275 752 E-mail: enquiries@ari-armaturen.com Web: www.ari-armaturen.com

Purifying wastewater with Verderflex Peristaltic Industrial Tube Pumps The Challenge A leading multi-national electronics company with numerous plants across South Korea has for many years been using Metering pumps for dosing Aluminium Sulphate in their wastewater treatment facilities.

The plant engineers approached the local Verderflex distributor Dong-Il Ent Co Ltd, looking for a solution to the following problems: • Inconsistent dosing of Aluminium Sulphate when tank levels were low • Unscheduled maintenance periods • High maintenance costs Verderflex Solution After consultation with the customer and site visits, 8 x Rapide R2S Peristaltic tube pumps were selected to replace the existing Metering pumps. The pumps currently operate at flow rates ranging from 78ml/min to 1080 ml/min with discharge pressures up to 1.5 bar.

Result The end user now experiences predictable maintenance patterns, whereby the service period has been increased from 600 hrs to 1000 hrs. This has reduced the process downtime that was experienced before with the metering pumps and has brought a significant reduction in the maintenance costs.

Jason Bang, Dong-Il Ent Co Ltd, Sales Manager “the customer is very happy with the simplistic operation & maintenance of the pumps. The ease in which the tube can be changed using the ski-boot clamp of the Rapide R2S, compared to the labour heavy and complicated maintenance of the Metering pumps is just one of the many reasons the end user decided to go for Verderflex Rapide pumps”.

Verderflex is a leading manufacturer of industrial peristaltic tube pumps. Verderflex range of peristaltic pumps has been developed according to the latest technology and subject to continuous quality control.

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

More Grundfos booster sets gain WRAS approval In 2013, Grundfos Pumps attained WRAS (Water Regulations Advisory Scheme) full product approval status for their range of Hydro MPC E/F/S booster sets. This scope covered Grundfos Hydro booster families that comprise of between two to six pumps, are up to a 16 bar PN rating and pump models up to CR(E)90.

Approval is only granted following rigorous mechanical testing and ensures that these complete booster sets comply with the various strict byelaw regulations and requirements as they currently exist in the UK. Now the range of Grundfos Hydro GTI booster sets, have also attained full WRAS approval status.

This range has been specifically designed to meet many boosting demands including: smaller commercial applications, residential homes, potable water, wash-down systems and irrigation systems. Sets are also suitable for Category 5 applications (as defined by Water Regulations Backflow Prevention) and are suitable for use in both new and retrofit applications, making them perfect for many different applications.

For more information of Literature request contact Grundfos Pumps Ltd, Leighton Buzzard, Bedfordshire.

Tel: 01525 850000 E-mail: grundfosuk@grundfos.com Web: www.grundfos.co.uk

TURBIDITY MONITORING SYSTEMS NEW CONTAMINATION MONITORING SYSTEM PROTECTS STEAM BOILERS AND ENABLES ENERGY RECOVERY Spirax Sarco has launched a Turbidity Monitoring System for detecting non-conductive contaminants such as fats, oils and greases in boiler feedwater, enabling steam system operators to recover substantial amounts of energy that would otherwise be lost.

Such contaminants, if accidentally released into condensate, could cause the boiler to overheat, requiring a lengthy shutdown for chemical cleaning, or at worst, causing boiler failure.

To eliminate this possibility, some operators may discard hot condensate rather than recycle it as boiler feedwater.

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With condensate containing around 25% of the useful energy in the original steam, recovering it can substantially reduce water, energy, effluent and chemical treatment costs.

The Spirax Sarco Turbidity Monitoring System helps operators to re-use condensate by providing realtime monitoring, raising an alert if contamination rises above a set level, allowing the tainted condensate to be diverted to drain immediately rather than fed into the boiler.

The Turbidity Monitoring System can also be used to monitor the quality of other water sources, such as mains, demineralised and reverse osmosis supplies. This

makes it suited to applications where water quality is paramount, such as cleaning-in-place and sterilisationin-place stations in food and drink manufacturing.

The Turbidity Monitoring System comprises a turbidimeter and a converter. The turbidimeter uses light in the visible and ‘near infrared’ range to penetrate the fluid medium.

Four sealed photodiodes detect any light scattered by contaminants. A fifth photodiode measures unscattered light to provide a reference measurement. This innovative ‘dual channel’ method compensates for colour and other variations in the water to provide more accurate and more reliable results than conventional single channel systems.

For more information on Spirax Sarco’s Turbidity Monitoring System E-mail: ukenquiries@spiraxsarco.com

PROCESS INDUSTRY INFORMER May 2014

FLUIDS & LIQUIDS HANDLING INC. PUMPS & VALVES

BOOSTER SETS WELCOMED TO BOSS RANGE BSS Industrial, supplier of heating and pipeline solutions, has added a range of one and two pump BOSS™ Booster Sets to its industry-leading, own-brand range of products.

The BOSS™ Booster Set range (with WRAS approved pumps and components) are suitable for a wide variety of system requirements, including potable water supplies.

Supplied fully-assembled to ensure ease of installation, BOSS™ Booster Sets have a compact design, produce minimal noise and provide constant pressure using an inverter with duty assist and duty stand by modes.

Ed Kendall, Project Category Manager at BSS Industrial, said: “This is a valuable addition to the BOSS range of products. The complete BOSS™ Booster Set range is stocked at our Magna Park National Distribution Centre, meaning we can provide unrivalled availability whilst our AMS Pumps team can commission the set for customers. Combined, this means we can provide a product and service package to make customers lives as simple as possible.”

The range consists of six, one pump variable speed booster sets and six, two pump variable speed sets for duty ranges between 0.4l/s and 7l/s.

For more information on BSS Industrial and to find your nearest trade counter, please visit www.bssindustrial.co.uk or call 0116 262 3232.

Follow BSS on twitter @BSSIndustrial.

AUMA App

Advances Data Downloads

A new AUMA Support App enables rapid download of actuator documentation.

Designed to make life easier for on-site engineers, a Data Matrix code on each actuator can be scanned using a smartphone to obtain support materials.

Adopted in industrial valve automation applications, AUMA actuators are individually tailored to meet the specific requirement of each installation. As a result, documentation including wiring diagrams, technical data sheets and inspection certificates is unique for every device.

Designed for convenience in the field, the AUMA App is used to scan the order number on the actuator’s name plate to download required documents. Material will continue to be available via the company’s website www. auma.com The free AUMA Support App is available for download and runs on Apple iPhone, iPad, and iPod touch for version IOS6.1 or higher.

AUMA - leading manufacturer and global supplier of modular electric actuators

A new smartphone App from AUMA gives easy download access to actuator documents

QR code direct link to the AUMA Support App in the Apple Store

For more information contact AUMA Riester GmbH, Müllheim, Germany Tel: +49 7631 809-0 Fax: +49 7631 809-1250 E-mail: Riester@auma.com Web: www.auma.com

N

EW

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

info@verderflex.com

www.verderflex.com Process Industry Informer.indd 1

PROCESS INDUSTRY INFORMER May 2014

2/4/2014 2:45:59 PM

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SOLIDS HANDLING & PROCESSING

SPIROFLOW TARGETS UK INGREDIENTS SECTOR WITH NEW CTE BULK BAG FILLER Manufacturers requiring safe, pin-point weighing accuracy and dust containment need look no further than Spiroflow Ltd, world-leading supplier of conveying and weighing systems: the company has launched the Cone Table Elite (CTE), adding to its range of bulk bag fillers available in the UK following the acquisition of Control & Metering of Ontario, Canada.

The CTE is filling technology designed to produce dense and safe bulk bags that are accurately weighed and stable when used with the most difficult ingredients, such as those found in the food, pharmaceutical, chemical, plastics, building and construction sectors.

Shifting millions of tonnes of potentially dangerous ingredients is part and parcel of many production processes for manufacturing companies, which must have systems and equipment in place that adhere to the European Union’s ATEX Directive 1999/92/E implemented by the Dangerous Substances and Explosive Atmosphere Regulations 2002 (DSEAR) act in the UK. Spiroflow is a world-leading manufacturer of ATEX

approved conveying and bulk handling systems that meet regulatory requirements for transporting and handling powders and other materials in environments containing a potentially explosive atmosphere, such as sugar storage areas or flour silos.

Its ATEX compliant fillers, conveyors and bulk bag dischargers incorporate venting systems and dust prevention features to help companies maintain good cleaning routines.

Exceptionally well suited to filling ingredients that are hazardous, toxic, require sanitary handling or are difficult flowing, the CTE features the patented cone densification table, hang weighing and hang filling. This provides the ultimate in densification and weighing accuracy.

This bulk bag filler from Spiroflow can be adapted for use with rigid IBCs, drums or Gaylords and is easily configured for automatic pallet and filled bag handling.

The single post, modular design allows easy access for rigging bulk bags of various sizes and is ideal for restricted space applications. Maximum bagging rates of up to 35+ bags/hour can be achieved.

Rob Hudson, Spiroflow Managing Director, said: “Bulk bags are one of the most convenient, cost effective methods of packaging, storage and transport. The CTE

Bulk Bag Filler provides maximum product densification that ensures bag stability. It also means that you can put more material into your current bulk bag or use a smaller bulk bag for a given weight. Either way, operating cost savings are the result.”

The primary objectives when filling a bulk bag are to produce a stable package that is easy and safe to handle, provides accurate weighing and effective dust control.

Spiroflow’s whole range of bulk bag fillers, like the CTE, are ideally suited to the most challenging applications.

In addition to bulk bag fillers, Spiroflow Ltd is also a manufacturer of Flexible Screw Conveyors, Aero Mechanical Conveyors, Tubular Cable and Chain Drag Conveyors, Vacuum Conveyors, Bulk Bag Dischargers, Ingredients Handling and Weighing Systems. The company’s technical and engineering expertise has led to it developing an international reputation for an unrivalled range of products with state-of-the-art control systems.

For more information on Spiroflow’s products and services contact Spiroflow, Clitheroe, Lancs.

Tel: +44 (0)1200 422525 Web: www.spiroflow.com

SIEVES & SIEVING

The Minor M200 The low cost solution to fast easy sieving The Minor M200 has been designed and manufactured to combine low cost with the benefits of a well designed and engineered shaker incorporating many features usually found only on larger more expensive models. https://www.youtube.com/watch?v=obx4pv56 pb8&feature=youtu.be Benefits at a glance • Affordable • Easy to use • Quiet operation • Compact

• Portable • It is ideal for the laboratory or plant since it is compact and genuinely portable (weighing only 17kg). There are no rotating parts in the Minor M200 consequently it is quiet in operation and maintenance free.

The sieve stack is held firmly in position between the location and clamp plates by poly fibre straps, these allow the whole unit to be packed away in a space less than 200 mm high.

• Simply set the 0 to 60 minute timer for

WEIGHING New hazardous area weighing terminal – safe, accurate and compliant

a timed operation or select “I” for continuous sieving. The vibrating action imparts a precise movement to the sieve stack ensuring efficient sieving and excellent repeatability.

• Maintenance free For further information please contact Endecotts Ltd, London, SW19 3TZ Tel: +44 (0)20 8542 8121 Fax: +44 (0)20 8543 6629 E-mail: sales@ endecotts.com Web: www.endecottscom

MAINTENANCE BEST PRACTICE GUIDE TO CORROSION PREVENTION

Finding the right solution for hazardous-area weighing applications is challenging.

Manufacturers must protect their equipment and products.

METTLER TOLEDO’s new ICS466x weighing terminal is designed for safe, accurate weighing in Hazardous Area ATEX Zone 1/21 and FM class I, II, III, Div 1 and helps ensure quality and compliance.

The easy to use ICS466x provides excellent flexibility with various data interface options.

A comprehensive range of modular, intrinsically safe components are available to build a system customised to your needs. You can benefit from: • Safe, robust and reliable design • Multi-scale interfaces • Simple to read LCD display Combining extreme temperature resistance with an intrinsically safe design, it offers compliance with the latest hazardous area requirements.

Corrosion prevention in refineries and chemical plants has been, and still is, the subject of many studies, papers and web forums. Although significant progress in understanding corrosion has been made, the problem continues to present a major challenge in this industry.

Access METTLER TOLEDO’s latest best practice guide “Corrosion Prevention in Chemical Plants and Refineries.”

This guide contains a collection of case studies and papers which demonstrate how in-line measurement solutions are used for cost efficient prevention of corrosion and fouling in process industries and utilities.

Highlights include: • Reducing corrosion in overhead condensers • Monitoring and controlling makeup water treatment • Measuring pH in low conductivity samples To download this best practice guide visit: www.mt.com/uk-corrosion-bestpractice

For more information about the ICS466x weighing terminal and to download a free white paper, visit: www.mt.com/ICS466x

For more information: Tel: 0116 234 5095 E-mail: enquire.mtuk@mt.com Web: www.mt.com/pro-chemical

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PROCESS INDUSTRY INFORMER May 2014

Change management systems: safeguarding your plant automation assets The increased use of plant floor automation to achieve production goals has created a dependency on PLCs, PC-based control systems, SCADA systems, robotic controllers and HMIs. It is therefore vital that companies ensure that proper safeguards are in place to protect and manage any changes made to control logic across the plant, says Andy Thorogood, Product Manager at MAC Solutions.

Plant floor automation control systems often involve an array of PC workstations, programmable logic controllers (PLCs), HMIs (human machine interfaces) and robotic controllers. Control logic is stored either in the device or on an associated workstation and can involve a large number of associated files and executable programs. This complexity poses a challenge to detecting unauthorised – and potentially hazardous – program changes, especially where systems from multiple vendors and the associated variety of program development and device management tools exist.

Until recently, proprietary protocols and network isolation provided adequate security from external threats. However, many vendors are abandoning proprietary communication mechanisms in order to lower costs and improve reliability. Similarly, more and more device management is moving to PC-based workstations and other ‘open’ systems. This transition to standard protocols and operating systems is making modern devices and systems more vulnerable to attack.

Change Management and the Plant Fortunately, software solutions are now available that can help to safeguard plant-wide automation and control assets. An automation Change Management Systems (CMS) such as Autosave from MDT Software, is a centralised system that manages changes to program logic for controls programs and devices such as PLCs, CNCs, HMIs, PC control systems, robots, drives and general automation programs. A typical small plant will have a few hundred programs that should be managed, while large plants will have several thousand.

Over the life of a facility the investment in program logic alone represents a significant expenditure that should be preserved and optimised. In order to do this, a CMS should have the following features:  A backup/archive of prior revisions of programs.  The ability to detect changes.  Tools for documenting changes and making these visible to users.  A historical record of who made the change, when, and from where it was made.  Secured user and workstation access.  Features for controlling editor operations mapped to user permissions.  Disaster recovery/procedures for recovering from hardware failures.  Change notification.

As automation devices have grown more complex and have incorporated more plant data in their operation, there is an increase in the need to make adjustments to variables and logic to continue smooth operation.

These adjustments may be minor individually, but are directly linked to machine throughput and uptime. If the current device program and configuration are lost, and an old version of the device program must be used, the result is decreased machine performance, decreased quality and/or downtime. While this situation is costly enough, consider the ramifications to plant operation if

PROCESS INDUSTRY INFORMER May 2014

there are no older versions of a lost program available and the program must be completely rewritten. This can and does happen, and the effects can significantly impact safety and plant throughput for months. These impacts added to the cost to re-rewrite, test and commission a single program are often greater than the cost to implement a plant-wide CMS solution.

Types of Risks There are many events that can have a negative affect on plant performance, and some that represent serious safety hazards. Reliable automation control logic can be compromised by the following events:  Human Error: If someone makes changes to a program that result in undesired performance, or corrupts the program due to inadvertent changes, the prior version of the program is readily available with a CMS.  Equipment failure: Equipment can and does fail.

If the hardware fails and the only good copy of the program logic was in that hardware, the plant has a problem. With a CMS, the hardware is replaced and maintenance staff download the latest version of the program to the processor resulting in only a few minutes of downtime.  Sabotage: As unfortunate as this threat is, someone can connect directly to many devices (especially those in remote, unsecured locations) and modify the program with harmful results. A CMS is designed to store processor passwords so these are not available without going through the CMS. Also, the CMS will periodically upload the logic from the processor for comparison with a copy on file.

Changes can be identified in graphical detail, and immediate notification can be sent to responsible individuals.  Power surges / interruptions: Power issues can cause equipment to lock up or go off-line. If these situations result in a loss of the program, it can be downloaded from the CMS after the hardware is reset.  Fire: Any fire will be a major disruption. Whether a single device or an entire facility is lost, having all program logic stored in a central, organised CMS repository accelerates the time and decreases the cost associated with resuming production. Insurance underwriters are beginning to factor in the use of a CMS in assessing the risk profile of facilities. Without proper system safeguards these events can lead to increased downtime and an increase in “mean time to repair” (MTTR). Recovering from these events quickly requires adequate planning on the hardware and maintenance strategy, and a reliable and recent backup of the automation control program logic.

Current and complete backup copies of the program logic require the features of a CMS. While a manual backup approach may appear adequate at first glance, experience has shown that plant personnel have too many tasks that compete for the time to manually back up programs on a consistent basis.

Also the increased visibility of changes through better reporting and the potential for process improvement brought about by the effective use of a CMS application can quickly pay for the CMS.

Impact of Plant Activities on Versions of Program Logic Each plant has a unique set of change types and frequencies that can affect a CMS strategy.

A selected set of activities is outlined below to prompt further thought and highlight the need for a proper implementation of a CMS in order to achieve optimum results.  Nature and Frequency of Changes: ensure that an adequate number of program copies are available to ensure that changes can be classified and reviewed.

Some changes represent true improvements, while others highlight a process problem or training issue that should be addressed by other means.  Process Enhancements: If changes are made in the process that make prior versions of the program obsolete, these enhancements should be clearly identified so that users do not revert to an older version of a program to fix a new issue. Plant operating guidelines should identify when the deletion of prior programs is warranted, and which users will have this permission.  Unmanaged Changes: Without a CMS the controls engineer would use the editor software on a workstation or laptop to make changes in a device.

If multiple people make changes from multiple computers, the documentation of changes is often lost. Using a CMS to compare the program running in the device with the last recorded version, a plant can identify changes that were made outside of the CMS. Once the CMS is implemented and sufficient device networking is in place, edits outside the CMS should be discouraged.  Temporary Changes: It is common to make a temporary change to a program to resume operation while a maintenance task is performed on a failed component. It is also common for these temporary bypasses to be forgotten, which can result in serious safety issues. A CMS is used to note these temporary changes and provide a means of easily restoring a prior version of the program once maintenance is complete.  Multi-Process or Recipe Operations: In facilities that run different processes or recipes it is important to manage which version of a program is being updated. The creation of specialised copies of programs to use as “master versions” for each of these processes can aid in managing these efficiently.

MAC Solutions, Redditch, Worcestershire Can be contacted via: Tel: +44 (0) 1527 529 774 Fax: +44 (0) 1527 838 E-mail: andy.t@mac-solutions.co.uk Web: www.mac-solutions.net

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A third way to better compressor efficiency Oil-free compressors and retrofit filtration options have provided efficient solutions when enhancing compressor efficiency but now the most innovative method of generating oil-free compressed air in many applications is to use oil lubricated standard compressors with a downstream catalytic converter. These systems provide a reliable supply of oil-free compressed air with lower energy costs, reducing maintenance costs to a minimum, says Mark Whitmore, General Manager, BOGE Compressors Ltd. The requirement for oil-free compressed air has grown rapidly in recent years, especially in markets such as food and drinks production, where for example the use of PET bottles has risen dramatically, and pharmaceutical and electronics where cleanroom environments dictate the use of high purity air.

For many companies, especially those with lower volume requirements, the use of oilfree compressors can be an expensive option. The traditional alternative has been to use micro-filters and active charcoal filters to remove oil vapour from the compressed air stream. With the introduction of self-contained catalytic converters there is now a third option. This can be used with existing compressors, yet delivers consistent quality oilfree air at low cost and with minimal maintenance.

Let’s take a closer look at these options. The most direct method of generating oil-free compressed air is to opt for an oil-free compressor. Oil-free screw or piston compressors are designed to compress air without coming into contact with oil. These compressors are known as ‘dry running’ units because the compression chamber is not lubricated and the screws operate ‘contact free’. With no oil in the system to penetrate into the compressed air the result is zero contamination. It is thought that these types of compressors offer completely oil-free air. However, despite the directness of this method, any hydrocarbons present in the ambient air will remain after compression, so merely using oil-free compressors without additional filtration does not guarantee oil-free compressed air. They can also be, as mentioned above, expensive to run.

For operations that do not use oil-free compressors a retrofit installation can be applied by using microfilters in combination with active charcoal filters, or active charcoal adsorbers, to remove liquid and vaporous oil from the compressed air. This solution provides oil-free compressed air with only a residual oil content that may even be below that of the ambient air. Depending on the demands of the application, this option can successfully fulfil many quality requirements.

Perhaps the most innovative method of generating oil-free compressed air is to use oil lubricated standard compressors with a downstream catalytic converter. This system enables any residual oil content present after compression to be run through the catalytic converter. Long chain hydrocarbons are opened until only CO2 and H2O are left - two harmless substances that are also present in ambient air. The result is efficient in more ways than one; the system achieves not only class 0 oil-free compressed air but also the entire elimination of the oil and expensive downstream condensate treatment, while the catalytic convertor itself is not subject to wear. They are ideal for generating Class 0 oil-free compressed air in particularly sensitive areas of production, such as the pharmaceutical, food and drink, and semiconductor industries.

New innovations Compressor technology continues to advance. Water-cooled screw and centrifugal compressors are now available that use state-of-the-art technology to produce oil-free compressed air. These systems provide a reliable supply of oil-free compressed air with lower energy costs.

New water-cooled screw compressors not only use less energy than previous systems but also generate up to 6% more compressed air and are quieter in operation. The use of a two-stage airend, with a low pressure and a high-pressure stage, is responsible for the extremely low specific power consumption of these compressors. The latest water-cooled screw compressors are now even available with IE3 premium efficiency class motors, which means that users are saving energy right from the very first minute of operation, and ensuring long-term generation of a sustainable, cost-optimised supply of compressed air. Innovations have also addressed issues of maintenance, such as durable coatings that prevent rotors and housings from corroding, while the best

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designs make components easily accessible and positioned within the compressor’s cooling air stream. Meanwhile the increasingly high-grade materials used, as well as the reduced number of wear parts, cut maintenance costs to a minimum and prolong service life.

Efficiency can be enhanced by operating compressors with frequency control to perfectly match compressed air output to the actual demand at any time. In peak load operation, or where compressed air demand fluctuates, or storage volume is limited, this has the virtue of appreciably lowering energy costs, since the amount of free air delivered by the compressor is adjusted by continuously varying the motor speed. This saves wear and tear on materials, minimises maintenance costs and reduces reaction times in operation to a minimum.

So how might this come together in practice to make significant cuts in costs? Can a significant sum be saved in energy consumption and maintenance right from installation by specifying one of the latest compressors?

As industry seeks and finds an increasing number of ways to enhance energy efficiency, a new compressor solution often dovetails very well with wider changes being made to the plant. For example, when structural changes are made to the plant to enhance energy efficiency in other ways, this can leave the business with an oversized compressor system. This is because as a result of purchasing compact, more efficient, faster equipment a plant can suddenly become much smaller and the savings made by streamlining the plant must not then be mitigated by an oversized compressor system that wastes energy. The manager of an existing plant that, say, requires two compressors with a third on standby may suddenly find that, after purchasing the new equipment, the company is only using half the space and requires nowhere near as much compressed air as it did before.

In these situations, a compressed air energy audit will show the loaded and unloaded running cost and reveal the total weekly running cost of running the compressors, as well as an evaluation of system efficiency.

A variable speed drive can be installed to recover the lost energy that older, fixed-speed units may be wasting and the existing compressor can be replaced with a new compressor, such as the BOGE SLF 125, which combines a direct coupled drive system with frequency control to provide the ultimate compressor for pressure control under variable output requirements. The SLF is a low carbon technology that works strictly in accordance with the compressed air demand by producing the exact volume of compressed air at the pressure required. Frequency control minimises idling time and evens out air demand fluctuations.

An audit such as this can maximise the effect of a new compressor system; for example, the consultant may even suggest that generation pressure is reduced, thus adding even further savings to the ones that the new compressor system provides. Service costs can thus be dramatically reduced and users are often delighted to discover that the compressor has paid for itself even quicker than initially envisaged. Maintenance is much cheaper on one compressor than three, and if the consultant does indeed recommend that generation pressure can be reduced with no detrimental effect to production this can reduce maintenance requirement and energy costs by reducing the running hours.

BOGE Compressors Ltd, Brighouse, West Yorkshire Can be contacted via: Tel: +44 1484 719921 Fax: +44 (0) 1484 712516 E-mail: UK@Boge.com Web: www.boge.co.uk

PROCESS INDUSTRY INFORMER May 2014

COMPRESSORS & COMPRESSED AIR

CALIBRATION

CRYSTAL CLEAR COMPRESSED AIR

NEW Fluke pressure calibrator for high accuracy transmitters, pressure switches and gauges

Tests from a leading laboratory show condensate from the revolutionary Opus Crystal compressors is so pure that any oil/ hydrocarbon content is barely measurable on the class zero scale.

By comparison, the so called ‘oil free’ compressor tested alongside Opus Crystal presented hydrocarbon content figures 4,000 times higher and the Ph was semi acidic.

The difference is that, unlike so called ‘oil free compressors’ which simply compress air, Opus Crystal both compresses and cleans at the same time. Opus Crystal removes airborne impurities as they pass through the compressor. No matter where the compressor is sited, the result is always totally oil free, crystal clear air.

Opus Crystal compressors are available from Motiviar, who with more than 60 years experience, offer the marketleading Flexible Service Plan, 24/7 emergency breakdown support, compressed air equipment & accessories, technical design & support services and much more.

For more information contact Jason Vigrass at Motivair, Burtnwood, Staffs. Tel: 0845 009 6161 or visit motivair.co.uk and opuscrystal.co.uk to find out more.

AIR CONTROL PRODUCTS Air Movement Specialist’s New Website Offers Significant Advantages For Customers Air movement specialist, Air Control Industries, has launched a new web site. It is faster and easier to navigate whilst also offering more resources to site visitors. It gives a clearer insight into what the company offers – products and services – backed up by an extensive library of application videos demonstrating products in use.

All ACI’s products feature – Fans, Blowers, DRI-Line bottle and can drying systems, Air Knives and its JetBlack personnel de-dusting units – with easily downloadable literature, data and drawings in various formats supporting on-line data.

To promote further site development and enhancement

visitors are encouraged to provide feedback via social media. This facility also permits visitors to ask questions and receive responses.

All these attributes are included in both UK/Rest of the World and USA versions of this new format website and both were launched simultaneously.

Future developments include an on-line shop which will again enhance the site visitor experience.

For more information contact Air Control Industries Ltd, Axminster, Devon Tel: 0845 500 0501 E-mail: matthewforknall@aircontrolindustries.com Web: www.aircontrolindustries.com

Fluke has introduced a pressure calibrator which is ideal for calibrating high accuracy transmitters, pressure switches and pressure gauges. The new Fluke 719Pro Electric Pressure Calibrator offers one handed pressure calibration and includes a full functioning loop calibrator that sources, simulates and measures mA signals.

The large backlit screen on the Fluke 719Pro Electric Pressure Calibrator displays three parameters at once: pressure measurement from the internal or an external sensor, sourced/simulated/ measured mA values, and temperature using an optional RTD probe.

The Fluke 719Pro is available as three models – to 30psi (-0.8 to +2 bar), 150psi (-0.8 to +10 bar), and 300psi (-0.8 to +20 bar) pressure ranges: these ranges can be extended by attaching any of 29 optional Fluke 700Pxx Pressure Modules. The 719Pro offers ideal accuracy (to ±0.025%) and performance for reference class transmitter calibration. The 719Pro features a unique integrated electric pump offering one handed pressure calibration. It allows the user to program target pressures for pumping, eliminating the danger of over-pressurisation.

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

ARRAY SPECTROMETERS

QE PRO SPECTROMETER DELIVERS MARKET -BEST SENSITIVITY AND PERFORMANCE The QE Pro from Ocean Optics is a high-sensitivity, back-thinned CCD array spectrometer with outstanding quantum efficiency, wide dynamic range and extremely low noise operation for applications with low light levels and where wide concentration ranges are measured.

The QE Pro’s optical design maximises performance for a range of application needs. With its 18-bit A/D, QE Pro has dynamic range performance that makes it the highest sensitivity miniature spectrometer available today. This is significant for users monitoring emission spectroscopy, especially fluorescence and Raman, where signals may be weak and minimum detectable sample limits are often challenging. In addition, for both absorption and reflectance in quality control applications, QE Pro provides lower limits of detection and enables measurements over a wider concentration range.

For kinetics researchers and scientists requiring fast, full spectrum acquisitions, the QE Pro provides onboard buffering capability. The 15,000 spectra onboard buffer maintains data integrity by buffering time-stamped spectra for USB communications.

PROCESS INDUSTRY INFORMER May 2014

Buffering enables full-spectrum kinetics measurements, such as those used in chemical and enzyme kinetics or protein folding to be performed every 8 milliseconds -- or 125 measurements per second.

Thermoelectric control of the detector improves the stability of the detector for lengthy measurements, where thermal noise convolutes the signal. TEC cooling dramatically reduces thermal noise and holds The

QE Pro’s stability to 4 dark counts over a 60°C ambient temperature range. This stability allows the spectrometer to be used for demanding online and at-line quality control measurements and environments susceptible to temperature changes.

QE Pro spectrometers are also available with replaceable, precision laser-cut slit and aperture assemblies for SMA 905 and FC connectors.

Replaceable slits give users more freedom in spectrometer design and the ability to switch among applications such as fluorescence and absorbance as easily as replacing a few screws. The slits are available with SMA 905 or FC connectors and are available separately or as part of a kit comprising one each of 5 µm, 10 µm, 25 µm, 50 µm, 100 µm and 200 µm width slits and one SMA bulkhead with no slit installed.

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

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INFRARED THERMOMETERS

NEW LOWER-PRICE FLUKE HIGH RESOLUTION VISUAL INFRARED THERMOMETER WITH AA BATTERY FLEXIBILITY Fluke has introduced the new Fluke VT04A Visual Infrared Thermometer - a lower-priced version of the Fluke VT04 with a manufacturer’s recommended price of £495. While including all the features of the high-end VT04, it is powered by AA batteries offering flexibility to technicians who may wish to replace batteries in the field.

The Fluke VT04A is a troubleshooting tool with an infrared heat map which offers high resolution as well as temperature alarms and time-lapse features. The VT04A comes with updated firmware that extends battery life by offering three screen brightness levels, automatic screen dimming after a set period with instantaneous override, a configurable automatic time-off capability, and the ability to save images in .bmp format. It also comes in a more compact, soft carry-case.

The Fluke VT02 / VT04 / VT04A Visual IR Thermometers instantly detect problems using blended thermal and digital imagery. They will display and save images as full visual, full infrared, or in three blended modes. Markers pinpoint hot and cold spots indicating the hottest temperature with a red box and the coldest with a blue box. A temperature reading is provided at the centre point.

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

NETWORK & COMMUNICATIONS Unmanaged Industrial Ethernet Switches Combine Versatility, CostEffectiveness And Ease Of Installation HARTING has introduced two new families of unmanaged Ethernet switches that are optimised for use in harsh industrial environments and offer a choice of compact designs for economy and ease of installation in a variety of customer applications.

With over 200 different models to choose from, along with a choice of RJ45 or fibre-optic cable ports, the HARTING Ha-VIS eCon 2000 and 3000 unmanaged Ethernet switches enable the cost-effective expansion of existing network infrastructures as well as the development of new industrial networks.

These compact “plug & play” switches can be easily and quickly put into operation. Two different compact, space-saving housing designs designed for “top hat” rail mounting guarantee the best possible use of available space in the switch cabinet.

The eCon 3000 family is based on a very narrow form factor with a width of 25 mm which permits high packing density in the control cabinet, helping users to save costs.

The eCon 2000 family, on the other hand, has a flat design with a depth of 27 mm which permits greatly reduced installation depth at the point of utilisation.

Units in the Ha-VIS eCon 3000 family each feature up to ten Fast Ethernet ports and offer economical and fast options to expand or set up network infrastructures. Full Gigabit switches are available with up to seven ports each for applications with high data throughput.

Switches in the Ha-VIS eCon 2000 family each offer up to 16 Fast Ethernet ports and are also available in a 7-port full Gigabit version. This allows customers to expand or set up network infrastructures in a time-saving, economical way.

The switches are designed for use over the industrial temperature range from -40°C to +70°C. For more information contact HARTING Ltd, Northampton Tel: +44 (0) 1604 827500 Fax: +44 (0) 1604 706777 E-mail: gb@harting.com Web: www.harting.co.uk

Go the extra mile for Mother Nature?

When it comes to cleaning up emulsified condensates BEKOSPLIT gives 10% customer satisfaction.

R

Not all condensate will seperate out by gravity. Some will remain in colloidal form and require splitting by a flocculent material.

Please call us on 01527 575778

BEKO TECHNOLOGIES, 2 & 3 West Court, Buntsford Park Road, Bromsgrove, Worcs, B60 3DX, Tel 01527 575778, Fax: 01527 575779 email: info@beko-technologies.co.uk website: www.beko-technologies.co.uk

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PROCESS INDUSTRY INFORMER May 2014

REDUCING COSTS

BY RECOVERING ENERGY FROM COMPRESSORS

By Philip McArragher, Technical Manager for HPC Compressed Air Systems

Reducing energy costs through operational efficiencies is a key objective for all manufacturers particularly in view of current economic pressures, as is the importance of effectively demonstrating ‘green’ credentials. For example in the instance of compressed air systems one particular area which offers the potential for significant energy savings but is still largely ignored is the recovery of heat actually produced by the compression process.

It is an inescapable fact that today’s screw compressor systems generate heat and although this may come as no surprise it is less well known that typically 100% of the electrical energy input into a compressor, is turned into heat. The action of compression charges the air in the compressor with potential energy which is given up (wasted) at the point of being used by the compressed air expanding and drawing heat from the surroundings.

However, Philip McArragher, says that up to 96% of this energy is recoverable he now explains, “Of the major proportion of the energy recoverable as heat, about 76% is found in the compressor cooling fluid / oil, approximately 15% is in the compressed air itself and up to 5% is given up by the drive motor to the cooling air”.

Phillip continues, “In a fully encapsulated oilcooled rotary screw compressor system even the losses from the electric motor can be recovered as hot air. This brings the total proportion of the input energy available as recoverable heat up to an impressive 96%. Of the remaining energy, 2% radiates away from the compressor package while 2% remains in the compressed air”. Therefore, energy conscious compressed air users wanting to improve the efficiency and economy of their compressed air plant can choose from a number of heat recovery methods:

Air or Space Heating The simplest and most direct method of recovering the heat generated in an oil cooled rotary screw compressor is by direct utilisation of the cooling air that carries away the heat from the air-end, oil cooler, motor, etc. This heated air can be ducted away for use as space heating in warehouses and workshops, or it can be used for other applications such as drying, heat curtains or pre-heating combustion air.

When the heated air is not required a manual or automatically activated flap / louvre can be used to discharge it to the atmosphere. In applications where temperature control is more critical, this flap can be thermostatically regulated to maintain a constant, set temperature. This space heating method allows 96% of the electrical energy consumption of a screw compressor to be recovered with considerable cost savings. For example, even

PROCESS INDUSTRY INFORMER May 2014

with a relatively small 18.5 kW compressor it is possible to easily recover enough energy to heat a small unit or office area.

Water Heating Another option to air or space heat recovery from compressors is hot water. This can be recovered for various purposes either from an air-cooled or water-cooled compressor system by using a heat exchanger installed in the air-end cooling oil circuit.

Plate or fail-safe heat exchangers can be employed for this, depending on whether the hot water is used for heating, laundry, showering, production or other commercial cleaning purposes. Water temperatures of up to a maximum of 70°C can be achieved with these heat exchangers. HPC’s experience shows that for compressor packages upward of 18.5 kW capacity the additional costs for these heat recovery systems can be realised within just two years (subject to correct design).

Considerations of Reliability Normally, the compressor’s primary cooling system should not be used both for cooling and as a heat recovery system. The reasoning behind this is that, should the heat recovery system fail, then the cooling of the compressor and the production of compressed air could be compromised. The safest method is to fit an additional heat exchanger in the compressor purely for heat recovery. In the event of it failing or if no hot water is required, the compressor can revert to its primary air or water cooling system and so continue operation. The supply of compressed air is then ensured.

In Summary It is important to realise that each application and compressed air installation is different and should be treated accordingly. The path to maximum energy savings is the efficient and proper application of compressor control systems and energy saving techniques.

Recovering the heat of compression for a useful purpose is an intelligent and practical way of reducing the cost of compressed air production whilst improving energy efficiency at the same time. The effort and additional investment involved is reasonably small and, depending on individual applications, can be recovered over a relatively short period of time depending on the purpose to which the heat is used and the method of recovery chosen.

HPC Compressed Air Systems, Burgess Hill, West Sussex Can be contacted via: Tel: +44 (0) 1444 241671 E-mail: mark.sharman@hpcplc.co.uk Web: www.hpccompressors.co.uk

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OPEN END TO ATMOSPHERE At the recent Air-Tech exhibition at the N.E.C Birmingham, BEKO TECHNOLOGIES

end of a production period i.e. could be three times per day. This practice was

gave a presentation in the seminar area entitled “open end to atmosphere”.

widespread and was wasteful in that the dirt/dust would resettle, the pressure

This presentation was an advice about the issues of having an air supply at

was not often regulated and it is a potentially dangerous practice particularly

say 7 bar (g) venting down to atmosphere without doing any useful work or

if the operative has an open sore then compressed air can be potentially lethal.

work that cannot be done more economically or safely by another medium. An

There is a simple answer, use a vacuum attachment to the airline or a “venturi”

example of this would be the use of blow guns to clean machinery down at the

assisted type which increases the flow at reduced pressure.

The opportunities for saving were broken down into 3 key areas. The first was leaks and it is well known that leaks from a compressed air system can be quite considerable. In fact a system with 10 % leakage is regarded as a good one. Bearing in mind that 10% of all power used in modern industrialised societies will be to compress air then we are wasting 1% of all power even when we are good at housekeeping so it is clearly important that we make sure that the wastage is not significantly higher than this.

What causes leaks in a compressed air system?

There are many opportunities for the compressed air network to develop leaks but the principle ones would be:• Corrosive condensate. The particulate material drawn into a compressor together with the small amount of oil carried over will become an acidic liquid when the compressed air cools and water vapour condenses out and mixes.

• Poor installation. Pipe supports not adequately deigned causing stress on joints which become leaks. Cheap solutions such as hoses for temporary solutions which become permanent • Impacts such as fork lift truck • Poor maintenance. The maintenance engineer has to see the compressed air network as a part of his maintenance routine rather than a one-off occasional exercise to cull leaks Also some machinery will be stopped at a point where a valve or orifice is open and will remain open until the machinery restarts. These may be small occurrences but the sum total of all these small leaks is normally in excess of 10% and for example a 75KW compressor running on load for a year will cost more than £70,000.

So it is important to check leaks via an ultrasonic device, mark up the leaks in some kind of classification as to the severity of the problem then fix the worst ones. It is then important to realise that this is not “job done”. The leaks will in some cases come back because of poor installation or appear elsewhere as the corrosive condensate or an impact creates a new leakage.

The second area is condensate draining…

It is important to understand that the condensate has to be drained efficiently or can be re-entrained and cause moisture problems and as just indicated will create leaks in the distribution system. There are not too many old fashioned steam type traps used anymore because they were subject to blocking through debris falling onto the valve seat and also to hydraulic locking requiring the installation of a balance pipe. Solenoid drains became popular and are still widely used but are inefficient because of the number of variables involved such as compressed air flow, pressure, temperature and relative humidity. All of these combine to ensure that the condensate volumes are different from day to day,

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morning to evening, winter to summer, UK to China. To be sure to get rid of the condensate then the blow down time will be set for the worst case which will mean considerable wastage on every occasion that does not equate to this set time. The solution to this is the zero loss drain which is becoming the product of choice because there are no losses of the expensive resource of compressed air.

There is an investment cost but in nearly all cases the return on investment can be shown as being acceptable.

There may be as many as 100 drain points in a large plant with outdoor piping so it is a simple but important area to consider for the maintenance routine.

For example, a customer in the Midlands recently asked us to attend site because of a perceived drying problem.

This problem existed and was being dealt with but as part of the routine checks the air receiver drain was checked.

With no exaggeration 15 minutes was required to drain the large air storage vessel. If the condensate level had become much higher then serious amounts of the contaminated condensate would have been re-entrained into their system. The company are involved in an industry where it is vital to be “just in time” and deliver direct to production lines. It is easy to imagine the large scale problems for this company and its customers if a large scale ingress of condensate had occurred. The installation of an efficient level sensing BEKOMAT solves a potentially disastrous situation at a small investment cost The other area where compressed air is wasted is in the drying process...

There are many processes which require a dew point below the -3°C which refrigeration dryers are capable of reaching. This could be for instrument air, for pneumatic conveying, food, beverage or medical grade compressed air to name a few processes. The lower dew point typically -40°C is achieved by use of a desiccant material which is unchanged by the process of attracting water vapour via molecular forces but will need to be regenerated in order to be used over multiple drying/regenerating cycles.

One of the regeneration methods is heatless or cold regeneration which requires a part of the dried compressed air to be expanded to become super dry and then flowed through the wet desiccant bed. Nature does not like large gradients and the difference between the water content of the desiccant and the regeneration air will create the migration across to the compressed air which is then vented to atmosphere. In this method 15% of the compressed air is used solely for drying which if we equate back to our 75 KW compressor would mean a cost of £10,000 or more. The reason this genre of dryer was popular was because of low price and simplicity but it is clear that for systems above the 75KW level other methods should be applied.

Zero Purge dryers are becoming the norm for larger installations. They use external heat to regenerate the desiccant and blown external air to cool meaning that the

costs are kept to a sensible level for the drying process.

An example given at Air-Tech was of a company in the automotive industry who had a part purge drying system so lost a smaller notionally 5% of the compressed air but had heating costs and cooling costs. The offer of a zero purge system showed a payback of less than 2 years for the purchase, installation and commissioning of 4 large BEKO FRAV dryers. Ongoing annual savings of more than £250,000 where attractive but another important customer benefit was that they could abandon their plans to add another large compressor into their network.

This would have been very costly because alongside the capital and running costs there would have to have been a large investment in creating a space suitable for a large compressor to add to their very large system.

Users of oil free compressor should also the consider the use of “Heat of Compression” types of dryer which take advantage of the higher temperatures generated in s dry compressor as opposed to an oil lubricated type, to use the heat for regeneration of a desiccant.

The message is clear and simple. Compressed air is the 4th utility but it is expensive and should be used selectively. When looking at energy saving possibilities the factory engineer should be serious looking and thinking… ”Have I got these open ends to atmosphere?” If the answer is yes then an action plan to reduce or eliminate should be high on his agenda!

BEKO Technologies Ltd, Bromsgrove, Worcs Can be contacted via: Tel: 01527 575778 Fax: 01527 575779 E-mail: info@beko-technologies.co.uk Web: www.beko-technologies.co.uk

PROCESS INDUSTRY INFORMER May 2014

HEALTH & SAFETY

HEAT TRANSFER & ENERGY

Static Grounding Equipment for Hazardous Areas

A common feature of powder processing equipment operating in hazardous locations is the potential for static electricity to accumulate on multiple parts of the plant equipment. Isolated components of fluid bed dryers, hoppers, micronizers, hoses and powder conveying systems can accumulate voltages capable of discharging electrostatic sparks into potentially combustible atmospheres with minimum ignition energies well below the energy of a static spark. For users requiring ground status indicators and process interlocks, the installation of multiple grounding systems to monitor each component individually is likely to be both cost and space prohibitive.

The Earth-Rite® MULTIPOINT is a discrete static grounding system, with process interlock capability, that can monitor and ground up to eight pieces of potentially isolated equipment, all at the same time, eliminating the need to install multiple grounding systems. The ground status of each object is displayed by an array of green and red LEDs mounted in a hazloc approved enclosure. If the MULTIPOINT detects that an object is not grounded it can be configured to shut down the transfer process to stop the electrification of equipment.

To learn more about the Earth-Rite® MULTIPOINT or the dangers of static electricity in hazardous areas please contact Newson Gale.

MICROTURBINES TURN STEAM PRESSURE REDUCTION INTO ELECTRICITY TO CUT UTILITY COSTS Spirax Sarco has launched a range of pressurereducing microturbines that generate electricity to reduce utility costs for steam system operators.

Suitable for saturated or superheated steam, Spirax Sarco TR Steam MicroTurbines are available in two sizes, up to 700 kW. Higher electricity outputs are available on request.

A microturbine producing 300 kW of electrical power can generate cost savings of more than £150,000 per year. The greater the steam demand, the more electricity the turbine will generate and the faster the payback.

Generally, higher pressure steam distributed from a boiler is conventionally lowered by a pressure reducing station, to match the needs of the heating or process application. With a Spirax Sarco TR Steam MicroTurbine, the steam is reduced to the required pressure as it travels through the turbine, with the energy released by the pressure drop being used to generate electricity.

Industries with potential for using the microturbines include food and drink, chemical processing, pharmaceutical and any facility with a pressure reduction requirement. The electricity produced can be used locally or exported and sold to the mains power grid.

Spirax Sarco TR Steam MicroTurbines can operate at up to 89 bar g and 550°C.

For more information contact Newson Gale Ltd, Colwick, Nottingham Tel: 0115 940 7500 Fax: 0115 940 7501 E-mail: groundit@newson-gale.co.uk Web: www.newson-gale.com

For more information on TR Steam MicroTurbines contact Spirax Sarco, Cheltenham, Glos. Tel: 01242 521361 E-mail: D3064_155x225mm PROCESS INDUSTRY INFORMER AD_Layout 1 08/01/2014 15:32 Page 1 ukenquiries@spiraxsarco.com Web: www.SpiraxSarco.com/uk

www.skillsstore.com

The winning formula to help you go for gold The Cogent Skills Store is now live and offers Gold Standard training covering technical competence, health & safety, business improvement and functional & behavioural skills. To claim your free Manual Handling e-learning module visit www.skillsstore.com

PROCESS INDUSTRY INFORMER May 2014

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IEC publishes state of t avoidance of hazards du The International Electrotechnical Commission has published a new Technical Specification called IEC 60079-32-1: “Explosive atmospheres - Part 32-1: Electrostatic hazards - Guidance”.

This Technical Specification is a guidance document which is the latest addition to the IEC series of 60079 “Explosive Atmospheres” standards that are designed to limit fires and explosions caused by electrical malfunctions within hazardous areas.

The 168 page document is the first of two documents to be published by the IEC under the “60079-32” designation and is intended to aid the designers and users of process equipment minimise the risk of incendive electrostatic discharges within potentially explosive atmospheres. It covers a broad range of process scenarios that can lead to the generation of electrostatic charges, provides examples of what measures can be taken to reduce charge generation and accumulation and outlines how process equipment should be grounded and bonded.

The second part, IEC 60079-32-2, is entitled “Electrostatics hazards – Tests” and outlines test methods to determine factors like surface resistance, earth leakage resistance, powder resistivity, liquid conductivity, capacitance and the incendivity of electrostatic discharges.

The stated objective of IEC 60079-32-1 is to provide: “the best available accepted state of the art guidance for the avoidance of hazards due to static electricity”.

To date guidance documents that address the ignition hazards of static electricity have either been published by national institutions like the NFPA or pan-European organisations like CENELEC. IEC 60079-32-1 has been collectively developed by a large number of technical committees from IEC member countries, making this document a truly global collaboration. It also builds on the work of national and regional guidance documents addressing electrostatic hazards, including CENELEC/ TR: 50404, NFPA 77, BS 5958, TRBS 2153:2009 and JNIOSH TR42.

Although the Technical Specification can be purchased from the IEC’s webstore, it will be the responsibility of national standards institutes like the ANSI in the U.S., BSI in the U.K. and DIN in Germany to administer the circulation of the document in their respective national territories. It is anticipated that European institutions will withdraw CENELEC/TR: 50404 and have it superseded

by IEC 60079-32-1. The ANSI has the document available for purchase from its website.

Overview of the Technical Specification: The Technical Specification is sub-divided into what are termed “clauses” that highlight the electrostatic hazards associated with various categories of materials, the hazards associated with people, including physiological shocks, and what grounding and bonding measures should be put in to practice.

The clauses are presented as: 1) The handling of solids.

2) The storage and handling of liquids.

3) The handling of gases and vapours.

4) The storage and handling of powders.

5) The storage and handling of explosives.

6) Electrostatic problems caused by people.

Owing to the fact that the document is 168 pages long, it would be impossible to provide a comprehensive overview of the guidance contained in the document in just a few pages. However, it would be worth touching on guidance related to the grounding and bonding of specific processes that utilise portable equipment at risk of static charge accumulation.

The design and monitoring of grounding systems: This section addresses the design and monitoring of systems dedicated to grounding permanent and portable plant equipment. Permanently installed plant equipment like reactors and pumps will most likely be grounded via the electrical grounding system for the plant. Electrical fault paths (and lightning protection paths) are more than adequate to dissipate electrostatic charge to ground.

For portable conductive equipment this section recommends that temporary connections using bolts or “pressure-type” clamps are capable of penetrating protective coatings, rust or product deposits that are typically present on the surface of such equipment, e.g. metal drums. It states that pressure-type clamps should be capable of establishing a connection resistance of less than 10 Ohms to the base metal of the conductive equipment.

Systems designed to monitor the resistance between equipment at risk of charge accumulation and earth (designated grounding points) should not only be capable of monitoring the resistance in the grounding circuit, but should also be capable of drawing attention to any changes in resistance. This is to ensure that malfunctions in the grounding circuit are detected as early as possible so that inspections and necessary repairs are made in good time.

Given that metal grounding circuits should not display a resistance above 10 ohms it would be prudent to specify grounding systems that are capable of identifying changes in resistance and alerting personnel as soon as 10 ohms in the ground path is exceeded.

7) Avoidance of electrostatic shock.

Type C FIBC:

8) Earthing and bonding of plant and machinery.

This section describes which hazardous zones the four bag types (A,B,C,D) are suitable for use in. The “zones” are based on the IEC method of hazardous area zoning classification which have been adopted in

There are also several Annexes that provide informative material, examples of which include a description of the various types of electrostatic discharges, the types

44

of electrostatic discharges that can be expected from processes carried out within potentially flammable and combustible atmospheres and the provision of an illustrated flowchart for assessing electrostatic hazards.

PROCESS INDUSTRY INFORMER May 2014

the art guidance for the ue to static electricity ATEX legislated countries, the U.S. NEC 505 & 506 and the Canadian CEC. It also specifies the types of liners (L1, L2, L3) and FIBC bag type combinations that may or may not be used in hazardous areas. This section heavily references IEC 61340-4-4: “Electrostatics – Part 4-4: Standard test methods for specific applications – Electrostatic classification of flexible intermediate bulk containers (FIBC)” which specifies the construction, testing and labelling criteria for Type A,B,C,D FIBC bags.

Under the requirements of this standard Type C bags must be grounded and for those manufacturing or using Type C bags the resistance from any part of the bag to a groundable point on the bag shall be less than 10 Megohm. This means that the conductive fabric or filaments that make up the grounding path for electrostatic charges should not have a resistance of more than 10 Meg-ohm to the bag’s grounding point. This is a change from CLC/TR: 50404 which recommended a maximum resistance of 100 Megohm.

The safest method of grounding Type C bags is to ensure the resistance through the bag is less than the benchmark value set by the standard(s) the site wishes to comply with. If a grounding system is to be specified, it is important to ensure the system tests the full range of permitted resistance. The specified resistance range for an IEC 61340-4-4 compliant bag will be any value under 10 Meg-ohm.

This section states that if Type D bags are used they do not need to be grounded, but conductive objects within the vicinity of the bag must be grounded.

Road Tankers: The precautionary guidance regarding the grounding of road tankers reflects the stated goal of the technical specification providing the latest state of the art guidance. Section 7.3.2.2.3, part C, states that the “earth cable” earthing the tanker should be part of a static grounding system that continuously monitors the resistance between the road tanker and the designated grounding point located on the loading gantry. It states that the grounding system should be interlocked with the transfer system to shut down the product transfer operation if this resistance exceeds 10 ohms.

It also states that the grounding system should be capable of recognising when it is not connected to the chassis/tank of the road tanker. This ensures that situations where the tank of the road tanker is not

connected to the grounding system, for example, where an operator could connect the clamp to an isolated metal mud-guard or wheel-nut, will not result in a permissive condition for the transfer operation, thereby eliminating the risk of electrostatic charging of the road tanker.

Vacuum trucks: The precautionary measures for the grounding of vacuum trucks state that the truck should be connected to a “designated” site earth before proceeding with the transfer operation. A “designated” site earth is a grounding point that has been verified as having a low resistance connection to “true earth” by suitably qualified engineers. These points are usually identified by tags or labels.

The guidance states that wherever a designated grounding point is not provided and portable ground rounds are permitted for use, or there is doubt regarding the quality of the site designated grounding point, the integrity of that grounding point should be verified prior to the transfer operation. This means that there should be a way of ensuring that the grounding point is actually connected to true earth in order to ensure the charges generated by the transfer operation do not accumulate on the truck or the hoses connected to the truck. This can be achieved via a truck mounted ground verification system or by engineers with ground testing meters. The resistance between the verified grounding point and the vacuum truck should not exceed 10 ohms and it is recommended that this resistance is verified by a truck mounted grounding system which will automatically indicate this to the driver or be verified with an ohmmeter (which should be used by a suitably competent electrical person).

This section also states that hoses used in the vacuuming operation should be compliant with the section covering hoses and hose assemblies. Table 18 in section “7.7.3.4 Properties and usage of ISO 8031 hose assembly grades”, describes the types of hoses that can be used for materials with varying electrical properties.

Technical Specification IEC 60079-32-1 is probably the most comprehensive guidance produced on avoiding the hazards of static electricity to date and with the content being developed and approved by a wide cohort of IEC national technical committees, represents a cohesive global approach to controlling electrostatic hazards in the workplace. This article provides a limited overview of the guidance contained in the document.

More information regarding the material, processes and equipment that can be susceptible electrostatic discharges, how charging can be minimised and what additional grounding and bonding practices can be put into action are described throughout the different clauses. Copies should be available for purchase from national standards bodies from October 2013. IEC 60079-32-2 is scheduled for release in 2014.

At the time of print IEC 60079-32-1 was available for purchase from the IEC’s webstore and the ANSI’s webstore.

Free Grounding & Bonding Handbook

Further information on hazardous area classification and zoning, their comparisons and differences, explosion protection techniques, and other factors related to hazardous locations can be viewed in the Grounding and Bonding Handbook.

To request a copy via the Quick Enquiry forms on www.newson-gale.co.uk

If non-metallic connections are used to ground the truck up to 1 Meg ohm resistance between the truck and the grounding point is permitted. It should be advised that if a 1 Meg ohm limit is being adopted that the grounding point to which the truck is connected has a verified low connection resistance to true earth, of not more than a few ohms. If a 1 Meg ohm limit is adopted for powder transfers it would be advisable to estimate the charging current generated by the vacuuming operation as very high charging rates are common place with truck vacuumed non-conductive powders.

Personnel grounding, flooring and footwear: Clause 11 provides guidance on minimising the risk of static electricity accumulating on people and describes various scenarios that can generate electrostatic charges on people. It also describes what methods can be adopted to dissipate charge off people, ranging from guidance on flooring, footwear and additional accessories that can be used to ground personnel working in zoned atmospheres.

PROCESS INDUSTRY INFORMER May 2014

Conclusion:

Newson Gale Limited, Nottingham, Nottinghamshire Can be contacted via: Tel: +44 (0) 115 940 7500 E-mail: groundit@newson-gale.co.uk Web: www.newson-gale.co.uk

45

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