Process Industry Informer Magazine Oct/Nov 2013 Edition by Process Industry Informer

PROCESS INDUSTRY INFORMER. INDUSTRY INFORMER. THE UK’S BIGGEST PUBLICATION SERVING THE PROCESS INDUSTRIES THE UK’S BIGGEST PUBLICATION SERVING THE PROCESS INDUSTRIES

OCT/NOV 2013 Volume 9 No. 6

Introducing the NEW interactive version of PII...

A whole new reading experience!

In this issue... • 11 Editorial Articles • Food Industry Focus • BPMA News • 60+ News Releases

Catch up with the SCADA v DCS battle, go 3D to save energy, make things easy with CAE, keep fluids thermally warm, check the flow, coat your bearings, come to terms with lead, and gee up the processing line just for starters.

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

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Contents

editorial features Intelligent financing techniques

News & Events 4-6 & 12

Pressure Calibration 32

Applications 6-11 & 12

Leak Detection 32

Network Communications 9

Viscosity or Flow Rate Sampling 36

Test & Measurement 9

Filtration & Separation 36

Variable Speed Drives 11

Health & Safety 36-38

Robotic Technology 12

Instrumentation 40

Recycling 12

Enclosures 41

Analysers 16

Data Loggers 41

Heat Transfer & Energy 18

Weighing 42

Water Treatment 18

Spray Nozzles 42

Control Panels 19

Crushing & Grinding 45

BPMA News from The British Pump Manufacturers Association 21-28

Size Reduction 45

Fluids & Liquids Handling inc. Pumps & Valves 29-32

Conveyors & Weighing 45

Water Testing 32

Suppliers Directory 47

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

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

for smart manufacturing 5 Effective Energy Management 7 Business turning to digital 3D technology 13 Industry 4.0 14 Has the Magflow Meter had its day? 17 Scada & DCS battle for Globalisation 20 Getting into Hot Water 34 Improving the workflow & quality with Computer Aided Engineering 39 Maximising profitability in the Food & Beverage industry 43 Increasing the operating life of Bearings in the Food & Beverage industry 44 Requirements for ‘lead free’ products in the Food & Beverage Industry 46

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

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

News & Events

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Environmental Award for Wanner International Following independent assessment, Wanner International Ltd., a global leader in the supply of seal-less positive displacement pumps, has been awarded ISO 14001 certification. ISO 14001:2004 is the only internationally-recognized standard for environmental management. “We have always been proud of our environmental stance and pledge to minimize our carbon footprint,” said a delighted Paul Davis, Man-

applications

Shepherd Neame brewery The Shepherd Neame brewery in Kent is the oldest brewery in Britain and can trace its official history back to 1698. Within the brewing process itself, little has changed over the years in terms of taking the four basic ingredients used: water, barley, hops and yeast and combining them together to create the world’s 3rd most popular drink after water and tea - beer. Today certain parts of the manufacturing process benefit from advances in engineering, so when Grundfos Pumps were contacted about the existing 35 year-old wort pump that had reached ‘end of life’, this offered the opportunity to upgrade to newer technology. Following discussions a Grundfos Hilge MAXA which is a long-coupled end suction pump with a low pressure seal flushing arrangement was selected. This pump is used as a casting pump within the hot wort circulation in the copper vessel when the hops are added in the brewing process and this is just one member of the specialist family of hygienic pumps from Grundfos. The success and longevity of the Shepherd Neame brewery can be partially linked to the water used in the process that is drawn from an on-site aquifer. The water is naturally filtered through a layer of chalk on which Faversham sits, and this purifies the water, which gives the beer its distinctive flavour. Grundfos are now playing their role in the process and the brewery is very pleased with the result, and has commented that “this is the best performing pump we now have on site”. For more information contact Grundfos Pumps Ltd, Leighton Buzzard, Buckinghamshire. Tel: 01525 850000 E-mail: grundfosuk@grundfos.com Web: www.grundfos.co.uk

aging Director. “ISO 14001 is an international certification that clearly demonstrates our achievements to date and our continued commitment to reduce the impact of out operation on the environment.” This award is in addition to the ISO 9001:2000 awarded to Wanner International Ltd., and highlights Company as one of the few in its field to hold both accreditations.

“Our Hydra-Cell pumps are environmentally friendly,” continued Davis. “Being seal-less they prevents leaks of potentially harmful chemicals and their outstanding efficiency helps reduce energy usage.” Its nice to think that having helped others to achieve ISO 14001, Wanner International itself has gained international environmental recognition. For more information contact Wanner International, Church Crookham, Hampshire. Tel +44 (0)1252 816847 E-mail: NHerrington@wannerint.com Web: www.hydra-cell.eu

robotic technology SWAPPAGE SCHEME ENCOURAGES UK MANUFACTURERS TO USE THE LATEST ROBOTIC AUTOMATION A new swappage scheme being introduced by ABB seeks to promote greater use of the latest robotic automation technology amongst UK manufacturers. Subject to the payload of the robot, the Robot Swappage Scheme enables operators to get up to £4,000* off the purchase cost of a new ABB robot when they trade in an existing robot from any manufacturer installed 12 or more years ago. Open from 8th October 2013 until 8th April 2014, the scheme is part of ABB’s drive to encourage the greater take-up of robotic automation in the UK manufacturing sector. The scheme is aimed particularly at small and medium sized businesses which have a current working robot which may be nearing the end of its useful economical working life. “A large number of robots in use in the UK are now at the point where they are becoming increasingly more difficult and costly to maintain,” says Dean Phipps, ABB Robotics’ Service Sales Manager for the UK and Ireland. “Difficulties in obtaining spares for obsolete models, the absence of any warranties and finding technicians qualified to work on older models are just some of the problems that can add to the heartache, expense and inconvenience of using older robots when issues inevitably occur. In such cases, replacing the robot with a new model can present the most sensible option.” “New developments in robotic technology may also mean

that companies using older models may be missing out on a raft of new productivity enhancing features. The enhanced efficiency, flexibility and reliability delivered by the latest generation of robots could help these companies to dramatically transform their production operations.” The scheme is open to end users only across any industry where a robot is currently being used to handle a particular task. Different discounts according to the payload of the robot being replaced apply. Robots with up to and including a 20kg payload will receive a discount of £2,000 off the listprice for each individual robot being scrapped and replaced, whilst robots with a payload greater than 20kg will receive a £4,000 discount. The scheme operates on a one-forone basis and will apply to any orders placed between 8th October 2013 and 8th April 2014. Discount applies to any robot with a payload of 20kg or greater. A separate discount of £2,000 applies to robots with a payload up to and including 20kg. To apply for the scheme or to find out more, please call 01908 350300 or email robots@gb.abb.com ref ‘Swappage’.

recycling Government urged to take action on scrap vehicle controls Calls for tighter controls on the treatment of scrap vehicles are being backed by MEP Chris Davies following his recent visit to Axion Polymers’ end-of-life (ELV) vehicle recycling facility in Trafford Park, Manchester. He was invited to tour Axion’s Shredder Waste Advanced Processing Plant (SWAPP) by CarTakeBack.com Ltd, the UK’s largest scrap car recycling network, which has voiced concerns over the UK’s poor legislative controls for processing end-of-life vehicles that mean up to half a million cars a year go unrecorded. Supporting the need for tougher legislation to ensure Certificates of Destruction are issued for all scrapped vehicles, Axion Director Keith Freegard said: “This would ensure accurate data on how many vehicles are going to de-pollution centres and being processed properly - and just how many are left on our roads. “Personally, I would like to see stronger drivers to link manufacturers’ responsibility to what happens to their end-of-life vehicles, particularly in terms of incentives to promote the use of recycled plastics back into new cars,” he continued. Working closely with CarTakeBack, Axion’s award-winning SWAPP facility is already capable of delivering over 95% recycling and recovery of materials from end-of-life vehicles, thereby already meeting the fast-approaching January 2015 target for ELVs. For more information, contact Axion Polymers, Salford, Manchester Tel: 0161 426 7731 Fax: 0161 426 7732 E-mail: sales@axionpolymers.com Web: www.axionpolymers.com

Process Industry Informer October-November 2013

Businesses turning to digital 3D technology to help cut energy costs and carbon emissions How does a business go about reducing its carbon footprint and energy costs to meet ever more stringent targets? Boardroom brainstorming; piecemeal measures; specialist consultants? customer with the impression that they are actually in the facility with a bird’s eye or even walkthrough view of the system, as in a computer game. Analysis at this stage reveals any problems with rates of carbon emissions, energy wastage, logistical inefficiencies or whatever is being targeted.

Increasingly, businesses across the UK are finding the answer to their prayers in virtual reality modelling. Using sophisticated computer software created for the purpose, users can re-create their own business digitally. Then, using 3D modelling techniques, they can accurately calculate, and ultimately reduce, their carbon footprint and energy costs, avoiding costly mistakes in developing their solution. “One of the biggest advantages of the virtual reality modelling approach is that it allows users to try out a wide range of alternative solutions to their problems before committing spend to actual changes: to try before they buy, in effect, ” says Ian Aubrey, Director of CyberPharm Ltd, leaders in the field with their premium Eco3D software and consultancy services. Aimed initially at larger businesses with factories and mass production lines, this advanced technology is now being used by businesses of all types and sizes. Using Eco3D software standard you can build a 3D computer representation of any business activity, and easily calculate energy usage. 3D layouts can be any size from small offices to large factories and from any industry sector. Energy saving calculations and features are designed to reduce energy usage and increase efficiency as well as predicting the effects of change over time. Initially, measurements and observations and data is gathered on site before using a powerful 3D modelling software tool, to create a 3D replica of the business or organisation as it operates – a simulation model of the processes involved. The business could be in manufacturing, warehousing and logistics, automation and robotics, healthcare and public services – virtually any commercial business endeavour and many public service organisations could use this method.

Walkthrough view The baseline simulation model developed in this way reflects how the processes work currently in a specific business. A dynamic simulation facility provides the

This versatile software can be used to experiment with new processes, designs, input or components. It enables cost, productivity, energy and carbon benefits to be accurately calculated before any actual change or investment is made. Clients are given advice, training and an extensive ‘component’ library to help them build these 3D models of their operations. This unique library is a large, ever-expanding resource detailing more than 60,000 energy-consuming products. All product information and energy consumption data is kept up to date, and allows users to input relevant details in order to build realistic models quickly. Proposed solutions are incorporated into a modified simulation model then tested to see how they work in a particular business environment. In this way, ideas are tried out in virtual reality, without a large cost to the bottom line.

Consultancy service Users of this software may manage the software themselves with advice from CyberPharm though many opt for a consultancy service too, explains Aubrey. “We offer a ‘fresh eyes’ service to businesses using our software. In these cases, we come and look at their problem, and the possible solutions clients have selected, and give our independent opinion. If needed, we can help them understand and clarify the pros and cons of their choices, allowing them to make more informed decisions.” To see how effective the system can be in practice, industrial bakers G.H Sheldon used Eco3D products to help make sustainable savings in their operations by reducing the carbon footprint of their industrial lighting.

Carbon cut by 80% Having grown from a small family enterprise to an industrial baker supplying supermarkets nationwide, G. H. Sheldon knew all about traditional baking and wanted to bring the same level of expertise to a very modern problem: the reduction of its carbon footprint. “Eco3D has helped us to understand how we can achieve significant reductions in our carbon emissions” says Lee Sheldon, Director of G.H. Sheldon Wholesale Bakers Ltd.

Process Industry Informer October-November 2013

The main focus for initial carbon and cost cutting was the outdoor lighting. CyberPharm began by visiting the site, talking with employees and analysing their ideas before presenting them to the financial director to show what changes they would suggest, and why. Readings were taken on site using meters and other equipment before Eco3D was brought in to visualise, in 3D, their existing systems and processes. The software simulated the existing lighting systems in combination with accurate sunrise and sunset times. On-going maintenance was also included before the simulation was run to cover various periods of 1, 5, 10 and 20 years. In this way they determined the cost of ownership of the existing system and were quickly able to see virtual efficiency. Next, the simulation was altered to incorporate alternative lighting technologies to reveal their impact on the setup and to provide optional improvements. The system and positioning finally selected brought additional benefits, including improved image quality on the existing CCTV system and the use of motion detection to switch lights on and off only when needed. Once implemented, the carbon savings identified by the software in Sheldon’s lighting were immediate: an 80% reduction in carbon emissions, and a predicted 50% reduction in the total cost of ownership.

‘Try before you buy’ Sheldon’s were able to clearly see and examine their options closely before committing to a big spend on changes,” says Ian Aubrey. “In effect, the simulations make it possible for clients to effectively ‘try before they buy’ the different scenarios.” Ian Aubrey sees businesses of all kinds turning to this exciting development tool: “With the advance of modern processors, there’s an increased ability to simulate ever more complex scenarios. Extra speed means that many alternative layouts can be tried and tested before a single physical action is taken. This allows more informed decisions to be taken, avoiding planning mistakes and defects which can so easily snowball project deadlines and budgets.” CyberPharm Limited, Macclesfield, Cheshire Can be contacted on: Tel: 01625 511528 E-mail: info@cyberpharm.co.uk Web: www.cyberpharm.co.uk

Bronze skies and

Industry Industry 4.0 is a new concept which has been gaining significant momentum in Germany and also across Europe. GAMBICA’s Deputy Director and convener of the organisation’s Variable Speed Drives group, Steve Brambley, explains how it applies to the automation industry.

A little known fact about the ancient Greeks is that they didn’t have a word for the colour blue. Because of this, the poet Homer described the sky as bronze in his writings. This is typical of the way language develops – the name we give something is coined after the thing itself comes into existence or is observed. However, Industry 4.0 didn’t follow the normal etymological route; the phrase was introduced at the Hanover fair in 2011 to describe a new trend towards the networking of traditional industries such as manufacturing.

Automation products such as PLC’s and Variable Speed Drives (VSDs) answer the need for flexibility and energy efficiency, which Industry 4.0 embraces. By using intelligent control methods and taking input from sensors, other machines and systems, real-time decisions can be taken automatically to optimise the process. Adapting the motor speed to meet the real-time requirements with a VSD can often save 30% or more of the amount of energy used by industrial electric motors, thus reducing costs and maximising ROI.

thanks to a wider distribution of processing power around the operation, which will allow raw data to be turned into useful information in manageable packages before it clogs up the network. Such a degree of distributed data handling would have been a lot less practical before the development of modern low-power processors, which has been driven by the mobile phone and portable computing markets.

Following this initial launch, the final report on the subject was published at the same event in 2013, prompting acres of media coverage.

Benefits

Some countries are currently more active than others in pursuing the concept of Industry 4.0. The German federal government has already made approximately e200 million available to help industry associations, research institutes and companies develop implementation strategies. Coordinated efforts and research projects such as the RES-COM project or the Intelligent Technical Systems OstWestfalenLippe (OWL) cluster, have already been launched.

Industry 4.0 is closely related to other industry concepts such as Machine-to-Machine communication (M2M), the Internet of Things (IoT) and Cyber-physical Systems (CPS). Alongside the German Government, Siemens had a key role in developing and promoting the concept. Industry 4.0 is expected to play a significant part in the future strategy of Siemens and other industry majors. The name Industry 4.0 recognises the existence of three previous industrial revolutions. The first was the mechanisation of manufacturing using steam power; the second was the introduction of electric power and the third was the IT revolution, particularly the use of computers in automating production. Industry 4.0 is the next paradigm shift towards selforganising factories, decentralised production and machines able to communicate with each other and with the products and components they are making. The direct consequence is that production lines will become more flexible and energy efficient. The era of mass production is giving way to an era of mass customisation. Peter Herwerck, head of corporate strategy at Siemens predicted that the transition to Industry 4.0 will take around 20 years and involve a number of developmental steps. However, some features and technologies of Industry 4.0 are already recognisable in manufacturing today.

Industry 4.0 is critically dependent on the disciplines of automation, sensing and networking. In the future, the richness of data available from the manufacturing process and the highly distributed nature of machine intelligence, will allow customised products to be made profitably, with consistent quality and previously unattainable process and energy efficiency. An Industry 4.0 smart factory would also reduce the risk of human errors. The human element in manufacturing would remain essential, but will tend to focus on the programming and servicing of machines. Energy efficiency is already a priority for manufacturers. Motor driven systems currently use up to 60% of all electrical energy in industry. Using variable speed drives to match the speed of electric motors to load requirements has had extremely positive results in many different manufacturing sectors. Another core benefit of Industry 4.0 comes from using industrial wireless networks in smart factories. Wireless technology allows monitoring and control equipment to be installed easily and cheaply by minimizing the need for cabling and associated cable-supporting structures. Increased interconnectivity allows devices to be more autonomous and systems which authorise different machines, to operate independently, according to manufacturing needs. This can boost flexibility and reduce energy consumption by powering down the parts of the plant that are not needed at a specific time. The presence of wireless networks also encourages the increased use of sensors, allowing processes to be monitored and controlled more closely. Sensors can also identify the need to replace or repair plant equipment, thus reducing unplanned downtime and lifecycle costs. Extra control and monitoring equipment creates additional data, which will need to be handled in real time by the industrial control software of the future. This will be possible

The future

This is in line with Germany’s position as a world leader in automation and manufacturing, and as a traditionally enthusiastic investor in industry. Given Germany’s excellent track record in automation over the last thirty years, there is a good chance the country will be successful in adopting these emerging technologies and delivering essential changes to manufacturing norms. The question is which other countries will be with them? Unlike in Ancient Greece, where the colour blue, despite being present in nature, wasn’t given a name until late in the civilisation’s history, the label Industry 4.0 was created by a marketing team to help a series of emerging technologies coalesce into a compelling vision of the future. Industry 4.0 is an opportunity for the UK to apply its many skills and technologies and gradually become one of the first states to eliminate lowcost labour as a pre-requisite of a successful manufacturing economy. If the UK thinks strategically and co-ordinates action between Government and industry while it still stands level with other countries on the starting line, Industry 4.0 could be the reason why the UK is ultimately successful in redefining itself as a manufacturingdriven economy.

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

Process Industry Informer October-November 2013

Can you save money by upgrading your valve positioner? Certainly.

Could your current valve positioners be costing you more than they should be? Find out with ABB’s compressed air calculator app. Comparing ABB’s EDP300 smart positioner to other market-leading devices, the app shows how you can dramatically reduce your compressed air costs without compromising your valve accuracy. To download the ABB app, search for “ABB Compressed Air Calculator” on the Apple app store or scan the QR code.

ANALYSERS MALVERN INSTRUMENTS CELEBRATES MASTERSIZER 3000’S SECOND ANNIVERSARY WITH NEW SOFTWARE DEVELOPMENTS A small footprint, exceptional Malvern Instruments is marking dry dispersion capabilities and the second anniversary of the software that continues to push market leading Mastersizer 3000 the boundaries of user/instrument laser diffraction particle sizing interface development, have system with the introduction propelled the system to its market of a host of innovative software leading position. updates and an extension to The new Mastersizer 3000E, an the Mastersizer family, the entry level laser diffraction particle Mastersizer 3000E. sizing system has measurement A global leader for particle sizing, range of 0.1 to 1000 microns, Malvern’s Mastersizer range has become synonymous with laser diffraction. The the system is offered with semi-automated wet Mastersizer 3000 delivers unique performance and dispersion units. Its performance can be extended productivity benefits, wrapped in a stylish, compact over time, with add-on software packages providing and practical instrument design. New software Mastersizer 3000E users with access to automated features, developed in response to customer dispersion units and the advanced analysis and feedback, now make it easier than ever to obtain method development support capabilities of the accurate particle size information. They also deliver Mastersizer 3000. an interface experience that chimes with the app- To find out more about the full Mastersizer range led approach now common in so many areas of or for information about laser diffraction particle life. Mastersizer software is now available in eight sizing visit the Malvern website at www.malvern.com/ languages to ensure full accessability for users mastersizerfamily around the world. With a dynamic range spanning 0.01 to 3500 For more information contact Malvern Instruments microns, the Mastersizer 3000 delivers precise, Ltd, Malvern, Worcs. Tel: +44 (0) 1684 892456 robust wet and dry particle size measurements Fax: +44 (0) 1684 892789 E-mail: tailored to the operator’s specific application needs. salesinfo@malvern.com Web:www.malvern.com 155x225mm PROCESS INDUSTRY INFORMER AD_Layout 1 14/10/2013 11:00 Page 1

Introducing a unique head mount transmitter for analytical sensors from Mettler Toledo In-situ analysers provide continuous, real-time information for reliable process control. What is often criticised though, is their complexity. METTLER TOLEDO has solved this problem by developing a unique head mount transmitter for analytical measurements. Discover more about the new M100 transmitter in the short online webinar: “Small Footprint Installation for Hazardous Areas” The M100 transmitter is a single channel, multi-parameter unit for pH/ORP, conductivity and dissolved oxygen measurement. It is designed for use throughout the process industries and is certified intrinsically safe for advanced diagnostics tools. It does not require a display or a local operator interface and is therefore kept extremely compact and sturdy. Upon connecting a calibrated sensor, the M100 automatically recognises the sensor and configures itself accordingly without operator intervention. It provides continuous information on sensor performance and gives predictive information for the remaining lifetime, calibration and maintenance requirements. Watch the webinar at www.mt.com/uk-M100-webinar For more information contact Mettler-Toledo Ltd, Beaumont Leys, Leics. Tel: 0116 234 5095 E-mail enquire.mtuk@mt.com Visit www.mt.com/M100

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Process Industry Informer October-November 2013

Has the Magflow Meter Had Its Day? By Keith Flint – Sales & Marketing Director, Pulsar Process Measurement Ltd

The well known and well-proven Magnetic flowmeter (magflow) is the default solution when the requirement is for monitoring flow in closed pipes. They are well understood, and are, for small pipe diameters at least, relatively inexpensive. Alternatives have been available, but have typically been difficult to install accurately, expensive and often unreliable. Now, though, new technology, powered by newly available acoustic signal processing techniques, is starting to make real inroads into the magflow meter’s dominant position, with lower purchase costs and a non-invasive installation that requires nothing more than a screwdriver to complete. There are many situations where reliable flow monitoring is desirable. Beyond the obvious of simply measuring flow rate, there are applications where flow throughout a process network should be monitored, checking on flow movement or warning of failures of valves, identifying when PIGs should be deployed to clean pipework, and often to check on the efficient operation of pumps. The magnetic flowmeter is a ubiquitous sight in process plants of all types across the world, providing reliable flow measurement for an enormous range of flowing liquids and slurries. Well understood, it has become the ‘go-to’ technology where flow needs to be monitored. That said, it has a number of drawbacks. As pipe diameter increases, the cost of the instrument rises dramatically and accuracy can fall. Because a magnetic flow meter is an invasive device, with a pair of electrodes in contact with the flow, corrosion and electrode coating or scaling are also potential problems. The main drawback associated with magflow meters, though, is the need to break into the pipe to install the device in the first place. Regularly, the civil engineering costs associated with the installation of the unit dwarfs the price of the magflow meter itself. In many of the applications mentioned above, a magflow meter installation would be too expensive, too cumbersome or require too much downtime, so process managers have to make do with inferred values or wait for problems to manifest themselves elsewhere! The obvious solution would be a non-invasive device, capable of being installed on the outside of the pipe and, of course, such things have been available, in the form of time-of-flight ultrasonic instruments, which typically feature a pair of sensors that need to be very precisely aligned on opposite sides of a pipe. Again, there can be significant issues in the installation of these systems, mainly because the alignment has to be extremely accurate. There are also limitations on the types of liquid flows that can be measured.

Solving the conundrum… So, an ideal specification emerges; a class of device that is non-invasive, that can be retro-fitted to an existing pipe, that will work over a wide range of pipe diameters, that will be reliable and repeatable, that is easy to install and requires no special positioning or alignment to work, and that will measure across the full range of pipe materials, brand new to fifty years old. It needs to be compact and able to interface with existing plant control infrastructure. Readers who have faced these issues over time will probably be aware that there is another group of products, one which has fallen out of favour over the years, based on the Doppler Effect. Doppler is a basic physical principle, which describes how the measured frequency of a wave reflecting from an object changes depending on whether that object is moving towards or away from a sensor. The most common example is the change in pitch of an ambulance siren as it passes you in the street. Or, indeed, the police speed gun! The Doppler Effect has been used for many years to measure flow, by the detection of particles as they pass a Doppler sensor. In many cases they have been very successful, and, because the Doppler effect is a basic physical principle, it should be extremely reliable and repeatable. The issue with Doppler devices has always been one of signal processing. Analogue and earlier microprocessor-driven instruments have simply not had the appropriate algorithms to allow the unit to reliably discriminate among the mass of echoes returning from the particles in the stream. Also, to be in any way reliable, the Doppler sensor has to be in the stream, so we are back to all the issues surrounding the installation of an invasive sensor.

Process Industry Informer October-November 2013

Not inside but outside…

There is, however, a new form of Doppler sensor now available, one that takes the basic physical principle and applies to it a completely new approach to analysing the signal. A non-invasive single point sensor, that simply clamps to the outside of a pipe, almost regardless of pipe material and on pipes of up to a metre diameter, with no issues around alignment or positioning, in fact installed with a single, simple screwdriver. This new class of sensor, exemplified by the Flow Pulse from Pulsar Process Measurement, works by ‘firing’ an ultrasound pulse from a high-output ceramic crystal through the pipe wall at 90º to the liquid flow, and analysing the signal that comes back from particles or bubbles in the fluid stream. The Pulsar system uses a novel signal analysis technique never before used in flow monitoring called Refracted Spread Spectrum Analysis (RSSA), which is able to consolidate the real flow information from the mass of signals coming from the particles, bubbles, turbulence, vortices and eddies within the flowing liquid. The crystal fires signals at a wide angle and RSSA analyses the returning ‘echo’ over a wide frequency range, then slices them for realtime analysis and flow rate calculation. Laminar flow is not necessary to get a reading, so there is a more flexible choice of installation position. One of the things that make these devices so attractive to process users is their versatility. The pipe material can be rigid plastic, stainless steel, mild steel or cast iron. Corrugated pipe is not a problem, and even light corrosion on the pipe does not prevent a good result. Typically, flow rates from 0.3m/s through to around 4m/s can be measured. In terms of the flows that can be measured, these are just as versatile, ranging from a slurry at the ‘thick’ end down to particle sizes as small as 100 micron and concentrations as low as 200ppm, the equivalent of hard water. The key to the success of these new non-invasive devices is repeatability in flow monitoring. In the majority of process plant applications the fundamental issue is to monitor and maintain relative flow rates, warn of impending plant issues around valves and pumps and keep a clear view of network issues. The Magflow meter still has an important place, for applications where it can be installed without disruption in an ideal, laminar flow position, and where accuracy rather than repeatability is key. For everything else, maybe the time has come to look at the very real alternatives. Pulsar Process Measurement Ltd, Malvern, Worcestershire Can be contacted on: Tel: 01684 891371 E-mail: info@pulsar-pm.com Web: www.pulsar-pm.com

heat transfer & energy SPIRAX SARCO LAUNCHES HIGH TURNDOWN, PLUG-AND-PLAY DESUPERHEATERS Spirax Sarco has launched the industry’s most comprehensive range of desuperheaters for precise control and efficient heat transfer when cooling superheated steam. Featuring a high turndown of up to 50:1, the desuperheaters are suitable for a wide range of applications and increase process efficiency by allowing waste and residual heat to be recovered and recycled. They also protect process plant from damage caused by overheating. Manufactured at Spirax Sarco’s UK factory, the desuperheaters are supplied as ready-to-install engineered systems, fully assembled with all the required valves, pumps, steam traps, controls and other ancillary equipment, saving installation time and project costs. Each desuperheater is tailored to the application for the highest efficiency in a wide range of industries, including food and beverage, chemical, pharmaceutical, processing, power generation and oil and petrochemicals. Desuperheaters reduce the temperature of superheated process steam by introducing finely atomized cooling water droplets into the steam flow. To be effective, the droplets must remain suspended in the downstream pipework for as long as possible, otherwise ‘water droplet fall-out’ occurs reducing efficiency and causing corrosion. Spirax Sarco desuperheaters eliminate water droplet fallout and ensure reliable, efficient energy transfer. The range comprises four designs. • The Spray Nozzle Desuperheater is inserted into the steam line and is easily retrofitted into existing pipes. It is particularly cost-effective for large diameter pipes. • The Spray Desuperheater is a complete pipeline unit incorporating spray nozzle technology with an integral thermal pipeline sleeve. Superheated steam circulates around the sleeve assisting the evaporation of atomised water, eliminating water droplet fall out. • Both types of spray desuperheater are suitable for steady loads, since they offer a maximum turndown of 5:1. Where tighter control of the downstream temperature is needed in processes with higher load fluctuations, a Venturi or steam atomising type desuperheater with a larger steam turndown could be a better option. • The Venturi Type uses a “double mix” operation combined with increased turbulence for more efficient steam cooling. With a turndown of up to 10:1, it suits most general applications. • The 50:1 turndown of the Steam Atomising desuperheater suits applications where the load varies considerably. A secondary, high-pressure steam supply is used to atomise the cooling water entering the superheated steam. Spray Type, Venturi and Steam Atomising desuperheaters can be installed vertically or horizontally to suit the application. The desuperheaters have no moving parts making them virtually maintenance free and highly reliable to support high productivity. For more information on Spirax Sarco’s range of desuperheaters E-mail: ukenquiries@spiraxsarco.com Tel: 01242 521361 or visit Web: www.spiraxsarco.com/uk

Moody offers customers 24/7 online access to heat exchanger test certificates Moody Heat Exchangers has launched an on-line web-based portal to allow customers to access their plate heat exchanger integrity test certificates and service reports 24 hours a day, 7 days a week. Moody Heat Exchangers know that quick and easy access to test certificates and service reports is important to customers in the hygienic processing industries when faced with internal and external quality audits. This secure, web-based portal allows customers to log on using a secure password to access vital quality information about their plate heat exchangers. Moody Heat Exchangers integrity test plate heat exchangers and pasteurisers using the PasTest2000 system which accurately detects plate cracks and holes which could cause product contamination. The PasTest2000 testing system has been tested by CampdenBRI, the leading independent food and drink research organisation. Moody Heat Exchangers are a one-stop shop for both testing and servicing of plate heat exchangers, operating the UK’s most modern plate heat exchanger service centre in Retford, Notts. Gaskets and plates are supplied for all known brands of plate heat exchangers including Alfa Laval, APV, Arsopi, Fischer, GEA, Pasilac, Schmidt, Sondex, Swep, Tetra Pak, Tranter, and Vicarb. To find out more please contact Moody Heat Exchangers free on 0800 666 397 or email us at heatexchangers@moodydirect.co.uk

Enlarged pit furnace accommodates today’s larger components Developments in renewable energy, mining and quarrying, oil exploration, marine and other applications have led to significant increases in the size of power transmission components like gears, shafts, pinions and bearings, to handle greater productivity demands. As these large components are exposed to severe duty cycles, there is renewed emphasis on the heat treating methods needed to enhance their wear resistance and strength properties. Estimated by industry sources to represent around 10 per cent of component manufacturing costs, heat treatment modifies the microstructure of metallic materials, influencing mechanical characteristics like strength, ductility, toughness, hardness and wear resistance. Anticipating growing customer demand for processing larger gears, shafts and other components, sub-contract heat treatment specialist Keighley Laboratories of West Yorkshire has enlarged the size of one of its largest pit furnaces, increasing dimensions to 1110mm working diameter and almost 1800mm maximum length, in the process gaining 30 per cent in overall capacity. At the same time, it has upgraded the lifting capacity of its overhead crane, which services all seven pit furnaces, a salt bath and tempering equipment, to 3.0 tonnes maximum lift. “This has opened up a new market for us amongst engineering companies and OEMs, who are looking to heat treat larger components” says Divisional Commercial Director, Michael Emmott. Further enquiries to Keighley Laboratories Ltd, Croft House, South Street, Keighley BD21 1EG Tel: 01535 664211 E-mail: memmott@keighleylabs.co.uk Web: www.keighleylabs.co.uk

water treatment solutions AQUAMOVETM LAUNCHES THE FIRST MOBILE MEMBRANE DEGASSER Veolia Water Solutions & Technologies has unveiled the latest addition to its AquamoveTM fleet of mobile water treatment solutions. REMOX is a membrane degasser which removes carbon dioxide and oxygen from water. The first membrane degasser available on the rental market, REMOX is housed in a fully air-conditioned standard 40ft container complete with all necessary compressed air, nitrogen and vacuum equipment. With two streams of membrane modules, REMOX can treat up to 100m3/h of water to less than 0.3mg/l dissolved carbon dioxide and up to 75m3/h to less than 0.01mg/l dissolved oxygen. Among the many applications for REMOX are deaeration of boiler feedwater to reduce corrosion, degassing of semiconductor rinse water to reduce wafer surface defects and to improve the shelf life and taste of food and beverage products. Additionally, ion exchange deionisation and continuous electrodeionisation processes operate much more efficiently if dissolved carbon dioxide is removed upstream. Aquamove REMOX removes dissolved gases without any chemical addition or waste water, providing safe operation. Complete with automatic monitoring, the AquamoveTM team can monitor the system data and performance, and control the plant. So the supply is maintained and optimised remotely, with total operational security. Visit www.aquamove.co.uk to find out more about REMOX and other mobile water treatment solutions for short or long term hire. For more information contact ELGA Process Water, Marlow, Bucks SL7 1YL Tel: + 44 (0) 1628 897000 E-mail: sales.uk@veoliawater.com Web: www.elgaprocesswater.co.uk

Process Industry Informer October-November 2013

control panels

RITTAL Available on iPhone SUPPORT ARM SYSTEMS

and Android devices

FOR HUMAN/ MACHINE INTERFACES

Rittal’s new range of modular support arm systems make it easy to turn, lift and swivel control panels with precision. Giving the operator a clear overview and the best possible control, the support arm systems provide an ergonomic interface between machines, control devices and operators. Encapsulating the latest thinking on human/machine interfaces, Rittal’s new modular support arm system offers the user consistency in both function and installation, reducing time required for assembly, alignment and maintenance and project planning. For more information contact Rittal Ltd, Rotherham, South Yorkshire Tel: 01709 704000 E-mail: information@rittal.co.uk Web: www.rittal.co.uk

Process Industry Informer October-November 2013

The line of functionality between SCADA and DCS is blurring. These two traditionally disparate technologies are now seen as competitors in similar application environments. Here Frank Horden, business development and marketing manager at Yokogawa, argues that the changing nature of globalisation means that there are still

SCADA and DCS battle for globalisation

distinct benefits in using SCADA as an umbrella layer on top of a DCS core. Not many things in life remain constant and ultimately change is inevitable. The much loved cartoon show The Simpsons, seems to have flouted this rule as it enters its 25th season this year. The show has captivated millions for nearly a quarter of a century. One of the key reasons for its success is the protagonist Homer Simpson. Viewers can relate to his on screen antics and naivety. His lovable nature however, seems somewhat paradoxical to his job as a safety inspector at Springfield’s nuclear power plant. It’s frightening to think that human beings, with our haphazard Homer tendencies, still form an integral part of such a highly regulated, automated and controlled environment. At the heart of such environments, lie platforms such as the distributed control system (DCS) which has developed over the years, from humble beginnings as a single loop controller housed in a panel. It is now cheaper and more intuitive, partly as a result of the use of PLC interfaces.

fence’ solution best suited to those continuous, PID control intensive applications. In contrast, SCADA can be seen as an ‘outside the fence’ solution, better suited to geographically dispersed environments using commercial off the shelf hardware.

The strength of a DCS lies in a single database setup with minimal complexity and low risk of data redundancy. Recent developments have seen a push towards better smart reporting and relaying of management information (MI) through Human Machine Interfaces (HMI).

SCADA is traditionally suited to batch and discrete production. Batch production includes food and beverage, pharmaceutical and general processing, whereas discrete production normally describes packaging and automotive applications.

On the other hand, the supervisory control and data acquisition system SCADA (Supervisory Control and Data Acquisition), has developed from a simple visualisation tool used in a bank of relays. It has reached a point where it can now provide an increasingly object oriented approach, storing hard I/O tags from numerous devices in its fast Historian databases.

Globalisation

Simultaneously, it can maintain its inherent flexibility by storing soft logic operation tags and using these to generate HMI based mimic diagrams and trend and diagnostic data along with MI, troubleshooting, logistics and maintenance schedules. Advancements in high power computing have also reduced the complexity of SCADAs multiple database setup and minimised the risk of data redundancy. This means that applications can now take more analytical advantage of the wealth of information available and interpret that data in more intuitive ways.

The confusion This convergence of the two overlapping technologies has created a level of confusion in the industry. At first glance, it seems that SCADA and DCS have become direct competitors, doing essentially the same thing. Vendors are partially responsible for this widespread misunderstanding. In continuous production environments, which are highly proportional-integral-derivative and PID control intensive integrated packages are beneficial. Examples of this include chemical, power generation, oil and gas, refining and water treatment. Buyers look to vendors that provide turnkey solutions with proprietary hardware that requires a minimal amount of customisation. However vendors may often use this as a marketing tool and promote overlapping functionality in order to maximise sales. Essentially, DCS systems are sometimes sold under the SCADA label and SCADA is sometimes branded as DCS. This does more harm than good for the industry by blurring the boundaries. The boundaries are evident when the production environment is seen as a garden. DCS is an ‘inside the

The evolution of these technologies has come amidst a greater shift in globalisation. Supply chain networks are being strengthened by advancements in international trade, improved transport infrastructure and telecommunications such as fibre optic broadband. Although this has reduced response times, production environments are under greater stress to deliver. With recent news of Toyota’s recall of 885,000 vehicles in the US, it is evident that non-traditional duties such as reverse logistics are placing undue stress on production environments. With the rise of multinational corporations diversifying their operations, control systems have to increasingly cater for business management operations in remote locations around the globe. The Nord Stream offshore gas pipeline exemplifies this issue. It supplies natural gas from plants in Russia to plants in Germany and is operated from control rooms in Switzerland. A DCS setup performs reliably on an individual plant level, but is unable to extend large distances over various networks. This means it struggles to manage the three remote plants, especially when limited satellite bandwidth issues arise. The use of SCADA in this situation allows business managers to benefit from a rich picture of events. The supervisory capability can be used to respond to political and market demands to remotely control the system, performing initiation and shutdown events as necessary.

Holistic architecture At Yokogawa we have always favoured an integrated approach. The developments in globalisation have meant that new norms in control architecture are now upon us. The irony is that a theory developed in a pre World Wide Web era is more relevant today than ever. Purdue Enterprise Reference Architecture (PERA) is a reference model for enterprise architecture in computer integrated manufacturing. Developed in the nineties, PERA theory led to the modern enterprise control standard known as ANSI/ISA-95.

The ISA-95 standard breaks down control environments into levels of integration. Level zero is defined as the physical process in a plant. Level one consists of intelligent devices such as smart sensing and actuation. Level two brings in control systems DCS and SCADA for supervising, monitoring and controlling the process. Level three introduces operation systems to manage workflows such as batch, continuous and discrete and maintenance and historian activities. Level four concludes with Enterprise Resource Planning (ERP) activities such as asset and inventory management as well as shipping and scheduling. It is evident that modern developments have blurred the lines between these levels. As such, Yokogawa’s integrated approach seeks to compliment the robust control of DCS on a plant level, with SCADA as a supervisory umbrella at the hybrid enterprise level.

The future So what of the future? Only five years ago the forward thinking trend was for real time information and big data. The Internet of things justified the idea of context based events, from alarm notifications to smart diagnostics. The trend is now moving towards mobile devices, operators in the field are given autonomy whilst maintaining a connection to a centralised system. This can bring together disparate resources such as human capital, in real time, from anywhere in the world. A field engineer on duty at a reservoir site in the Philippines can seek assistance from an expert in the Gulf of Mexico. Wearing a heads up display such as Google glass, a live feed could be streamed over cellular networks. A new era of HMI is rolling out through the use of intuitive touch screen tablet devices. Maintenance crews can be notified via satellite ground positioning systems (GPS), of nearby alarms, allowing them to respond immediately, pulling up PDF troubleshooting and data sheets in the process. All this data is increasingly being stored in the Cloud. Although there are still security concerns for mission critical applications, improvements in data encryption mean that this is fast becoming a viable option. As we move towards an uncertain but exciting future, one thing remains certain, that change is constant. Human beings are still very much part of the process and will remain so for the foreseeable future. We can only hope that we have as lasting an impact as Homer Simpson. Yokogawa United Kingdom, Runcorn, Cheshire Can be contacted on: Tel: +441928 597100 E-mail: Sian.Hamer@uk.yokogawa.com Web: www.yokogawa.com/uk

Process Industry Informer October-November 2013

NEWS

OCT-NOV 2013

A Year of change... At the beginning of this year BPMA

President

Ken

Hall

Standardised

Customised

Systems-based

One provider

announced that, effectively the stalwart of the association, Brian Huxley would be standing down as the Director and Chief Executive of the association after many years at the helm. Oh calamity. The

BPMA

without

Brian

seemed unthinkable, but with a sigh of relief, all was not lost as he was just cutting down on the days per week that he was “in control”. No longer the Director and

KSB

Chief Executive, Brian accepted the role of Executive Director, whatever that means!!! and has passed the mantle over to Steve Schofield who has “grasped the nettle” with vigour and enthusiasm and is doing an excellent job - but that’s youth isn’t it.... Steve is being ably assisted by Assistant Director, Jeanne Page - and all is well.

Another move... If you are considering attending the 2014 Pump Industry Awards

You choose. We supply.

Gala Evening on March 27th, and I hope that you are, remember not to hare off to the St Johns Hotel in Solihull. If you do you could be on your own as the event has a “new home” in Kenilworth at the Chesford

Our wide range of standard pumps and valves provides plenty of scope for individual demands. You can select the materials, hydraulic systems and drives. When you’re facing complex tasks, we’re with you from Day One – whether you want planning guidance, specially designed components or help with commissioning. But see for yourself. Test our products for quality and versatility and discover why KSB is so often first choice. www.ourtechnology.yoursuccess.ksb.com

Grange. To book your place go to www.pumpindustryawards.com

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.

KSB Limited • 2 Cotton Way • Loughborough • Leicestershire • LE11 5TF • 01509 231872 • www.ksb.co.uk

Our technology. Your success. Pumps • Valves • Service

NEWS BYTES 

Market Surveillance Market Surveillance is a key element of a fair and efficient EU internal market: - It should ensure that products placed on the community market comply with EU regulations and do not pose any safety and environmental threats for users and the public at large - It should ensure a level playing field/fair competition on the market - It should safeguard the coherence of the European regulatory framework, the consistency of which depends on effective enforcement However, whereas consumer goods benefit from well organised and efficient market surveillance, capital goods (pumps) suffer from a certain lack of focus - market surveillance tends to be more reactive (eg. Following an accident) than preventative. For such reasons the following are considered by Orgalime (the pan European Electrical and Mechanical Engineering Industry Association) to be the key elements of an effective market surveillance strategy that can safeguard the competitiveness and interests of such as the pump sector; 1. Allocation of sufficient resources (both financial and staff) to market surveillance authorities so they can actively control compliance of machinery entering the European market. 2. The setting up of a common Commission- Member States co-operation platform under Regulation 765/2008/EC, with an industry advisory forum for preparing Europe wide targeted campaigns focusing on certain products or product categories with a view to achieving maximum effectiveness with limited resources. The decision on the areas to be selected would be made after consultation with stakeholders, including the industry affected by noncompliant products. 3. A better coordination of market surveillance and harmonisation of enforcement practices (e.g. a common approach to risk assessment) with colleagues in other EU Member States: it is of the utmost importance to enhance mutual confidence, avoid double checks and maximise the use of human resources for multiple and intelligent market surveillance activities. 4. The establishment of close relations between market surveillance and custom authorities: all customs officials should receive training to help them identify potentially non-compliant products (e.g. by making use of the manufacturer’s declaration of conformity, as requested for all harmonised products. 5. The implementation of actions as early as possible in the supply chain: the

 2014

earlier the products are checked in the supply chain, the less damage they cause on the market if they are not compliant. This should apply first of all to imported goods. 6. Setting up an agreement between the EU Member States to meet a set of essential requirements for efficient Europe wide market surveillance. This requires deterrent sanctions against rogue traders (e.g. fines, destruction of non compliant goods at the responsible market operator’s expenses). Sanctions should be considered also against conformity assessment bodies (e.g. economic or related to accreditation), if necessary. 7. The Commission to finance , e.g. within the framework of the European Structural funds, assistance to Member States whose geographic or economic conditions place them in a weaker position to fight against illegal trade and unlawful imports from abroad. This is especially true for countries with maritime ports, where 90% of the goods imported into the EU transit every day. 8. Cooperation with colleagues outside the European Union: close cooperation between all authorities involved in customs controls and market surveillance from the main EU trade partners, and in particular EU neighbours, is necessary to ensure that most imported machines are compliant. 9. Internal coordination at national level across the various authorities involved in the enforcement of different legal requirements (health and safety, environment, energy efficiency...) because machinery often has to comply with various types of regulatory requirements. 10. Increased awareness among market operators about the working methods and actions through a European awareness campaign (including awareness about the obligations related to the affixing of the CE marking and about sanctions in case of non-compliance), Economic players should be encouraged to inform authorities about non-compliance. With the above in mind BPMA met with the National Measurements Office (NMO) in October. The NMO are the UK Market Surveillance authority in respect of products in scope of the Energy Related Products Directive (Circulators and Water Pumps effective from January 2013) BPMA wished to raise concerns with the NMO about blatant nonconforming Circulators being placed on the UK Market. Our concerns were duly acknowledged and BPMA will work with the NMO over the coming months to address the situation.

EUROPUMP

Europump to visit Scotland in 2014 for its Annual Meeting The British Pump Manufacturers Association, host of next year’s Europump Annual Meeting, has recently announced the launch of its dedicated website -

http://europump2014.com Providing full details on the event, which is being staged at the luxurious Fairmont St Andrews Resort in Scotland from 22-24 May, the website offers a ‘one stop shop’ for all those pump executives looking to attend this important industry event. A comprehensive programme of meetings, workshops and presentations has been configured to allow all matters pertinent to European and American pump companies to be addressed. Topics such as directives, standards, market reports and other business initiatives, along with the latest appraisals on energy efficiency across the sector will be covered. Full details on the venue, the programme, the pricing and the registration procedure can be found within this online provision. Further information regarding the event, including specific details on the associated ‘National’ and ‘Gala Evenings’, will 2

uploaded over the coming weeks. Next to the many meetings and workshops, an extensive ‘partner programme’ has been produced, including award winning afternoon tea overlooking the Old Course at St Andrews, a trip to The Hill of Tarvit, one of Scotland’s finest Edwardian mansion houses, lunch at the world famous Sea Food Restaurant, a cocktail master class and a fantastic Falconry Display. Additionally, following the General Assembly there will be the opportunity to participate in a golf competition, sponsored by WEG Electric Motors and hosted on one of the hotel’s championship courses. Please ensure you book your place(s) early, as onsite accommodation cannot be guaranteed for any reservations received after 31st March. For further information, contact: Andrew Castle - Touchwave Media, andrew@touchwavemedia.co.uk, T: 07785 290034, www.europump2014.com

 Energy Savings Opportunity Scheme (ESOP) As reported in our last edition, ESOP is the UK Government’s response to the implementation of Article 8 of the EU Energy Efficiency Directive - which mandates Energy Audits on large enterprises (ie. Non SME’s) by 5 December 2015 and thereafter every four years. Furthermore SME’s are to be encouraged on a voluntary basis to similarly conduct audits. Accordingly, BPMA, in consultation with its members, submitted its response to the ESOP consultation in October - essentially promoting the BPMA Certified Pump Auditor (CPSA) Scheme - bearing in mind pumps are the single largest user of electricity in industrial and commercial applications. BPMA believes adoption of CPSA principles can achieve in excess of 6TWh annual savings - equivalent to nearly a million tonnes of carbon.

NEWS BYTES   Building Information Modelling (BIM) The Europump Standards Commission have agreed to establish a Building Information Modelling (BIM) working group and are now looking for interested experts. The BPMA have agreed to provide the secretariat of the new WG and have nominated a volunteer to be Chairman. The proposed Chairman is Mr Wayne Rose of Armstrong Fluid Technology and his position was sanctioned at the Standards Commission meeting held in Zurich on 18th September. We understand that many members of Europump are already working internally on BIM and BPMA’s goal is to identify an acceptable way forward for the pump industry and other parties involved. To explain further , Level 1 BIM has been used across Europe for some time. It involves 3-D modelling, often termed 3-D CAD. We believe the construction industry now faces Level 2 BIM. Level 2 promises to transform the design, construction and operation of buildings by involving all participants in a ‘complete’ digital model of a building. What this actually means to the pump industry still needs to be defined and hopefully addressed so we have a mutual approach across Europump. Accordingly, a meeting has been convened in Brussels in November to: • Define what is currently happening across Europe • Identify what has already been done • Identify an acceptable way forward for Europump and the construction industry • Identify a work program and timescales.

 Pump Technology

Training

We have had a very successful 2013 calendar of lecture based- training (“the course catered to all levels”) presented both abroad and in the UK with almost 40 courses taking place both in-house and at our facility in West Bromwich and over 200 delegates attending the various modules we are currently able to provide. (“the lecturers were very knowledgeable within their fields”) Feedback from both delegates and companies give us great encouragement that BPMA are definitely providing the right sort of knowledge-based modules created to arm the student with a sound technical ability to enable them to either progress further in their chosen career in the pump industry or for those wishing to widen their expertise. (“Lecturers were friendly, knowledgeable and took time to explain”) In-house bookings taken for 2014 are already well ahead of schedule. Courses are held throughout the year at the National Metalforming Centre and dates already fixed for 2014 are as follows:11 February 2014 - Module 001 Part 1, Pumping Fundamentals 12 February 2014 - Module 001 Part 2, Pump Selection 4 June 2014 - Module 001 Part 1, Pumping Fundamentals 5 June 2014 - Module 001 Part 2, Pump Selection 16 June 2014 - Module 007, Pump Testing 17 June 2014 - Module 008, Pump Systems 23 June 2014 - Module 009, Hydraulic Design of Centrifugal Pumps For further details on costs or availability please contact Jeanne Page at j.page@bpma.org.uk

 MDS visit to Redditch drives home efficiency Redditch, Worcestershire (06 November 2013) - The Motor Driven Systems Conference visited Redditch on Tuesday in the third of five UK dates aimed at helping industry to generate huge financial savings from motor driven apparatus. Hosted at the UK headquarters of WEG Electric Motors in Redditch, the presentations from BSI, Energy Solutions Associates, Mitsubishi, GAMBICA and Siemens Financial Services, among many others, once again contributed to a lively debate on how to reduce energy and make these potential savings a reality. Patrick O’Neil, Managing Director at WEG Electric Motors, commented “We are delighted to have hosted the Midlands leg of the MDS Roadshow and to have played our part in helping industry better understand the key issues surrounding improved energy efficiency. The theme of the event is synonymous with our own core beliefs, and it was gratifying to witness such in depth discussion between Speakers and Delegates. I feel sure all the attendees will have taken away some extremely valuable information, which can hopefully be converted into practical application. We look forward to attending the remaining the events”. The second presentation of the day was given by Mike Malina of Energy Solutions Associates, who argued that ‘Short Termism - Damages Sustainability’ He said after the event, “MDS has created a fantastic opportunity for discussion and dialogue, in what has to be one of the most important issues affecting UK industry today. The overall theme of these events clearly presents and underpins the need for ‘joined-up thinking’ when dealing with matters of energy efficiency; something which is sadly long overdue”. Next stop for MDS is Hatfield at the UK headquarters of Mitsubishi Electric. The final event in the 2013 programme will be held at ABB’s Motion Control Centre in Bristol on 4th December. For more information about this event and to book your place, please visit the dedicated MDS website - www.motordrivensystems.com.

 BPMA 2013/14 Directory and Buyers Guide 2013/14 now available Our every popular and much in demand Directory and Buyers Guide is now available from BPMA. Over 80 pages packed full of member articles, technical information, latest innovations as well as a comprehensive pump sourcing guide. Apply direct from our website www.bpma.org.uk or simply email j.page@bpma.org.uk to request a copy. 3

WEG to supply six custom-made squirrelcage motors for driving plunger pumps on offshore oil production ships in Brazil Wepuko PAHNKE GmbH (Wepuko), a specialist in high-pressure pumps and compressors which is headquartered in Metzingen, Germany, relies on drive solutions from WEG. Electric motor manufacturer WEG is supplying a total of six squirrel-cage motors from the Master Line series to drive triple-plunger highpressure hydraulic pumps. According to Fabio Viviani, Project Manager at WEG Germany, the MGF 560 models for this application are special products rated at 1,203 kW and will drive pumps on the P66 to P71 floating production storage and offloading (FPSO) ships of the Brazilian oil producer Petrobras. The explosion-proof six-pole squirrel-cage motors (type MGF 560 A, rated at 1,230 kW, 13.8 kV, 60 Hz, IP 56 W) operate reliably and securely at all times even under the extreme conditions of offshore oil production in pre-salt deep-sea oil fields. Long-time business partner Wepuko bid directly for this highprofile project with WEG motors. The first two MGF 560 motors are scheduled for delivery to Metzingen later this year, with the remaining four to follow in in 2014. Offshore applications in the oil and gas sector are generally regarded as one of the most severe application areas for high-power electric motors. Oil production in deep-sea fields off the Brazilian coast is especially demanding because the oil is not only located over 1,000 metres below sea level, but also covered by a salt layer up to 2,000 metres thick. WEG has specifically adapted the MGF 560 motors

for use on Petrobras’s P66 to P71 FPSOs operating in that region. The units are explosionproof for Zone 2 (group IIA, thermal class T3) and designed for an ambient temperature range of -45 to +45°C. The starting current is limited to six times the rated current. Due to the aggressive ambient conditions, the heat exchangers, fasteners and motor fans are made from stainless steel to provide enhanced corrosion resistance. The motor windings are protected against voltage surges by capacitors and integrated surge protectors. The motors are certified by INMETRO for use in explosion hazard areas and by BV Bureau Veritas for shipboard use. The motors operate reliably and with guaranteed efficiency even under extremely harsh conditions. According to Andreas Schulte Mesum, Director Energy Business at WEG Germany, Petrobras chose the Wepuko solution with WEG motors not just for technical reasons: “We have already executed several projects successfully for Petrobras. As a result, we are very familiar with the customer and the specific requirements of offshore oil production. We specifically adapted our MGF motors for this especially demanding project - you could almost call them ‘handmade’. Another small plus was unquestionably the fact that we could supply the complete documentation in Brazilian

Portuguese. We are especially pleased to be able to carry out this exciting project together with an experienced partner like Wepuko.” The motors in the Master (M) Line were developed in response to the needs of the global oil and gas industry. They provide high performance, reliability and security under the harshest operating conditions on land and in the offshore sector. They also combine many years of experience with a broad application range and all classifications for explosion hazard areas in accordance with the ATEX directive. M-Line motors are used worldwide in a wide variety of applications, including water injection, multi-stage gas compression and oil pipeline operation, and they are WEG’s core product for the oil and gas market. With rated power up to 30 MW, these induction motors are designed for relatively large applications and can be built as squirrel-cage or slip-ring rotors. The housing is made from grey cast iron for frame sizes from 280 to 560, while fully welded housings are used for frame sizes from 630 to 1800. The motors are available with operating voltages from 2.3 kV to 13.8 kV in 50-Hz and 60-Hz versions, with 2, 4, 6, 8, 10 or 12 poles. Standard cooling is provided by an air/air heat exchanger; other cooling types (e.g. air/water heat exchanger) are available as options. For more information contact WEG Electric Motors (UK) Ltd, Redditch, Worcestershire. Tel: +44(0)1527 513800 Fax: +44(0)1527 513810 E-mail: wegsales@wegelectricmotors.co.uk Web: www.weg.net

DART1

Wireless Machinery Monitoring System (ATEX Zone 1 Certified) As part of our commitment to continually reduce the cost of clients’ condition monitoring and improve safety in collecting data from hazardous or inaccessible areas, John Crane has developed an advanced technology, intrinsically safe wireless machinery monitoring system. Specifically designed for condition monitoring of rotating machinery in hazardous areas (ATEX Zone1), the system is battery powered, designed to be easily installed and virtually maintenance free. • Fit in a day • Easily moved from skid to skid for bad actor RCA • Up to 16,000 point data spectrum • Real time and long time trending graphs • Monitor in hazardous areas • Monitor in inaccessible areas • Monitor infrequently run equipment with “wake up” feature • Dashboard GUI with alarm function • Can run on standard PC • Free issued software and no annual charges • 3 to 8 year battery life John Crane UK Ltd Nash Road, Trafford Park, Manchester, M17 1SS 24hr Emergency: 0800 917 2408 Colin Ure T: 07786 727997

John Crane UK Ltd Aberdeen Oil and Gas Support Unit, Asset Management Solutions, Grampian House, Mugimoss Road, Bucksburn, Aberdeen, AB21 9NP Rod Mackenzie T: 07917 227825

www.johncrane.com E-mail: hannah@touchwavemedia.co.uk

16617 BPMA 112x150mm Ad_AW 2.indd 1

28/01/2013 16:52

Pumping Up the Pressure Sundyne HMD Kontro Introduces New High Pressure Sealless Pumps Enjoying an enviable reputation for providing pumps to suit high pressure applications, Sundyne HMD Kontro has launched the new HPGSP magnetic drive sealless pump, the top end pump in its high pressure range. Capable of easily handling system pressures up to 185 bar and higher, dependent upon temperature extremes, HMD Kontro HPGSP pumps are exceptionally versatile yet safe and secure. With no seals, the pumps have no leaks, less maintenance, reduced downtime and offer substantial cost savings. The HPGSP range comprises pumps based on the HMD Kontro GS drive, built to API 685 specification, suitable for heavy-duty applications. The separate mounted design is available in eleven hydraulic sizes and two basic frame sizes to suit power requirements. Standard materials of construction are S-81 and S5, D-1j and D-2j. Other variations are available on request. The performance parameters for the HPGSP include: head up to 150 metres / 700 feet, flow up to 290 m3/hour / 1500 gpm, temperatures: -100 to +260 DegC / -100 to +500 DegF and pressure: 185 bar / 2700 Psi. Sundyne HMD Kontro sealless pumps are designed to comply with the requirements of API 685 specifications for magnetic drive, sealless end suction, centrifugal pumps required by the oil, gas, petroleum and heavy chemical industries. HMD Kontro has been building sealless magnetic drive pump units for the oil and gas industry since 1983. With increasing demands for the safety and welfare of personnel, plus the environment, its sealless pumps are playing an ever greater part in maintaining these goals. Improved magnet drive technology has enabled

more efficient and powerful pumps to be built, including high pressure units such as the HPGSP, thus increasing the application scope for this technology. A copy of the new brochure for the HPGSP can be downloaded from the Sundyne HMD Kontro website at www.sundyne.com/hmdkontro. For further information, please contact Vince Lee on +44 1323 45200 or by email to vlee@hmdpumps.com

Motors | Automation | Energy & Distribution | Coatings

The ﬂameproof W22X. Ultimate safety. Ultimate efﬁciency.

Historically, hazardous area motors have been a compromise between safety and efficiency. Not any more. Our new W22X flameproof motors are IEC compliant for use in hazardous areas. They’re also the only flameproof motors rated IE3 for energy efficiency. So your customers get flameproof protection and money saving efficiency, too.

To learn more about our new W22X, the ultimate hazardous area motor, visit www.weg-ie4.com/hazardous

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

AxFlow to distribute Aturia centrifugal pumps AxFlow Limited has announced that it has entered into an agreement to distribute Aturia centrifugal pumps in the UK. This major development will expand AxFlow’s pump offering to include DIN, ISO, split case, mag drive, borehole and fire-fighting pumps. “Adding the Aturia to portfolio provides us with another 20 ranges of ‘mainstream’ centrifugal pumps,” reports Malcolm Walker, AxFlow centrifugal pumps manager. “With three manufacturing plants in Italy, Aturia is one of the country’s largest pump manufacturers as well as being one of its oldest. AxFlow has been looking to expand it centrifugal pump business in recent years, but has been waiting for the right partner to present itself. By taking on the distribution of Aturia products, we have added to our already extensive range of high-end cost effective and technically sound pumps for the process, water, food, and pharmaceutical industries.” This move allows AxFlow to offer the most comprehensive range of technical pumps in the UK and when added to the company’s engineering and maintenance services, (based in London, Windsor, Aberdeen, Huddersfield and Durham), establishes AxFlow as one, if not the, leading independent supplier of pumps and pump related products in the UK. For more information contact AxFlow Ltd, Ealing, London. Tel: 020 8579 2111 E-mail: info@axflow.co.uk Web: www.axflow.co.uk

Partnership Network NOV Mono has entered into a new working partnership to expand the levels of support and service it delivers to water and wastewater customers in Germany. Under the new agreement, Würdig Pumpentechnik will provide sales and service support from its offices in Berlin, Potsdam and Fürstenwalde. “Würdig Pumpentechnik covers various areas in Eastern and North Eastern Germany, such as Berlin, Brandenburg, Mecklenburg-Vorpommern and Sachsen-Anhalt,” says Werner Potrafke who manages sales of Mono Universal Parts and Mono’s EZstrip™ products in Northern Germany. “The company offers a range of services for the water and wastewater industry, from design and construction through to delivery and repair,” he adds. “Over the past 33 years the company has serviced more than 100,000 pumps and thereby gained an excellent reputation for reliability and service quality. Their knowledge of engineering, plant construction and pumps is first-class. This has led to them working with a wide range of water and wastewater customers, in both the public and private sectors, so they are an excellent fit for the Mono™ range of products and services.” “This new relationship with Mono™ will allow us to improve the support we offer to our customers through things such as our 24-hour emergency service,” adds Würdig Pumpentechnik’s owner, Dipl.-Ing Uwe Worthy. “Mono customers now have more dedicated and easily accessible support than before, so the new partnership will bring benefits to everyone involved.” For more details on Mono™ visit www.mono-pumps.com or call +44 (0)161 339 9000

New pump hoses for food applications with 80% greater life • Long life peristaltic pump hose promotes uptime and reduces maintenance • New food grade hose has a white inner lining and is FDA certified Watson-Marlow Pumps Group is introducing a new food grade hose for use with Bredel pumps. FDA and EC compliant, the new F-NBR hoses offer better wear resistance and longer life for improved production efficiency and process/product safety. Any manufacturer in the food and beverage sector that is using peristaltic pumps to dose additives or transfer abrasive, shear sensitive and viscous substances, will know all about the need for process uptime. To better meet this perennial requirement, Bredel is launching its F-NBR food grade hose which meets FDA 21CFR177.2600, EC 1935/2004 and BfR XXI cat.4 regulations and provides up to 80% longer life. Bredel hose pumps can deal with products as diverse as soft fruit and shell fish, abrasive yeast and finings, as well as fluids containing high concentrations of hard solids such as whole spices. Hygiene is seen as another key benefit - unlike other pumps which incorporate a variety of moving parts and can contribute to microbial growth

and contamination, Bredel hose pumps have no direct contact with the product at any stage of the production process. The new F-NBR hose can be cleaned by clean-inplace and steam-in-place sterilisation at full velocity, without the need for a bypass. At a time when organisations are under particular pressure to contain costs, maintain and improve quality and limit the expense of downtime and lost production, the introduction of the new F-NBR hose is good news to sfood manufacturers. Available in size 10-100mm, F-NBR hoses are manufactured in accordance with cGMP guidelines. 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.uk

New Arla site laps up the attention

On a 115-acre site on the outskirts of Aylesbury in Buckinghamshire, a new £150m Arla Foods site is setting new standards when it comes to dairy processing. Not only is the new dairy the largest fresh milk processing facility in Europe, it will also be one of the most environmentally efficient milk processing plants in the world. When it is fully operational the dairy will employ 700 people and will be capable of packaging up to 1.0 billion litres of milk annually. Such an important development demanded only the best and the volume of milk to be moved around the site and processed means pumps play a vital role. Recognising this, Grundfos Pumps has worked closely with N G Bailey - which provided all the M&E solutions - from the outset to supply the entire pump solution.

The solution was delivered in two phases. The first phase saw the main services delivered in pre-fabricated modular sections that were built at NG Bailey’s prefabrication plant. These modules were then bolted together to form a 204m corridor at the site and contain all the process piped services, including a wide range of Grundfos pumps that supply the chilled water, low temperature hot water heating plus a range of other circuits and services. The second phase saw the delivery to the 90m by 60m energy centre of 14 heavy duty plant skids - complete with Grundfos pump solutions - which were also built offsite using innovative manufacturing techniques and 3D modelling. In total Grundfos supplied 90 pump solutions that included circulators, in-line centrifugal pumps, end suction multi-purpose pumps and a total of 7 energy efficient Grundfos Hydro MPC-E booster sets - so vital in this type of operation. Grundfos have worked with Arla Foods in the UK for many years and understands its exacting requirements and the importance of assisting to maintain a 24/7 operation under stringent hygiene conditions. For more information contact Grundfos Pumps Ltd, Leighton Buzzard, Buckinghamshire. Tel: 01525 850000 E-mail: grundfosuk@grundfos.com Web: www.grundfos.co.uk

Cat Pumps slash energy and maintenance costs at food processing plant A Cat Pumps Model 6831high pressure pump is cutting energy and maintenance costs at a leading food processing plant in the UK. Supplied by AESPump Limited in June 2012, the triplex positive displacement plunger pump has replaced two aging and troublesome Pitot Tube pumps used for washing filter screens and supplying high pressure wash-down hoses. In its first year of operation, the Cat Pumps unit has reduced the energy costs from £45,200 per annum to just £13,300, and maintenance costs from £30,000 per annum to £2,800. Of equal note is that the payback period for this change-out was just 9.9 months. With annual running costs in the region of £75,200, the food company implemented a project to look into replacing these two pumps with a more reliable product. AESPump, who had been providing the processing plant with pump maintenance and improvement services was brought in for advice. They recommended that the Cat Pumps triplex pump would be the best solution being a true positive-displacement reciprocating pump as they offer excellent energy efficiency & consistent flow rate unaffected by discharge pressure. Cat Pumps and AESPump say that their customer has been delighted with the first year’s operation. For more information contact Cat Pumps (UK) Ltd, Church Crookham, Hants. Tel: 01252 622031 E-mail: sales@catpumps.co.uk Web: www.catpumps.co.uk

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

KSB’s valves used in the salvage of the MEMBERSHIP Costa Concordia

BPMA

Pump manufacturers, contractors, distributors, seal, bearing, motor, castings suppliers etc involved in the UK market for pumps and pumping equipment can all participate as members of the trade body for the UK Pump industry (BPMA). Keep abreast of Technical Standards and EU Directives affecting the industry, participate in industry events and marketing initiatives, access free membership services. Invest in business support for your company by taking advantage of introductory offers for membership of BPMA. Visit the BPMA website www.bpma.org.uk and download our latest BPMA membership brochure.

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

Over three hundred ISORIA pneumatically adopted in the event of actuated butterfly valves have been supplied by insufficient compressed the KSB Group for use in the salvaging of the air supply. If the actuators cruise ship Costa Concordia, which capsized off cannot be controlled due KSB ISORIA butterfly Giglio Island on 13 January 2012. to a power supply failure, valve at the floor of one The role of the 328 valves is to fill and vent tanks it is also possible for divers of the sponsons that located in the sponsons (giant steel boxes), the first to operate them manually. were attached to the 15 of which were welded to the port-side hull to act As soon as the 50-metre ship’s port-side hull and as ballasting bodies when righting the wreck. At a crack in the ship’s side has flooded. (© KSB Italia later stage, these sponsons, together with another been sealed, the sponsons S.p.A.) 15 to be installed on the star-board side of the cruise will be filled with air to get ship, will be flooded and used to the vessel up and floating again. stabilise the wreck. For more information Prior to being used in the contact KSB contact: recovery, the ISORIA pneumatically Christoph P. Pauly, actuated butterfly valves were Press Officer, subjected to special pressure KSB Aktiengesellschaft. tests at the Italian KSB plant in Tel.: +49 6233 86 - 3702 Concorezzo. There, KSB Italia’s Fax: +49 6233 86 - 3456 technicians simulated an ambient E-mail: pressure corresponding to a water christoph.pauly@ksb.com depth of 40 metres. Web: www.ksb.com The valves’ actuators are View of the Costa Concordia with designed to ensure that a the sponsons attached to her portpre-set fail-safe position is side hull. (© KSB Italia S.p.A.)

Need to save energy? Then talk to Grundfos

Mr/Mrs etc:........ Initials:..... Surname:.................................. Job Title:............................................................................ Company:.......................................................................... Address.............................................................................. .......................................................................................... ................................County:................Postcode:.............. Tel:.......................................Fax:........................................ Email:................................................................................. Main Business Activity:....................................................... Estimated No. of Employees at this address:......................

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

With increasing pressure on both the public and private sectors to attain cost savings - there has never been as much focus on delivering sustainable energy savings. As a global pump manufacturer at Grundfos we know that although pumps may be hidden away in plant rooms, they are big energy consumers as they currently account for 10% of global electricity. The good news is that we also know that most pumps are incorrectly sized for their current application which means that changing pumps for more energy efficient models can be a quick win for you. So speak to a company that can deliver a wide range of high efficiency pumps and advanced motor technology that can reduce the average pump’s energy consumption by up to 60% - a company like Grundfos Pumps. As the largest pump manufacturer in the world Grundfos are experts in calculating the current efficient levels of your pumps and can then deliver a bespoke range of solutions that will benefit any organisation. We even offer our customers a Pump eXchange scheme that ensures your business will get the full re-cycling value of any pumps you chose to replace. So regardless of the application or business model, talk to us about how we can help to support your business and deliver real, tangible energy savings... year after year, after year... For more information contact Grundfos Pumps Ltd, Leighton Buzzard, Buckinghamshire. Tel: 01525 850000 E-mail: grundfosuk@grundfos.com Web: www.grundfos.co.uk

FLUIDS & LIQUIDS HANDLING inc. pumps & valves

Portable valve actuators aid safety in paper industry Large valves used in the paper and pulp industries can be safely operated with Smith Flow Control’s EasiDrive portable valve operating system. EasiDrive’s reaction device transmits torque onto the valve body and away from the operator, making it one of the safest valve operating systems available. EasiDrive is a cost-effective alternative to a dedicated valve actuator. Paper and pulp plants often use manually operated valves with high operating torques. These can require hundreds of hand wheel turns to open and close or are just difficult to operate. Unlike an impact wrench that can damage a valve, the EasiDrive is a continuous drive system. Typical pulp and paper applications can include large, sluice gate valves, valves with stem extensions and valves operated by gear boxes with a high number of turns. To request a site demonstration or to find out more, please call Smith Flow Control, Witham, Essex on +44 (0)1376 517901 E-mail: sales@smithflowcontrol.com or visit the company website at www.smithflowcontrol.com.

AIRpipe… THE NEW COMPRESSED AIR PIPE SYSTEM Having experienced unprecedented sales growth success following the introduction of a number of exclusive brands in this year’s Flowtechnology UK Catalogue, the company has announced the launch of another new exclusive range comprising an innovative Compressed Air Pipe System. AIRpipe, founded over 15 years ago, specialises in the production of quick-connect air piping solutions for new projects, renovations, extensions and modifications to existing systems. A cleaner alternative to traditional galvanised piping, the AIRpipe system is suitable for use with compressed air, vacuum and inert gas applications. The AIRpipe full performance compressed air pipe system differentiates itself through outstanding design, material and production processes. John Farmer, Product Management Director for FTUK commented: “AIRpipe provides an adaptable, durable and flexible compressed air solution, and with the increased focus from manufacturers on compressed air systems that enhance the provision of air reducing energy costs, AIRpipe presents the perfect solution. Added confidence in the system comes from the 10 year guarantee, and we are convinced that this range will have a positive impact in the UK market”. Benefits to the range include; • Corrosion Resistance and cleaner air • Reduced pressure drop – energy saving • Flexible, quick & easy Installation with seamless compatibility • Durable & resistant • Adaptable - bespoke compressed air systems can be made through the company’s design service • 10 year guarantee For further information, please contact Flowtechnolology UK, Skelmersdale, Lancs. Tel: 0845 456 1222 Fax: 01695 51748 E-mail: sales@flowtechnologyuk.com Web: www.airpipe-eu.com + www.flowtechnologyuk.com

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

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

For more information contact MV Fluids Handling, Reading, Berks Tel: 0118 9503707 Fax: 0118 9504066 E-mail: straub@mvfh.co.uk Web: www.straub.co.uk

Process Industry Informer October-November 2013

FLUIDS & LIQUIDS HANDLING inc. pumps & valves New pump hoses for food applications with 80% greater life • Long life peristaltic pump hose promotes uptime and reduces maintenance • New food grade hose has a white inner lining and is FDA certified Watson-Marlow Pumps Group is introducing a new food grade hose for use with Bredel pumps. FDA and EC compliant, the new F-NBR hoses offer better wear resistance and longer life for improved production efficiency and process/ product safety. Any manufacturer in the food and beverage sector that is using peristaltic pumps to dose additives or transfer abrasive, shear sensitive and viscous substances, will know all about the need for process uptime. To better meet this perennial requirement, Bredel is launching its F-NBR food grade hose which meets FDA 21CFR177.2600, EC 1935/2004 and BfR XXI cat.4 regulations and provides up to 80% longer life. Bredel hose pumps can deal with products as diverse as soft fruit and shell fish, abrasive yeast and finings, as well as fluids containing high concentrations of hard solids such as whole spices. Hygiene is seen as another key benefit - unlike other pumps which incorporate a variety of moving parts and can contribute to microbial growth and contamination, Bredel hose pumps have no direct contact with the product at any stage of the production process. The new F-NBR hose can be cleaned by clean-in-place and steam-in-place sterilisation at full velocity, without the need for a bypass. At a time when organisations are under particular pressure to contain costs, maintain and improve quality and limit the expense of downtime and lost production, the introduction of the new F-NBR hose is good news to food manufacturers. Available in size 10-100mm, F-NBR hoses are manufactured in accordance with cGMP guidelines. 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.uk

RELIEF VALVE PREVENTS LOW PRESSURE DAMAGE TO EQUIPMENT Brownell Ltd has introduced a large range of pressure relief valves to prevent damaging pressure differentials in a wide range of industrial applications. Flow rate requirements from just 0.1 litre/min up to10,000 litres/ min depending on the applications and maximum allowable differential pressures. Pressure relief valves are used for preventing the pressures and vacuums that can be destructive or cause malfunctions in equipment containers, storage vessels and pressure sensitive instruments. In the event of increasing pressure due to system malfunction or environmental heating (or cooling), the relief valves will open at the set point and relieve the pressure of air or gas until a safe working level is achieved. The relief valves automatically reset when the re-seat level is reached and continue to maintain a safe working pressure. A typical valve application would be on cargo containers being transported by air. They can prevent an in flight hazard in the event of depressurisation or system malfunction. For more information contact Brownell Ltd, Park Royal, London Tel: 020 8965 9281 Fax: 020 8965 3239 E-mail: marketing@brownell.co.uk Web: www.brownell.co.uk

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

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

ONIS “Quick-Action” Lineblind

Making light work of a heavy maintenance process...

LEAK-FREE TURBINE PUMPS IDEAL FOR CHALLENGING APPLICATIONS Pump specialists MICHAEL SMITH ENGINEERS now offer a range of magnetically-driven regenerative turbine pumps which are an ideal solution for low-flow / high-head applications where zero leakage is required. Available in a wide range of wetted materials the M Pumps range is designed to handle liquids containing up to 20% entrained gas, as well as thin, non-lubricating liquids, or for pumping small flows at high differential pressures. The pumps can handle capacities up to 13m3 /hour at differential heads up to 164 metres for single stage designs and up to 500 metres for multistage pumps. Low NPSH versions are also available for refrigeration / cooling applications, or for pumping boiling liquids or high vapour pressure liquids, with an NPSHR down to 0.5 metres. The key features and benefits of the M Series includes; a high-head, low-flow capability which minimises the need for bypass requirements, hydraulically and dynamically balanced impellers which are designed to handle liquids containing up to 20% entrained gas and a close-coupled design which eliminates alignment issues. They also have ability to handle liquids with a wide range of viscosities from less than1 cP up to 200 cP. M Pumps are available in polypropylene, PVDF and stainless steel liquid end construction. Further details on the range of M Pumps are available from:Michael Smith Engineers Ltd, Woking, Surrey Tel: FREEPHONE 0800 316 7891 Fax: 01483 723110 E-mail: Info@michael-smith-engineers. co.uk Web: http://www.michael-smith-engineers.co.uk/products/ turbine-pumps/turbinepumps-products.htm

Process Industry Informer October-November 2013

FLUIDS & LIQUIDS HANDLING inc. pumps & valves

HYDRA-CELL MONO- Smooth, crevice-free valves BLOCK PUMPS for aseptic applications EASE INSTALLATION & SERVICE Wanner International has introduced an optional Mono-Block style pump head on its Hydra-Cell G03, G13 and P200 seal-less pump models. The new Mono-Block pump head combines the traditional valve plate and manifold into a single component, allowing easy access to the cartridge style valve assemblies. The valves are accessed easily without the need to disassemble the pump or disturb the system pipework. Routine maintenance, valve inspection and, if necessary, replacement, can be carried out quickly and efficiently and causes very little downtime while cutting service and maintenance costs. A further benefit of the Hydra-Cell with Mono-Block pump head is its ability to prime quickly at slow speeds. Mono-Block pump heads are available in brass or 316 stainless steel. Diaphragms are available in a range of materials from PTFE and Viton to Buna, Neoprene and EPDM, to suit the requirements of the liquid being pumped. The Mono-Block pump head is reported to be a further improvement to the design superiority and operational excellence of Hydra-Cell pumps. For moreqdos information contact: wmb-606 ad_Layout 1 Wanner International, 16/01/2013 15:36 Fleet, PageHants. 1 Tel: +44 (0)1252 816847 E-mail: NHerrington@wannerint.com Web: www.hydra-cell.eu

Eliminating areas in process systems which may increase the potential for bacteria growth, such as traps and crevices, is an important requirement for control valves used in aseptic applications. Control valve specialists SAMSON CONTROLS offer a range of products incorporating these features which are manufactured to quality assurance systems certified to ISO 9001, whilst also meeting stringent FDA requirements. For example, their type 3347 control valve has polished steel parts to ensure the highest purity for the process medium, special PTFE bushing along with an additional steam line connection that is used to meet very stringent purity requirements preventing bacteria from spreading at the actuator stem guide. Another example is the Type 3249 valve which is equipped with an EPDM diaphragm and a back-up safety packing box to ensure total protection against bacteria spreading and prevent product leakage. These sealing systems, which constitute the main components of the valve construction, have been thoroughly developed and designed to ensure a long and reliable service life. Process applications which involve pasty, fibrous or highly viscous products are best controlled by Samson’s Type 3345 cavity-free valve body which features a diaphragm available in either rubber, nitrile, butyl or PTFE which acts both as a seal and a valve plug. These valves can be easily installed into the process line as they are available with various connections including hygienic couplings, flanges and clamp connections according to ISO 2852 and welding ends.

Further details and product literature is available from: Samson Controls Ltd, Redhill, Surrey Tel: 01737 766391 Fax: 01737 765472 E-mail: Sales@samsoncontrols.co.uk Web: www.samsoncontrols.co.uk

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Process Industry Informer October-November 2013

FLUIDS & LIQUIDS HANDLING

leak detection

Pump control on the GO POWERFUL NEW ELECTRONIC SURFACE In order to get complete control over pump performance, LISTENING DEVICE FOR ‘HANDS FREE’ Grundfos Pumps developed the innovative Grundfos GO App that offers intuitive, handheld pump control. Grundfos GO is LEAK DETECTION AND PINPOINTING designed to save time and effort for the user. The App can be downloaded to any compatible device i.e. with an iOS or Android operating system. Today, the Grundfos GO CAPS and GO Remote have now merged into one App. So, if you just want to research pump selections this can be done by downloading the free Grundfos GO App as this offers the most comprehensive platform for pump selection including sizing, replacement and a range of documentation. If you want to use the Grundfos GO to communicate via radio and infrared technology with e-pumps, in order to get started you will need to order the mobile interface attachment either for your iPod Touch or for your Apple or Android smartphone device and download the free Grundfos GO App from the App Store or Google Play. Then reap the benefits of intuitive, handheld assistance and access to Grundfos online tools, saving valuable time on reporting and data collection. These innovations mean the industry’s most advanced mobile solution has taken pump control and selection - on the move - to a whole new level.

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

Acoustic water leak detection technology leader HWM has launched the Bmic hands-free leak monitoring device. With a belt-mounted control unit for handsfree operation, the lightweight Bmic is comfortable, easy to use and provides high quality sound reproduction. To avoid unnecessary excavation and ‘dry holes’ which do not expose the leak on an underground pipe, the Bmic helps leak technicians precisely pinpoint the leak location from the surface. Available as standard with the proven “elephant’s foot” windproof microphone or in the Bmic Lite package with a lightweight hand probe and “tripod foot”, it offers an economical way to improve the leak pinpointing and repair process for all levels of requirement. The “elephant’s foot” microphone, planted on the ground at surface level, provides superior sound quality by reducing background noise, allowing the user to accurately identify where the leak is and exactly where any digging should take place. The hand probe option is also available to use with attachable tripod, or for making direct contact on accessible pipes and fittings - enabling the operator to carry out traditional acoustic surveys. A simple push of the button on the belt-mounted control unit activates broad-band amplification technology to make the sound clearer and pinpointing even easier, and the windproof housing on the microphone coupled with the included studio quality headphones ensures the best possible audio quality.

For more information contact HWM-Water Ltd, Llantarnam Park Way, Cwmbran Tel: +44 (0)1633 489 479 Fax: +44 (0)1633 877 857 E-mail: sales@hwm-water.com Web: www.hwm-water.com

water testing PALINTEST LAUNCHES PORTABLE PHOTOMETER 8000 FIELD KIT FOR ON-SITE WATER TESTING The new, upgraded Photometer 8000 Field Kit from Palintest has now been launched for use in the drinking water, wastewater, surface water and process water markets. The kit brings together a portable multiparameter photometer and all required accessories to conveniently and accurately test in almost any application environment. Equally suitable for use in the lab or in the field, it successfully and economically answers the call for a single water technician’s kit that is suitable for virtually any situation and set of test parameter. Included within the kit’s sturdy IP67 case are cuvettes, sample preparation apparatus and interface cables to allow USB or RS232 connection of the Photometer 8000. Transport containers within the case allow users to carry any of the range of tablet or liquid reagents used for determination of species such as ammonia, nitrate, heavy metals and chlorine. For more information contact Palintest Ltd. Gateshead, Tyne & Wear Tel: +44 (0)191 491 0808 Fax: +44 (0)191 482 5372 E-mail: sales@palintest.com Web: www.palintest.com or by following @Palintest on Twitter.

pressure calibration New Fluke pressure calibration tools Fluke has introduced new pressure calibration tools to its extensive range, including new solutions to measurement that were not met previously. Ideal for instrument, process and plant maintenance technicians, these tools include the Fluke 719Pro Electric Pressure Calibrator, featuring an electric pump and now offering up to 20bar, the Fluke 721 Dual Range Pressure Calibrator and a host of pressure gauge range additions to the Fluke 700G Pressure Test Gauge Series. All come with a 3-year warranty. The rugged Fluke 719Pro Electric Pressure Calibrator features a backlit display and offers high accuracy pressure measurements and an on-board electric pump that can generate up to 20bar. It also measures, simulates and sources 4-20mA loop current signals and can measure up to 30V DC. An internal 24V loop power supply can power a transmitter under test. The rugged Fluke 721 Dual Range Pressure Calibrator provides accurate measurement of static pressure, difference in pressure and (optional) temperature of gas flow. It also measures 4-20mA signals, up to 30V DC, and an internal 24V loop power supply will power a transmitter under test. The large backlit display will show two pressure readings and a temperature reading simultaneously. For more information contact Fluke (U.K.) Ltd., Norwich, Norfolk Tel: 0207 942 0700 Fax: 01603 256 606 E-mail: industrial@uk.fluke.nl Web: http://www.fluke.co.uk

Process Industry Informer October-November 2013

The best bits from In the Hot Seat and latest Top Tips To read these in full subscribe to our new Interactive version of PII available on iTunes Newsstand - download via the QR Code

Likes: Triumph Motorcycles, not to take life too seriously, Being in the mountains

things and, frankly, it changed my life. Chris Hansford, Hansford Sensors

Dislikes: Poorly thought-through arguments, Temperamental lab equipment, dishonest people

What is the most successful product your company has launched & why was it so successful?

Best & worst business decision you have made Best: Commercialise two patents, which doubled our turnover in a very short space of time. Mike Watson, Tubetech Worst: I once joined a company, having been promised the earth (you know exactly what I mean you’ve no doubt been there) and literally within three hours of joining, I knew I’d made a dreadful mistake. I don’t mind admitting I was in despair. I knew for the sake of my family - not to mention my career - I had to stick it out ... and three years later I left to take up my dream job. Dr Timothy C Whelan, Castell Safety International

What has been the most important advancement in technology for your business? The development of new tribology test equipment. The knowledge and experience we can get through them is extremely valuable. Using them, we can reproduce the contacts, interfaces and running conditions of machines we see in the field, thus enabling us to identify and prove the best lubrication solutions for the end users; to reduce friction power loss, wear and maintenance. Moreover, we can vary specific parameters (speed, load, temperature), try new component materials and develop new lubricant technologies. Dr Chris Dyson, ROCOL

It could be the next one! There’s a new range of sensors in the pipeline that are currently being evaluated within the UK paper industry and they could be a turning point for us. If they’re as successful as we hope, they will take us to the next stage of our company development. Chris Hansford, Hansford Sensors

What can’t money buy? Love, health, contentment, loyalty, creativity, hope. Dr Timothy C Whelan, Castell Safety International

Best advice you have ever been given and what advice would you give to aspiring engineers? Best advice is to be fair, reasonable and above all be consistent and to aspiring engineers - the keyword is ‘communicate’. Mike Watson, Tubetech

What has been the most unusual project your company has undertaken? It may be the project we did with a very well-known manufacturer of aircraft engines. They had a system for firing chickens (which were deceased before firing, I might add) at the rotating aircraft engine blades and our products interlocked the power supplies of the test rigs with the chicken firing points! Dr Timothy C Whelan, Castell Safety International

What was the first ‘proper’ job you ever had?

What has been the most embarrassing moment at work?

When I left school I was a dreadful disappointment to my parents! I didn’t get my A-levels and it looked like the end of the world - then I found a position working for an independent engineering company called Fulmer Research. They sent me to college and I got my engineering qualifications. That first job gave me a fantastic overview of engineering because the work was so varied... we were involved in testing bulletproof vests, electronic dartboards - a whole host of different

I was staying overnight on business. I’d booked into the hotel so that I could get to the venue the next day nice and early and prepare for an important presentation to some very influential potential customers. I was sure I’d packed a spare shirt and so in the morning, as I usually do, I used my old shirt to polish my shoes. I gave them a right good shine and took all the mud and dirt off my shoes in the process. I then reached into my case to get my new clean shirt - only to find I hadn’t brought one!

Get involved!

I had no choice other than to wear my old crumpled, mud-stained shirt, covered in black boot polish to my presentation! I did my best to button up my jacket as closely as possible (even though it was a stifling day) and spent the meeting pretending that I had a fever and that’s why I was so hot! Dr Timothy C Whelan, Castell Safety International

If you were invited to appear on Mastermind what would be your specialist subject and why? Blues music. I enjoy listening to it of course but I’ve always been fascinated by the history of blues music as well. Dr Chris Dyson, ROCOL

In 140 characters tell people why they should ‘Tweet’ or ‘Like’ this post Chris Dyson is a tribologist at ROCOL Lubricants. This does not mean that he studies tribes. Find out what a tribologist does instead.

Most recent Top Tips:

Our new ‘Top Tip s’ section offers usual advice across an array of different subjects - visit ww w.piimag.com/toptips to read more. For effective ener gy management through optimise d power transmiss ion For Safe Industrial Flooring

Finding a Suitabl e Pump For Gas Sensor Pl acement To improve produc tivity in today’s food manufacturin g environment To ultimate light ing control For effective ener gy management through optimise d power transmiss ion

Would you like to take part in our ‘In the Hot Seat’ or ‘Top 10 Tips’? We would love to hear from you – Please email guyullmann@piimag.com or call 01428 751188

Process Industry Informer October-November 2013

GETTING INTO

By Chris Horsley, Managing Director of Babcock Wanson

HOT WATER

Heating water based solutions for maximum reliability at minimum cost

In the grand scheme of things, heating water or a water based solution doesn’t usually represent the greatest engineering challenge the world has ever seen. Keeping the heated process at a precise temperature adds another dimension, but let’s face it, it’s not rocket science.

A further option is to use a Steam Generator, heating the process using simple, high output, heat exchangers often solves the problem of space due to high heat transfer rate achieved by steam. Modern, fast response Steam Generators are able to deliver steam on demand when already hot or on standby, or within a few minutes if the Generator is cold. Unlike other traditional boilers, Steam Generators do not require extensive buildings or supervision and are easy to operate and maintain. However, where’s there’s water there remains the potential for corrosion and the time demand and cost of annual inspection still remain. So is there a way of combining the benefits of Steam Generators – most notably ease of use, high heat transfer rate and fast response with cost-effective operation – whilst avoiding the use of water as the key heat source? The answer, as many of you will be aware, is yes and it comes in the form of thermal fluid heaters.

Advantages in abundance… Using many of the same design elements as the standard hot water heating system we mention above, thermal fluid heating systems offer the best of all worlds for the majority of applications.

Process vessels That said if you want to achieve reliable, repeatable heating with energy efficiency and at a minimum cost, then you need to get the grey matter working a bit harder. Whilst water heating based on the domestically familiar scenario of electrically powered immersion heater elements or a simple gas fired heater may be a simple and effective approach, it can be inefficient depending on the process needs you are trying to meet. Such systems can be inexpensive to install depending on the degree of support plant required, but it is the overall operating cost that will really make the difference as to which design is the correct choice. Direct heating using gas or oil fired burners either mounted under a tank or by immersed tube are other obvious methods that can be applied but this type of system can take a toll on the equipment being heated; in no time at all you may find yourself having to fork out to replace those tanks and burners. And so we come to another familiar form of heating which is often considered when the process has limited heating surface or the temperature is close to or above 100°C; the use of high pressure hot water. There’s no doubt about it, this method is tried, tested and proven to be effective although care still needs to be taken to ensure an adequate heat transfer surface can be installed. So that’s that, problem solved? Well, apart from the high ongoing maintenance costs. Oh, and the potential safety issues faced by having large quantities of water under high pressure. And let’s not forget the ongoing costs of annual inspection and insurance reviews plus the ever present risk of corrosion.

A thermal fluid system consists of a gas or oil fired heater connected to carbon steel flow and return pipework with a thermal fluid operating as the heat transfer medium rather than water. Different fluids, including a wide range of mineral oils or synthetic based fluids, can be used to meet specific process heating requirements and, in some cases, doubling as the cooling agent as well.

Removing water from the system also removes the problems caused by corrosion. Even with the best intents, corrosion will eventually occur where water is present requiring regular maintenance and repair but which can eventually lead to equipment failure or at best, the replacement of major system components. Thermal fluid, on the other hand, does not cause corrosion or scale, requires very little maintenance, is not subject to frost damage and does not need to be kept under pressure so there is no risk of a corrosion based leak of pressurised hot water and no need for annual shutdown inspection, which should please both your health and safety officer and your financial manager! The removal of water from the equation also has another, maybe unexpected, benefit in that thermal fluid is a more environmentally friendly option. What could be more environmentally acceptable than water, you might be thinking. Clean, pure water wins hands down every time, but the water used in heat transfer circuits has to be treated with a chemical oxygen scavenger, sludge

conditioner and pH control correction. Even when using top-grade, environmentally friendly treatment chemicals that are safe and simple to handle there’s no escaping from the fact of chemical intervention. Thermal fluids do not require any chemical intervention and are more often than not a simple mineral oil that can be recycled. The oil typically lasts up to a decade and, with it being contained in a closed circuit no loss system, the only effluent is the exhaust from the heater. Such a design also makes for great energy efficiency, with thermal fluid heating systems regularly boasting 30% energy savings over steam systems. Whilst on the subject of costs, it should also be noted that not only do thermal fluid heating systems not require equipment for water treatment as we have already seen, but as the systems are packaged as a compact unit, special site work is generally not required. This not only has a major impact on overall cost but can mean the system can be installed close to where the heat is needed further reducing the cost of operation. Lastly, but still an important consideration, is ease of use. With all the other systems we have mentioned, varying degrees of skill and experience are required to operate the system effectively, especially where handling chemicals for water treatment is concerned. A thermal fluid system requires the least expertise. Whilst you wouldn’t go as far as to call it child’s play, operating a thermal fluid heating system is very easy, requiring minimal training and virtually no day to day involvement. The system can even be pre-programmed for specific processes. Babcock Wanson, for example, offer a unique menu driven system to allow companies to create and store up to 50 programmes for a heating / cooling system in a simple and operator friendly manner. Each programme can include a ramp up temperature, process soak period and a ramp cooling profile at the end of a cycle. All the operator is required to do is select the desired programme and press the start button. What could be simpler? So it may not be up there with the greatest engineering challenges of our day but for processes that require a plentiful and reliable supply of heat, selecting the right heat raising system is vital; it’s vital to ensure the heat is there when it’s needed and at the correct temperature, that it’s cost-efficient to install, operate and run and that it has minimal environmental impact. For the large majority of applications, this is best achieved with a thermal fluid heating system. Babcock Wanson Ltd, Borehamwood, Hertfordshire Can be contacted on: Tel: 020 89537111 E-mail: info@babcock-wanson.co.uk Web: www.babcock-wanson.co.uk

Process Industry Informer October-November 2013

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viscosity or flow rate sampling

FILTRATION & SEPARATION

Consistometer

Textile Filters

Let it flow! The Consistometer is a low cost, durable, instrument for accurately checking laboratory or production samples against consistency, viscosity or flow rate standards. This instrument is used to determine the consistency of viscous materials by measuring the distance that the material flows under its own weight in a given time interval. The instrument allows producers of such viscous products as jellies, preserves, sauces, etc to predetermine formulas for their product and to standardize production lots. It uses little bench space yet is probably the simplest, most accurate method of conducting a variety of flow associated tests. It is already widely used in the chemical, paint, cosmetic and food processing industries. It provides a single parameter for a variety of flow tests which can be carried out over any period under as near identical conditions as possible. The Consistometer or Bostwick Consistometer is manufactured from stainless steel engraved with a series of precise graduations at 0.5 cm intervals. To ensure accurate reproducibility the instrument is levelled using the adjustment screws and spirit level. METHOD OF USE: 1. A measured sample, usually 75 ml, is placed in the reservoir behind the gate. 2. The gate is released, by pressing the lock release lever - the spring action ensures it opens instantaneously. 3. As the fluid flows down the instrument its progress can be accurately measured using the graduated scale. By comparing the flow rate to specified time periods the physical properties of the sample can be calculated. For more information on Endecotts products please contact: Tel: +44 (0) 208 542 8121 E-mail: apatel@endecotts.com Web: www.endecotts.com

- The implications of washing on the filtration performance

Reduced purchasing costs and environmental considerations are one of the many advantages that textile filters have over one-off disposable alternatives but this often raises the question of how should they be washed? It is important to know that not every textile filter can be washed and that the filtration performance will deteriorate over time through washing, similar to the way your clothes are affected by the washing process. How quickly that degradation will happen and how much this will affect the filtration performance does depend on type of polymer and fabric and the processing conditions. Getting reliable advice from the filter manufacturer and following these instructions carefully will give you a long lasting and well performing textile filter. DRM has been manufacturing textile filters since 1970 and has acquired a wealth of knowledge regarding the washing of technical textiles and the consequences this may have on their performance. For more information contact DRM Industrial Fabrics Ltd,. Tel: +44 161 763 1776 E-mail: info@sedi-filter.co.uk Web: www.sedi-filter.co.uk

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NEW TRUCK MOUNTED STATIC GROUND VERIFICATION SYSTEM IMPROVES SAFETY Newson Gale’s award winning “Earth-Rite® MGV” enhances the protection of personnel and equipment during vacuum tanker and road tanker transfers of flammable or combustible materials by preventing uncontrolled electrostatic discharges. With the operation taking place in a hazardous area, the need to control all types of ignition sources is absolutely paramount however the vacuum transfer process can generate large amounts of static electricity, requiring confirmation of proper bonding to a verified grounding point. The new truck mounted Earth-Rite® MGV derives its power source from the vehicle battery, and uses certified Intrinsically Safe monitoring techniques to not only indicate a good bond to a static grounding point, but more importantly verification that the ground point to which it is attached represents a satisfactorily low resistance to true earth. Units have obtained Intrinsically Safe certification for use in the Global Petrochemical Industries, according to the requirements of IECEX, ATEX, CSA/ US and NEPSI (China), and may be used in all common gas, vapour or dust explosive environments. To learn more about the Earth-Rite MGV or the dangers of static electricity in hazardous areas please contact Newson Gale. www.newson-gale.com 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

Process Industry Informer October-November 2013

health & safetY HANOVIA’S Fortress Interlocks VALIDATED introduces compact SR PURELINE PQ UV safety key switch DISINFECTION IS A to isolate power HIT AT DRINKTEC The new SR unit from Fortress Interlocks is a compact safety key switch that is ideal for isolating power to machinery. For example, when the key is trapped inside the SR unit the power to machinery is on, and when the key is free, power is off. This allows the person carrying the freed key to enter the machinery or guarded area safely and power is not resumed until the key is returned. This is a typical sequence and other sequences can be specified. The key switch is heavy duty, housed in a metal enclosure which is IP rated 65/66/67. Its compact design allows the customer plenty of space for wiring, a feature not available in previous switch offerings. The switch current is 20A. The SR key switch is part of Fortress’ mGard range of safety interlocks. mGard is the premier range of modular trapped key products that are used to safeguard dangerous machines and hazardous processes. Individual modules can simply be added or removed depending on the application which allows flexibility and tailoring. Fortress’ mGard range of products is suitable for use in high risk applications. For more information about how the SR unit can be used in your application, please contact Fortress Interlocks Ltd, Wolverhampton Tel: +44 (0)1902 349 000 Fax: +44 (0)1902 349 090 E-mail: sales@fortressinterlocks.com Web: www.fortressinterlocks.com

NEW FLEXIEDGE FAST-ACTION INDUSTRIAL DOORS – JUST £90 A MONTH! Stertil Stokvis has introduced a special offer alongside the launch of its FlexiEdge range of fast-action industrial doors. Providing exceptional safety plus unrivalled resistance to wind, weather and impact damage, the new doors are available from just £90 a month. The new FlexiEdge range comprises 16 models of many different types and styles including internal and external doors, all-weather doors, cleanroom and freezer/coldroom doors plus emergency exit doors incorporating breakthrough curtains. Standard models are available in widths up to 11 metres and heights of 5.5 metres whilst bespoke and special sizes may be specified. The FlexiEdge range is so new, it’s not yet on our website. For details of the launch offer, call the FlexiEdge Hotline on 0870 770 0471. Stertil UK Ltd, Northampton Web: www.stertiluk.com

Hanovia’s PureLine PQ UV disinfection range was a hit at this year’s Drinktec exhibition in Munich, with a great deal of interest from visitors. Designed specifically for disinfecting water, it is part of a UV system portfolio for the disinfection of sugar syrups and brines and the de-ozonation of process water in the food, beverage, dairy and brewing industries. The PureLine PQ has also been endorsed by leading manufacturers worldwide, all of whom report that the system is simple to install, easy to use and, above all, that it offers exceptionally high levels of disinfection. Ensuring biosecurity of water systems, the UV system is tested and approved by independent experts to the requirements of the USEPA UV Disinfection Guidance Manual (UVDGM). Benefiting from full flow bioassays conducted by independent engineers across a wide range of operating and water quality conditions, the PureLine PQ guarantees 99.999% disinfection at its maximum bioassayed dose.

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

tGard - the New Customisable Safety Product from Fortress Interlocks tGard is the new approach to controlling access to hazardous machinery and equipment. It is a compact, metal-bodied safety system that enables the configuration of various safety products including electrical safety gate switches (with or without guard locking), mechanical trapped key interlocks and electrical operator controls, either as separate devices or integrated into one device. Fortress Interlocks offers tGard as a customised product, as standard. It is defined by a range of tGard elements, including safety switches (solenoid and non-solenoid), personnel keys, emergency release, push buttons, estops, indicator lamps and a choice of operating handles for both hinged and sliding guard doors. These elements are simply selected and then assembled into a robust housing, suitable for mounting onto machine guarding, providing the user with an exact configuration specific to the application. tGard is quick and easy to install and can be mounted directly onto a flat surface, doors or extruded aluminium profiles without the need for mounting plates or brackets. It is IP65 as standard and has been designed to be fully compliant with the new machinery safety standards. For more information about tGard and its applications contact Fortress Interlocks Ltd, Wolverhampton Tel: +44 (0)1902 349 000 Fax: +44 (0)1902 349 090 E-mail: sales@fortressinterlocks.com Web: www.fortressinterlocks.com

CASTELL LAUNCHES NEW SPRING-LOADED INTERLOCK KSP more efficient than traditional bolt interlocks Industrial safety specialist Castell has launched a new spring-loaded lock, the KSP, to increase efficiency in traditional bolt interlock applications. The KSP is a spring-loaded version of the Castell K lock, and uses an internal spring to automatically extend the lock’s bolt to its fullest extent when circumstances permit. The key-operated mechanical interlock is suitable for the safe locking of simple actuating mechanisms. The KSP is generally used at the start of a process and traps a key while equipment is running. When the equipment is switched to a safe state and the aperture in the actuating mechanism is aligned, the spring-loaded bolt automatically extends and is locked in position. This represents an advantage over existing bolt locks as the operation happens immediately and without the need for human intervention.

Process Industry Informer October-November 2013

Once the equipment is in the safe state, the key is released and can be used to gain access or start a separate process. The key must be inserted and turned, retracting the bolt, to allow the actuating lever to be moved again. Paul Marks, Castell’s technical director, said: “We were already using a spring-loaded lock within our product range and realised that the same device could deliver significant benefits elsewhere for our customers. We view the KSP as an important addition to our existing K bolt interlock range.” For more information contact Castell Safety International Ltd, 217 Kingsbury Road, London, NW9 9PQ Tel: +44 (0)20 8200 1200 Fax: +44 (0)20 8205 0055 E-mail: pr@castell.com Web: www.castell.com/en

health & safetY

CROWCON’S I-TEST ENSURES GAS DETECTORS ARE COMPLIANT Bump testing & calibration station tests and verifies Crowcon Gas-Pro detectors The new Crowcon I-Test bump testing and calibration station is designed specifically to test and verify that Crowcon’s Gas-Pro portable gas detectors are in a compliant state. Bump testing (gas testing) standards globally are becoming ever-stricter and the demands on fleet managers to control bump and calibration records are increasingly stringent. The I-Test simplifies this process as much as possible. The accompanying I-Test Manager software tracks which Gas-Pro units need calibrating and allows storage, interrogation and convenient presentation of large amounts of bump testing data. Calibration certificates are automatically created and stored and many different types of reports and graphs can be created for easy interpretation. All this information is then easily accessible for audit and compliance purposes. The Crowcon I-Test allows a fleet manager to do the following: • Change alarm levels on each sensor • Control calibration gas and lot numbers • Set up banners on the display • Set calibration information and store results • Set bump test information and store results • View event and data logs and run reports • Print calibration and bump certificates • Run and print exception reporting • Customise reports and save to databases These are just the main features, but the I-Test has a lot of flexibility and each site manager can determine what’s important for their site. Once these features are set up for the first time the system can then manage an entire fleet of Gas-Pro detectors. For more information contact Crowcon Detection Instruments Ltd, Abingdon, Oxon. Tel: +44 (0)1235 557700 Fax: +44 (0)1235 557718 E-mail: sales@crowcon.com Web: www.crowcon.com

Taking electrical safety to a new level with loto and Marechal sockets The combination of the unique safety features of MARECHAL Electric’s DECONTACTOR™ connector technology and Lockout / Tagout protection offers a dual approach to enhancing electrical safety for staff during maintenance or when moving electrical equipment. Marechal DECONTACTOR™ sockets have become industry’s first choice for ease of connection and disconnection of electrical equipment, including motors and pumps, to and from the power supply. The integral decontactor socket switch is operated on load at the push of a button. This reduces downtime for maintenance, re-positioning of production equipment, etc., because both qualified and multi-skilled staff can operate the socket release button to disconnect production plant. Once released the plug is dead. It is impossible to pull them out live. The potential for danger, however, is always present when production plant and other electrical equipment is scheduled for routine maintenance or indeed has suffered failure. Maintenance staff are under pressure to make repairs as quickly as possible to minimise downtime and get the plant up and running again. This is when safety procedures must be followed to prevent accidents. The slightest lack of concentration can have disastrous effects. Maintenance staff are issued with lock-offs that should be fitted to electrical equipment to prevent that equipment being energised mistakenly during the servicing period. When all work is complete the final lock off may be removed by the duty holder once he is satisfied. Now decontactor sockets can be supplied with a padlocking facility that enables users to comply with LOTO procedures for the increased safety of plant workers. The socket padlock bar when fitted prevents

the socket release button from being pressed which in turn prevents the plug from entering the socket. In this state visible isolation is achieved. It’s also possible to lock-out the plug itself to prevent unwanted re-connection elsewhere. With an industrial switched decontactor range from 20 to 250A and switched ATEX range from 20 to 200A MARECHAL offers a quick disconnect/ isolation/LOTO safety solution for any plant and helps duty holders comply with HSE requirements. DECONTACTORS are robust, watertight devices that offer enhanced electrical performance to keep crucial plant running and maintenance staff safe.

Secure, long-term connection

By providing secure connections and long-term reliability MARECHAL DECONTACTORS are fit-andforget connectors. DECONTACTORS are manufactured with silver-nickel tipped, spring-loaded contacts that resist corrosion and eliminate the risk of cold-welding. Glass fibre-reinforced housings provide robust physical protection in hostile conditions and automatic IP66/67 sealing ensures moisture is kept at bay. The introduction of LOTO-compatible padlocks onto MARECHAL DECONTACTORS marks a new level of electrical safety for industrial sites. This allows duty holders to ensure that the working environment complies with the Electricity at Work Regulations (1989) when human intervention is required. For more information contact MARECHAL ELECTRIC Tel: 01244 851926 E-mail: contact@marechal.com Web: www.marechal.com/en

Available on iPhone and Android devices

New rupture disc detection system Ex d-approved Flo-Tel™ XD represents another industry-first for Elfab Leading rupture disc manufacturer Elfab has introduced the industry’s first Ex d-approved burst detection system, FloTel™ XD. For over a decade Flo-Tel™ has offered customers across a wide range of industries the unique features of ATEX Zone 1, non-invasive, failsafe and re-useable detection when using rupture discs. Working with key customers, Elfab’s engineers have sought to offer a more cost-effective system for key applications, such as LNG. FloTel™ is now fully Ex d-approved, negating the need for intrinsically safe barriers and interfacing directly with the customer’s remote terminal unit, all of which reduces installation costs considerably. As with all of Elfab’s Flo-Tel™ products, Flo-Tel™ XD is a onetime-only installation unit. The system has no moving parts and is

therefore exceptionally reliable. Its method of operation is specifically designed to be fail-safe. Any periodic maintenance checks specified by customers can be carried out by a non-electrically-qualified fitter using the Test-Tel™ installation tool. The Flo-Tel™ sensor fits into the rupture disc holder while a magnet is attached to all Elfab rupture disc products. When the disc bursts, the magnet arcs away from the sensor and produces an open circuit signal. After functioning, only the disc needs to be replaced, saving on both costs and downtime. Elfab’s Opti-Gard™ range of rupture discs was recently tested to over one million life cycles, a service life more than four times longer than the previous industry-best. For more information contact Elfab Ltd, Alder Road, North Shields, Tyne & Wear. Tel: +44 (0)191 293 1208 Fax: +44 (0)191 293 1200 E-mail: pr@elfab.com Website: www.elfab.com

Process Industry Informer October-November 2013

Improve workflow and quality with computer aided engineering A powerful new generation of software is revolutionising electrical engineering design and process engineers are well placed to benefit, says Ken Christie, director of EPLAN UK. At the heart of the new computer aided engineering (CAE) systems is a database which can connect all the different engineering disciplines that are contributing to a project – from process engineering to fluid and electrical engineering - enabling colleagues to work simultaneously instead of sequentially and providing transparent, easily understood documentation throughout the design process.

Streamlining workflow This means that the highly varied and diverse tasks involved in planning process plant projects can be streamlined to accelerate the entire process. CAE provides a seamless, enterprise-wide workflow and improves accuracy by eliminating the possibility of human error that exists when manually exchanging data. As a project progresses, changes are documented and updated instantly and can be seen by everyone involved - all engineers, all departments, the customer and, eventually, even the maintenance team. Crucially in today’s global marketplace, CAE software can effortlessly convert project documentation to a language convenient for customers, vendors and subcontractors, and export it in one of many common file formats including intelligent PDFs and DWG. Using these accessible formats to import and export mark-ups can tighten up the sometimes lengthy process of obtaining and applying customer revisions and gaining approvals. Once a decision is finalised, the CAE tool can automatically generate a complete building package for manufacturing that includes all diagrams, lists and component IDs. If desired, automated setups for Numerical Control (NC) machining and wire processing can be exported as well. Once a project has been completed, CAE systems allow all modified data to be shared with service technicians who can access files on a laptop for quick and mobile troubleshooting. They can even click on a specific part to view its data sheet within the PDF.

Automating design Many projects require a significant amount of recurrent information to be entered. With traditional CAD tools, this tedious task was not only time-intensive, but also prone to error. In contrast, CAE systems allow this information to be inserted into a project with a single keystroke and also automate other time-consuming processes such as device tagging and wire numbering. During the design process, engineers are able to import component data directly from vendor catalogues which saves time, improves accuracy and enables costs to be assessed quickly and a bill of materials (BOM) to be produced. Some CAE systems allow intelligent macros to be created thanks to a powerful database which can contain every type of component from the IEC symbol library, from a simple fuse to information about a PLC. This enables common sub-assemblies like motor drives to be inserted into projects within seconds, generating all wire and terminal numbering. Used at the earliest stages of design, CAE tools enable engineers to be more creative and explore more design concepts than before by merging data with 3D modelling software. These virtual prototypes are invaluable in proving a design before manufacture and also enable faster, more informed decisions to be made as schemes progress through the design cycle.

In practice Fischcon PV, the Dutch-based manufacturer of custom hydraulic packs and firefighting systems used in oil and gas exploration, found that installing a CAE system to optimise parts management accelerated order completions, reduced risk of errors and reduced time spent fulfilling orders by up to 20%. The database was originally stored in the mechanical PDM system used by its mechanical engineers and available only to them. However, because Fischcon´s electrical engineers now work in EPLAN CAE, they were able to establish a bidirectional link so that the database could be accessed by everyone. The benefits of centralised component management include significant financial savings for the company. For one of its larger systems, it has reduced time spent fulfilling orders by about 500 hours per unit, a 20% improvement that translates into annual savings of about A150,000. Similarly, Advanced Machine & Tool Corporation (AMT) switched from a previous provider three years ago and reports that projects are consequently completed in approximately a third of the time. AMT specialises in the building of coiling and winding equipment and other machines used in the production of electric motors, generators, alternators and other devices for the automotive and other industries, much of it for OEMs (original equipment manufacturers). For AMT the engineering phase of fulfilling an order can take as little as three days, or as much as 60 weeks for the most elaborate projects, but a typical order involves a customer wanting a single machine to produce a new motor or for augmenting or streamlining current production. “It might be as simple as adding a machine similar to one they have now, or showing us a product they want to produce and asking ‘How do we manufacture it?’”, says ATM electrical engineer Mark Lohrman. “Using the customer’s prints, mechanical engineering will design the machine, after which the electrical engineers get involved developing the control system.” AMT initially took a conservative approach to implementing the new system, and benchmarked projects to verify productivity gains against time. They found that the automation of many essential, timeconsuming tasks allowed for savings of 23 – 28 hours in a project that would have taken two weeks using their previous supplier. This has been achieved in four main areas: • Device tagging and wire numbering has been automated along with the generation of the actual device tags, wire numbers and terminal tags. AMT engineers use CAE’s internal functionality to set up the printers by transmitting an Excel spreadsheet with all the data, saving four to five hours. • Error-free terminal diagrams and BOMs automatically generated, saving five hours.

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• Standard circuitry is archived and re-used from project to project, saving eight to twelve hours. • Fluid schematics have been integrated into the overall project, eliminating errors with device naming and missed components, saving six hours. “Automatic numbering is a big thing for us, as is parts management,” says Lohrman. “I can go to the parts list

Process Industry Informer October-November 2013

and pick out a part and, if there is a macro associated with it, I am set”. AMT engineers are also able to download component data sets from leading suppliers. “It’s a major time saver not having to go through all the pages of documentation to find out measurements,” says Lohrman.

Selection criteria Not all CAE systems offer the same benefits and companies should consider their future needs when investing. They should also consider the advantages of adopting a modular system which allows further specialist products such as fluid power engineering or piping and instrumentation diagrams to be added on so that businesses can tailor their software to match their developing requirements. The new generation of CAE is revolutionising electrical engineering design by accelerating turnaround times, improving accuracy and allowing engineers to understand, predict and improve product performance at the earliest stages of design. Companies embracing the new technology are well placed to compete in the marketplace. Computer aided engineering is, without doubt, the future of electrical design. EPLAN Software & Services Rotherham, South Yorkshire Can be contacted on: Tel: 01709 704 100 E-mail: info@eplan.co.uk Web: www.eplan.co.uk

instrumentation Available on iPhone and Android devices

NEW HIGH-END VISUAL INFRARED THERMOMETER WITH HIGHER RESOLUTION PLUS ALARMS AND TIME-LAPSE FEATURES

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

PRECISE control of valuable constituents COMPACT footprint for optimal location COMPLETE measuring, controlling or dosing solution

Innovation – Experience – Excellence

1 Kings Court, Willie Snaith Road, Newmarket, Suffolk CB8 7TG T 01223 833222 - E sales@bronkhorst.co.uk - I www.bronkhorst.co.uk

Fluke has introduced the highend Fluke® VT04 Visual Infrared Thermometer, a troubleshooting tool with an infrared heat map which offers higher resolution as well as temperature alarms and time-lapse features. Fluke Visual IR Thermometers combine the visual insight of a thermal imager, the visual images of a digital camera, and the point-and-shoot convenience of an IR thermometer. Compared to the VT02, the Fluke VT04 offers a wider field of view for improved scanning and up-close evaluation and four times sharper images. The Hi/Lo temperature alarm enables hot spots to be found in seconds, and time-lapse functionality automatically monitors equipment over time or automatically captures images after an alarm has been triggered. Images are saved to a micro-SD card, eliminating the need to write down measurements: analysis and reporting software is included. The VT04 instantly detects problems using blended thermal and digital imagery, saving images as full visual, full infrared, or in three blended modes. For more information contact Fluke (UK) Ltd, Norwich, Norfolk Tel: 0207 942 0700 Fax: 01603 256 606 E-mail: industrial@uk.fluke.nl Web: http://www.fluke.co.uk

Process Industry Informer October-November 2013

enclosures

RITTAL’S NEW PC ENCLOSURE Now with even greater security the new PC enclosure from Rittal with integrally moulded side panels and roof, internally glazed door and lockable keyboard drawer provides increased protection against unauthorised access. Fully compatible with Rittals range of system accessories with options of glazed doors, keyboard drawers, desk sections and small to large mounting compartments, Rittal‘s PC enclosure system can accommodate all computer equipment from monitor, computer system, printer and keyboard to the mouse. Providing a Protection category of IP 55 the new PC enclosure based on Rittal’s SE 8, replaces the PC enclosure based on TS 8. The latter will be available from stock for a further 6 months (Rittal Product Lifecycle Policy). For more information contact Rittal Ltd, Rotherham, South Yorkshire Tel: 01709 704000 E-mail: information@rittal.co.uk Web: www.rittal.co.uk

Efficiency – it’s not just about operating energy consumption Rittal’s new TopTherm fan-and-filter unit makes installation and servicing simpler and quicker as mounting on the enclosure, electrical connection, reversal of the direction of airflow and replacement of the filter mat are all possible without the use of any tools. The changeover to Rittal’s TopTherm fan-and-filter unit has been made as simple as possible by maintaining the air throughputs and cut-out dimensions of the previous product range. Original equipment manufacturers, panel builders and end users alike may upgrade to the new fan-and-filter without any change to the metalwork in which it is to be installed. The same may be said of Rittal’s TopTherm Blue e cooling unit, as the cooling outputs, mounting cut-outs and dimensions of the series that it replaces, have been maintained. Improved performance against increased static pressure difference results in an extended filter service life that not only reduces running costs but also saves time due to longer maintenance intervals. RiDiag II is a useful software tool for the TopTherm Blue e cooling unit, allowing the parameters of cooling units to be changed quickly and easily, as well as stored remotely. The RiNano coated condenser in Rittal’s cooling units extends servicing intervals by minimising the adhesion of water, dirt and oil, ensuring a more consistent cooling output for a longer period of time.

RITTAL STAINLESS STEEL COOLING UNITS Rittal now have standard pricing for the stainless steel variants of their cooling units, including those from the TopTherm Generation Blue e range. A selection of wall-mounted cooling units, with nominal outputs in the range 300-1500 W and rated operating voltages of 230 V AC and 400 V AC, are now also available from stock. Cooling units keep the air inside an enclosure below a maximum permissible temperature, which may be even lower than that of the air surrounding it. The ambient air is used to cool refrigerant, which removes the heat from the air inside the enclosure, at a high temperature and pressure. However, due to separate internal and external air circuits, these units satisfy an ingress protection category of IP54 and the air inside the enclosure is simply recirculated preventing the ingress of dust or other contaminants into the enclosure. To lessen their impact on the environment and reduce operating costs Rittal’s TopTherm Generation Blue e cooling units incorporate energy efficient EC fans, revised components in the refrigerant circuit and an energy saving control strategy. The Eco-mode software, which restricts the use of the internal fan, can have a significant impact on energy consumption, particularly in periods when no cooling is required. As a result of the now standard pricing and ready availability of wall-mounted stainless steel cooling units, Rittal can respond quickly to demands for enclosure cooling when standard units do not meet the needs of the application. Equipment destined for, for example, the food and beverage and offshore industries may fall into this category. For more information contact Rittal Ltd, Rotherham, South Yokshire Tel: 01709 704000 E-mail: information@rittal.co.uk Web: www.rittal.co.uk

For more information contact Rittal UK, Rotherham, South Yorkshire Tel: 01709 704000 E-mail: cooling@rittal.co.uk Web: www.rittal.co.uk

data loggers

Tinytag Data Loggers for the process industry The Tinytag range of data loggers includes devices that are ideal for temperature monitoring in process applications. These loggers have a rugged, waterproof and dustproof design, and if required, accompanying probes are available for measuring extremes of temperature, product core temperatures, or for comparison of both ambient and process temperatures. The range includes a thermocouple logger which supports type K, J, T and N thermocouples, providing fast response, versatile monitoring from -270°C to 1370°C. Specialist ATEX validated units are also available for use in intrinsically safe areas. Manufactured in the UK, the Tinytag range includes a wide choice of units for accurately monitoring temperature, humidity, single and three phase power usage, CO2 and other environmental parameters across many industries and applications. Data from the loggers is downloaded to a PC via a USB connection and viewed with easy to use Tinytag Explorer software. For more information contact Gemini Data Loggers (UK) Ltd, Chichester, West Sussex, Tel: +44 (0)1243 813000 E-mail: info@tinytag.info Web: www.tinytag.info

Process Industry Informer October-November 2013

weighing

Introducing the new precia-molen i series of indicators Following years of research and development, weighing specialist Precia-Molen has introduced a new unique family of indicators based on an excellent quality/price ratio. Replacing an existing range of instrumentation the new i series offers high levels of performance with unparalleled technical features.

® With four models (i20/30/35/40) available the new range can accommodate simple vessel weighing, weighing of products, and provision of an interface between the weighing platform and management systems, or integration into any plant process requiring weight measurement. With an increased number of functions available, whilst maintaining ease of use, the new range of indicators provide weighing information to management or automation applications via the latest software tools (USB, Ethernet, Fieldbus), with easy implementation. The new i range has been developed to aid preventative maintenance and remote system monitoring. Innovation and environmental responsibility

Explosion Safety in the Wood Industry More than just a must.

The new range has been specifically developed to limit the carbon footprint with both the FSC LCD display using less energy, and on a ‘like for like’ power consumption the new i range of indicators is 10 times lower than that of the models they replace. Additionally, Precia-Molen selected LifePo4 technology to limit the environmental impact as it is manufactured without the use of toxic elements. The ATEX version presents any risk of explosion in the event of shock or short circuit. Features • IP66 stainless steel housing – wall or table mounting • Extended range of operating temperatures • ATEX version • EC approved 2 x 6,000 divisions with Vmin per division – 0.5µV • Mains power or integrated LifePo4 battery • FSC high contrast LCD colour display (7 background colours) • Configuration by soft-touch keys, or via PC using an internet browser. 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

NEW VIDEO SHOWS CONTROLLED FILLING OF VARIOUS CAPACITIES ON SAME DEVICE

rembe.com

Using the right weighing technology to control the filling process of small and large containers is vital in order to achieve fast and accurate productivity. As a machine and instrument manufacturer you need to be able to fill various size containers using the same machine whilst guaranteeing 100% in-process quality control (IPC). A new video from METTLER TOLEDO shows how easy it is to efficiently verify 100% of your output by integrating fast, compact weighing modules into your filling process. The modules, which cover a large weighing range, provide reliable and accurate in-process quality control of different sized containers on a single filling device. They can be configured for any environment and come with easy-to-use software for a fast start up. IP54 rated for protection against dirt or other particles, makes the weigh modules are ideal for all industrial environments. The video shows how the WMS weigh modules offer a 100%

For more information contact Mettler-Toledo Ltd, Beaumont Leys, Leics. Tel: 0116 235 7070 Fax: 0116 236 6299 E-mail: enquire.mtuk@mt.com

spray nozzles

NEW CATALOGUE FEATURES LARGEST RANGE OF SPRAY NOZZLES

Are you really safe?

The underestimated explosion hazards in wood handling facilities Intelligent protection concepts Speak with the experts – today. for Europe

REMBE ® GmbH Safety+Control 59929 Brilon, Germany T +49 2961 7405-0 | info@rembe.com

for North-America

REMBE ® Inc.

woodworking-55,5x255mm.indd 1

BETE Ltd, the spray nozzle specialists have recently published a new product catalogue which represents the most comprehensive guide ever produced for their extensive range of spray nozzles, spray applications and spray technology. The 129 page catalogue includes a new tank wash section, a new air-atomising nozzle range, an updated spray lance section along with all the new and improved product ranges introduced over the last 6 years. Available on-line or in hard copy, the catalogue covers spray nozzle options for just about any possible spraying application including; full cone nozzles, hollow cone nozzles, flat fan and misting nozzles, tank washing heads, spray lances and spray bars, plus specialist purpose nozzles. Click here to view the catalogue: http://www.bete.co.uk/resource-links/catalogue-group/catalogue-by-nozzle-design Further details or copies of the catalogue are available from: BETE Ltd, Lewes, East Sussex Tel: +44 (0) 1273 400 092 Fax: +44 (0) 1273 401 220 E-mail: Ivan@bete.co.uk Web: www.bete.co.uk

Charlotte NC 28217, United States T +1 704.716.7022 | info@rembe.us

in-process control by weighing all filled vials, which is often required in the pharmaceutical industry today. Watch the free online video and learn more about 100% in process control www.mt.com/ind-filling-ofpharmaceuticals

18.10.13 12:29

Process Industry Informer October-November 2013

F O O D I N D U S T RY F O C U S

Achieving maximum profitability in the food and beverage industry relies heavily on the ability to maintain and further increase manufacturing efficiency and product quality. Phil Burge, Country Communication Manager at SKF, explains how food processing and packaging companies can make significant improvements to production line efficiency.

APPETITE FOR IMPROVEMENT The food and soft drinks industry is the UK’s largest manufacturing sector and has remained strong in the difficult economic conditions that prevail, even as commodity prices have climbed. One reason for this is that, whatever the economic climate, we tend to carry on eating and drinking product of one kind or another. However, it may also have something to do with good installation and maintenance. Food processing and packaging companies understand more than most the vital need to protect production and optimise productivity, and ensure reliable predictive and preventative machine maintenance programmes to avoid delayed deliveries, wasted produce and damaged reputations. In food manufacture and processing, components must perform consistently well under both extreme temperatures and high levels of humidity. Crucially, they must also meet strict hygiene requirements and retain their integrity during often vigorous cleaning processes. An extensive range of bearings and seals has been developed with specialised features that meet these needs, enabling food and beverage manufacturers to maintain and increase efficiency. Manufacturers can also reduce unscheduled downtime by introducing a more controlled, predictive maintenance approach. For example SKF recently assisted a dairy product manufacturer that was experiencing a particularly high incidence of unscheduled maintenance and downtime. This project began with vibration analysis on a number of assets, which identified bearing and pulley drive problems and misalignments that could have developed into serious incidents and yet more damaging stretches of downtime. By first identifying and later replacing drive and bearing components, the plant enjoyed increased confidence in the reliable operation of its blowers, fans, pumps and gearboxes. However, even without an asset optimisation programme food and beverage manufacturers can achieve performance and efficiency gains by, for example, looking at the drive chain. With drives expected to work reliably day upon day (and in some applications around the clock), the best manufacturers are preparing their belts and chains for high performance in extreme temperatures and/ or contaminated environments. Corrosion Resistant Chains in stainless steel or with a protective coating cope with not only aggressive environments where protection is required to withstand the elements but also hygienic applications such as food processing where the surrounding environment needs to be protected from contamination. Heat is a challenge common to food manufacture and processing applications, with bearings and seals continually subjected to extreme temperatures,

exceeding 150ºC in baking, frying and roasting equipment. SKF Y-bearing units have been developed to withstand an extremely wide range of operating temperatures between -150ºC and +350ºC and require little or no lubrication, enabling users to reduce both maintenance requirements and costs. Where temperatures do not exceed 95ºC, Solid Oil bearings, which feature a solid form of lubricant that completely fills the free space within the bearing, minimise the risk of food contamination, as the components are able to withstand considerable centrifugal forces without leaking. At the opposite end of the temperature scale, components are also under considerable stress. Standard seals are generally unable to cope with temperatures inside freezers, leading to equipment failure and downtime, while lubricants can also freeze, bringing production to a standstill. Seals are also damaged by severe changes in temperature, such as when low temperature equipment is cleaned during wash-downs; temperature can change dramatically, causing the air in a bearing first to expand as it heats up and then to contract as the temperature drops again, putting immense pressure on the seal to open up. These intense cleaning processes also present the risk of moisture entering a bearing cavity and corroding the component. However, a range of seal materials have been developed for use in food industry applications, to prevent the bearings being corroded and food being contaminated by leaking lubricant. For example, PTFE is able to withstand extreme temperatures and lubricant-free installations, as it displays low friction levels and will not adhere to a bearing’s counter surface. These seals can also effectively withstand particularly aggressive chemical cleaning, eliminating the problem of flaking and bacteria accumulation. PTFE seals are available in FDA approved compounds, specially designed for reducing contamination in food processing applications.

Take an example… The result of applying these innovations to the food and beverage industry is frequently a massive payback on investment when measured against the cost of maintenance and downtime that would otherwise be incurred. For example Evron Foods who specialises in the manufacture of bakery products for retail, wholesale and beyond, both on behalf of private labels and under its own Easibake brand. The company operates from two sites, one based in Northern Ireland and the other in Wales. At both of these sites, transfer units move trays of product through the ovens to carry out the baking process. These transfer units run on

Process Industry Informer October-November 2013

rollers inside the ovens and four rollers are required for each support station along the way. As there are five support stations in each oven, and therefore 20 rollers, each oven requires 40 bearings. The efficient daily repetition of this process therefore depends greatly on the use of efficient, resilient bearings but Evron were growing increasingly unhappy with the existing bearings that were simply unable to cope with the high temperatures of the ovens and required replacement at a rate of approximately once every three months, causing frequent downtime and lost production. The solution was to use high temperature bearings, which are fitted with a graphite cage that releases minute amounts of graphite powder to lubricate the bearing, offering an excellent dry lubricant option for low-speed, high temperature applications such as ovens. The switch effected a 1000% improvement on the previous bearings and have extended maintenance intervals from three months to almost three years. SKF (U.K.) Ltd, Luton, Bedfordshire Can be contacted on: Tel: 01582 490049 Fax: 01582 848091 E-mail: marketing.uk@skf.com Web: skf.co.uk

F O O D I N D U S T RY F O C U S

Materials and coatings increase operating life of bearings

Dr Steve Lacey, Engineering Manager at Schaeffler UK, discusses the importance of selecting a special surface coating or corrosionresistant material for rolling, plain and linear bearings operating in harsh food and beverage environments.

In the food and beverage industries, production is typically based on highly automated, fast moving processes and systems, where every second of production counts. In these operating environments, unscheduled production downtime is a crime and so processes, systems and individual machine components such as bearings must be energy efficient, cost effective and capable of withstanding harsh, often highly corrosive conditions. When selecting bearings for these applications, robust, reliable bearings are often required, with corrosion protection, sealing and lubrication for continuous operation. New materials and surface coatings for bearings are constantly being developed by suppliers, which can provide even higher levels of protection and even longer operating lives.

Bearings to suit every application A wide range of bearings are available to suit most types of food and beverage applications. Schaeffler, for example, offers deep groove ball bearings, radial insert ball bearings, plain bearings, housed units, track rollers, slewing rings, ballscrews and linear guidance systems.

Deep groove ball bearings in a bottle labelling machine

For harsh food and beverage environments, bearings should fulfill several key principles: compact design; maintenance-free operation; reliable, long operating life; modular components and sub-systems matched precisely to each other; and minimum number of interfaces through functional integration where possible.

Special materials and coatings While standard, catalogue bearings may guarantee the customer optimum performance and a long service life, in many food and beverage environments, a standard bearing material or coating may need to be upgraded in order to prevent wear or corrosion of the bearing and to improve the service life. Coatings can be applied to the surfaces of rolling bearing components without forming a material bond, for example, by diffusion between the coating and base material. In many cases, it is sufficient to coat only part of the bearing or one of the parts that come into rolling contact. A good bearing supplier will be able to advise the customer when a coating is appropriate for a particular bearing and what type should be used in certain applications. As well as offering special corrosion-resistant coatings, some suppliers can also provide corrosion-resistant materials for rolling bearings that enable their products to operate in corrosive environments. While standard steel bearing materials provide satisfactory corrosion resistance in many applications, for higher performance requirements, highly corrosion-resistant, nitrogen alloyed martensitic HNS (high nitrogen) steels are recommended. These types of steels provide maximum corrosion resistance under extreme operating conditions, including dry running applications or when bearings come into contact with aggressive media such as water, salt spray, acids and cleaning chemicals. Schaeffler’s own Cronitect® steel, for example, is a highgrade martensitic hardening steel that is based on the consistent refinement of high-grade corrosion-resistant

steels. Through its unique composition and new thermochemical surface layer treatment process, this material achieves an extremely high hardness. Even after 600 hours of Radial insert bearing protected salt spray testing against corrosion by Corrotect® in accordance with DIN 50021 SS, the material shows no signs of corrosion. The heat treatment process optimises the surface zone and core properties of the base material. This produces a hard, wear-resistant surface zone with very high corrosion-resistance and a tough core. The material is therefore suitable for a wide range of industrial applications, particularly food and beverage processing such as filling plants, fish processing and poultry production.

beverage processing plants, can also be protected with various coatings in order to prolong their operating life. The housings and insert bearings can be corrosion protected and the housings themselves can also be made from a corrosion-resistant (stainless) sheet steel or plastic (e.g. glass fibre reinforced PBT).

Bearings can be provided that combine conventional stainless steels such as AISI440C for the rolling elements with corrosion-resistant rings and bearing seals. In these configurations, the focus is on extended life under insufficient lubrication and on emergency operating features. These types of materials can significantly increase the availability of machinery, providing extended maintenance intervals. For example, bottling plants would typically need to replace all their AISI440C rolling bearings that come into contact with cleaning detergents, every four months. With Cronitect® bearings, this interval can be doubled.

Linear guidance systems

In a recent cam control solution for a bottle capping machine company replaced its original solution – a standard stud type track roller immersed in an oil bath – with a roller stud, Cronitect outer ring, corrosion-resistant steel balls and an HRS seal. This improved solution requires no lubricating oil, has extremely high resistance to corrosion and aggressive media, while presenting no risk of contamination of foodstuffs. This has resulted in improved hygiene, reduced maintenance costs and higher machine availability.

Ceramics and plastics Other special bearing materials are available from suppliers, including ceramic rolling bearing components, which provide excellent characteristics for certain applications. Silicon nitride balls, for example, are light and offer a longer operating life than standard steel ball elements.

Plastic housings are highly resistant to moisture, UV radiation, bacterial and fungal attacks, as well as many chemical media. These bearing units are used predominantly as locating bearings, but are also suitable as non-locating bearings under low loads and speeds.

Track rollers Due to their numerous technical advantages, track rollers generate added economic benefits for machine operators, for example, in bottling and filling plants. Track rollers require little installation space and operate reliably with low wear. They also have large grease reservoirs and effective sealing, which means relubrication is seldom required. As well as rotary bearings, linear bearings and guidance systems are commonly required in food and beverage production. Examples include shaft, track roller and monorail guidance systems; linear recirculating ball bearing units; miniature guidance systems; linear actuators and linear tables; ballscrews and planetary roller screws.

Dynamic linear ball bearing & guideway assemblies

Some suppliers now offer linear accessories in the form of ‘kits’ that include a variety of linear components such as front and additional wiper seals, sealing strips and long term lubrication units. These types of accessories help to protect the guideways from contamination, providing long relubrication intervals, ensuring that lubricant is provided where and when it is needed.

Slewing rings

Ceramic balls make rolling bearings lighter & more durable

High performance plastics such as PEEK can also be used for bearing components operating in corrosive environments. PEEK is resistant to high temperatures and, depending on the load, is suitable for operating temperatures of up to 250°C. The wear resistance is strongly influenced by the filler materials and is significantly better than that of the standard material PA66 with glass fibre reinforcement that is often used for bearing cages.

Plastic & stainless steel housed bearing units Housed bearing units (e.g. flanged, take-up and plummer block designs), which are commonly found in food and

High performance capacity slewing rings In bottling and filling plants, larger bearings are often required. The load carrying capacity of large slewing rings is needed to provide secure bearing supports for filling machines, star wheel transfer units or bottle rinsing machines. These damp, aggressive operating environments require highly reliable slewing rings. Schaeffler (UK) Ltd, Sutton Coldfield, West Midlands Can be contacted on: Tel: 0121 313 5870 E-mail: info.uk@schaeffler.com Web: www.schaeffler.co.uk

Process Industry Informer October-November 2013

conveying & weighing equipment

size reduction technology

Spiroflow’s top-notch testing steers customers in right direction

LOOKING FOR BESPOKE MACHINES? WHY NOT TRY GLEN CRESTON! LEADERS IN SIZE REDUCTION TECHNOLOGY

Very few people would buy a new car without a test drive, or a house without at least one visit and evaluation. So why would a manufacturer make a significant investment in new capital machinery without having the chance to test it? Spiroflow Ltd – renowned for its unrivalled product range and superior standards of customer service – is one of the few suppliers of conveying and weighing equipment to offer a full state of the art testing process prior to purchase. Spiroflow believes that customers should have complete confidence in the efficiency of their new systems, regardless of the level of investment. The world-leading manufacturer of conveying and weighing systems actively encourages customers, old and new, to use the fully equipped test centre at its Conveyor Lancashire site before purchasing any of its Flexible Screw Conveyors, Aero Mechanical Conveyors, Tubular Cable and Chain Drag Conveyors, Vacuum Conveyors, Bulk Bag Dischargers, Bulk Bag Fillers or Ingredients Handling and Weighing Systems. Whether the equipment is required for efficiently conveying food ingredients such as flour, cereals and coffee granules or accurately controlling the flow of materials for the chemical and water treatment sectors, high quality testing facilities like those at Spiroflow can reassure customers that the systems they are planning to invest in will provide optimum performance and offer value for money. Spiroflow says that carrying out thorough throughput and degradation trials using its conveying, bulk bag filling and discharging technology - replicating the client’s working conditions including temperature and humidity - can iron out any flaws and ensure each system will meet requirements. Spiroflow works closely with the customer on the testing, sharing the results for analysis and, if necessary, conducting follow-up tests. Offering this outstanding level of customer service is part and parcel of the Spiroflow experience and is one of the reasons why companies in the food, chemicals and process industries return again and again to Spiroflow for their filling, discharging and conveying needs. Spiroflow’s After Sales Manager, Jeanette Carter, explained: “We offer a comprehensive testing and installation facility because we want to make sure the client is buying the right equipment for the product. Once we have a guideline from the customer, a dedicated test engineer will set up the trial in accordance with those requirements. He will also make additional recommendations if he believes it will improve the process. “For example, if we set up a system with a spiral conveyor and the product is smearing or sticking to the tube wall, we can change the profile of the spiral to achieve the result the customer is looking for and the throughput requirement that they are aiming for as well. We can monitor changes to bulk density during conveying or assess the effect of conveying at very steep angles. Obviously we are also careful to ensure safe working practice and satisfy COSHH and ATEX regulations.” 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. Underpinning this high quality equipment is Spiroflow’s willingness to invest in a modern testing facility as part of its first-class customer support. To learn more about ‘Spiroflow’ Flexible Screw Conveyors, Aero Mechanical Conveyors, Tubular Cable and Chain Drag Conveyors, Vacuum Conveyors, Bulk Bag Dischargers, Bulk Bag Fillers or Ingredients Handling and Weighing Systems visit their website at www.spiroflow.com or call them on +44 (0) 1200 422525 to discuss your specific requirements.

For preparation of larger laboratory samples or for light industrial applications, Glen Creston offers a range of ‘bespoke’ machines that can cope with higher throughputs whilst still producing reasonable small particle sizes. From our Jaw crusher, for primary sample breakage prior to further processing, to the McCrone Mill, which will grind to analytical fineness, these machines can cope with a wide range of materials from rocks to edible grains. Glen Creston also manufactures special machines for sample processing production needs. These machines are designed for processing anything from small samples to larger scale continuous flows for industrial applications. The Roller Crusher Mill is one machine from our range of laboratory and pilot scale/ light industrial equipment. Glen Creston have improved the design and function of the Roller Crusher: • It can be supplied with a new control box with PLC which allows remote monitoring and control of the crusher in process applications. • The largest single shaft unit is now 800mm long by 500mm wide internally and designed for crushing lump coal up to 250mm. High temperature versions are available for crushing power station ash at up to 250 degrees centigrade • This rugged, slow-running mill is equipped with either a single or double roller shafts fitted with crushing cams which rotate between crushing and stripping combs. Different shaped crushing elements are available depending on material. This machine is particularly suitable for de-agglomeration of materials from sacks or silos, pre-crushing softer minerals and for granulating coarse lumpy, caked or compacted materials. Features include: • Robust construction • Minimal maintenance • Compact design allows retro-fitting into existing process lines. • Parts easily removed for maintenance/repair Suitable for: • Pigments and Resin • Food and Pharmaceutical • Coal • Waste materials and Ash • Minerals

OPERATING PRINCIPLE /CONSTRUCTION The wear resistant steel crushing cams are mounted on the roller shaft in staggered positions, accurately spaced so that they pass between the crushing and stripping combs which are mounted laterally on opposite sides of the inner housing. For further information on Glen Creston ‘bespoke’ equipment please contact E-mail: enquiries@glencreston.com Tel: +44 (0) 208 545 9140 Web: www.glencreston.com

crushing & grinding

CROSS BEATER MILL This compact yet powerful mill is designed for crushing and grinding all types of materials up to the mediumhard range within a variety of industries, including construction, environmental, mineral, chemical, agricultural and ceramic. The mill is available with a variety of options including chamber and door linings in cast iron, chrome steel or stainless steel, beater arms in cast iron or stainless steel and beater tips in chrome steel, stainless steel and low chrome. OPERATING PRINCIPLE - The material passes from the

A versatile mill for universal use in laboratory and production areas

hopper into the grinding chamber where it is pulverised between the hard grooved door and chamber linings. Added impact is provided by the tips of the three rotating beater arms. Interchangeable screens determine the final particle size. CONSTRUCTION - The housing is of heavy duty cast iron. The grinding chamber lining and door lining are available in cast iron, chrome steel and stainless steel. Beater arms come in cast iron and stainless steel. Beater tips are available in chrome steel, stainless steel and low chrome. Cast iron is very hard, and most frequently used. Chrome steel is usually selected for grinding abrasive materials. Stainless steel is used for applications demanding improved chemical resistance, as well as for food and

Process Industry Informer October-November 2013

pharmaceutical applications. Fitted with 1.1kW brake motor; starter and overload safety cut out plus door safety switch. • Maximum Feed Size: 10 mm • Final Sample Size: (depending on material) down to 50 microns • Throughput: 200g batches up to 50Kg/h • Dimensions: W600mm x D700mm x H1150mm • Gross Weight (with stand) 80kg For more information about Glen Creston products please contact: E-mail: enquiries@glencreston.com Tel: +44 (0) 208 545 9140 Web: www.glencreston.com

F O O D I N D U S T RY F O C U S

Meeting the requirements for ‘lead free’ products in hot water supplies in the food and beverage sector Continued concerns over the presence and effects of lead in water supplies to food and beverage production facilities has driven a raft of local, pan-European and global legislation and guidelines on maximum lead content in water. This issue has placed manufacturers under continued pressure to create solutions for the components of water processing equipment which minimise lead content. Dave Whelan of Norgren discusses the requirements and developments in technology being made to meet them Manufacturing and production in the food and beverage sector requires an understanding of the materials that will be in contact with food and the levels of lead within them to minimise the risk of contamination and therefore of harm to the end consumer. Essentially, food contact materials are products that are intended to be in contact with food and beverages in processes ranging from fruit and vegetable growth, harvesting and transportation, to the manufacture of confectionery and beverages such as beer, wine, as well as sauce, dressing and oil production. Obvious examples include a glass bottle or a soft drinks can, but food contact materials also include machinery in food factories and its components. More sophisticated packaging means a variety of materials could be in contact with the products at the same time, such as plastic, rubber, paper, aluminium and other coatings. For legislative purposes, areas within production facilities are split into a number of categories, depending on the levels of potential contamination. Food areas are defined as product-contact areas, while splash areas refer to surfaces across which food may splash but will not return to the product being manufactured. Products specified for usage in any of these areas must be washable, disinfectable, corrosion resistant, non-toxic and non-absorbent. Ensuring that water supplies used throughout the process of food or beverage production are, as far as possible, lead-free is crucial to guarantee that products leaving the facility do not contain harmful levels of lead and so are safe for the consumer.

You can’t be too careful… There is a wide range of legislation governing pan-European guidelines on the maximum lead content allowed in water, but it is important to bear in mind that this varies from country to country. Local codes of practice differ widely. It is also crucial to note that manufacturing requirements and standards are often individual and bespoke, and determined by tailoring the best solution with the customer’s requirements. Similarly, the processes and chemicals used for cleaning

will vary from plant to plant, although an improved focus on cleaning is pan-European. Regulations to ensure food safety are key, as during the production process, molecules can migrate from the food contact material to the final product. The EU Drinking Water Directive (1998) lays out the requirements in exacting detail, and is accompanied by the World Health Organisation’s 2006 Guidelines for Drinking Water Quality, and the 2011 EU Directive Plastic Materials for Food. Ever more stringent legislation continues to rightly put component manufacturers under pressure to create solutions for processing equipment which minimise lead content. In Germany, for example, the maximum allowable amount of lead in water has reduced from 0.040mg/l in 1990 to 0.025mg/l in 2003, and will reduce further to 0.010mg/l later this year. Calculation of likely contamination is generally considered in terms of the area of wetted surfaces which come into contact with metallic materials. This has driven a number of key technological breakthroughs in the area of system components in recent years, each of which perform significantly better in key areas – in particular, in minimising the potential for lead contamination within wetted surface contact areas. Stainless steel is regarded as a very safe option, with strong corrosion resistance and does not require the wetted surface calculation, but is generally expensive, while question marks remain over the quality of die casting and surface finish achievable. Another option is ‘lead-free’ brass which has a significantly lower lead content than the typical 5% found in leaded brass, but even that, at typically 0.1%, is nowadays still considered excessive. Calculation of the wetted surface is problematic as it applies to the average lead content of the entire wetted system, including all valves, fittings and pipework. Again, there are uncertainties over machinability, with the possibility of cross-contamination within the machining facility, meaning dedicated equipment is needed, while by no means can it be considered a ‘best cost’ option. The most recent innovation in material development in this sector is high-tech polymer. Capable of performing at high temperatures, it requires no wetted system calculation and meets all current legislative standards. As a cost-effective option, it can cope with a variety of challenging operating conditions, meeting all panEuropean legislative requirements, and can be cost-effectively produced in high volumes, with very tight tolerances in terms of surface finish achievable. Norgren Limited, Lichfield, Staffordshire Can be contacted on Tel: 01543 265000 E-mail: advantage@norgren.com Web: www.norgren.com/uk/foodandbeverage

Process Industry Informer October-November 2013

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PROCESS ANALYTICAL SOLUTIONS

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Speed

Unlimited connections

The complete isolation safety package from MARECHAL® MARECHAL® DECONTACTOR™ sockets have become the first choice for ease of connection and disconnection of electrical equipment, including motors and pumps, to the power supply. The integral socket switch enables equipment to be connected and disconnected on load at the push of a button. This reduces downtime for maintenance, repositioning of production equipment etc. because both qualified and multiskilled staff can operate the socket release button to disconnect plant. Once released the plug is dead. DECONTACTOR™ sockets can be supplied with a padlocking facility that enables users to comply with LOTO procedures for the increased safety of plant workers. The socket padlock bar when fitted prevents the socket release button from being pressed thus providing visible isolation. It’s also possible to lock-out the plug to prevent unwanted reconnection. TECHNOR ITALSMEA is a leader in the design and manufacture of luminaires, enclosures and electrical panels for potentially explosive atmospheres. More information on technor.com

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