Process Industry Informer October 2018 by Process Industry Informer

OCTOBER 2018

www.processindustryinformer.com

Volume 14 No.5

THE UK’S LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

Manufacturing

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Contents

FEATURED ARTICLES WWEM 2018 to focus on the hot topics

PRODUCT SECTIONS

PAGE

NEWS & EVENTS

04 – 08

APPLICATIONS

09 & 10

Test & Measurement

WELDING & CUTTING

BPMA NEWS

PUMPS & VALVES

Pros and Cons of Cooling Tower Power Transmission Technologies

21 – 28

PROCESS MEASUREMENT & INSTRUMENTAL

Heat Transfer & Energy

PIPING SYSTEMS

EXPLOSION SAFETY

TANK CLEANING

FILTERATION & FABRICATION

SHAPA NEWS

Look for the right balance of initial cost versus lifetime cost

32 & 34

SENSORS

A world of environmental monitoring under one roof

A smart approach to compressed air maintenance

Regular Calibration Keeps Quality High and Costs Low in the Food Industry

39 – 47

The argument for Canned and Mag drive pumps

Manufacturing switches on to light as a service

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ART DIRECTION Louise Brooks & Milana Veselinovic

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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 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 items 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 the 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.

October 2018 – Process Industry Informer

NEWS & EVENTS

Fulton Training Course Achieves CPD Certification

Fulton has achieved CPD Certification for its Vertical Tubeless Boiler Operation & Maintenance course.

call-outs to ‘boiler breakdowns’ that require no more than the simple flick of a switch to resolve.

Commenting, Jeff Byrne says: “Fulton has always promoted the benefits of operator training and CPD Certification adds real value to our course offering.”

For further information contact Jeff Byrne, Fulton Ltd, Bristol Tel: 0117 972 3322 Fax: 0117 972 3358 E-mail: training@fulton.co.uk Web: www.fulton.co.uk

Designed for boiler operators, the course covers basic day-to-day operation and monitoring of steam boilers and provides employees with the knowledge required to monitor boilers and ensure they are running efficiently and safely. It also includes training in operational procedures, daily blowdowns and the checking of water levels, alarms, etc.; as well as examining the importance of correctly treated feedwater and what boiler inspectors will look for during routine insurance inspections. Training is proven as being invaluable and provides operators the knowledge and ability to handle more of their own maintenance and repairs and avoid

Make your business more competitive by switching to robots

ABB Robotics seminar and workshop for UK SMEs explains how investing in robots can help transform performance. ABB demonstrated how robots can help UK SME manufacturing companies to become more productive and competitive at its forthcoming Switch to Robots seminar. This was taken at ABB’s Milton Keynes site on Wednesday 17th October 2018, the event provided a simple step-by-step guide to introducing robot automation to the factory floor. The seminar provided a step-by-step guide to the key issues around specifying, installing and operating a robot, including how to assess which processes can be automated and how to develop the right solution for your needs. Other topics covered included how to calculate the potential return on investment that can be achieved in different types of applications and how to make the case for an investment to your Financial Director.

There was also be a hands-on workshop session in ABB’s training centre, providing the opportunity to see and use some of the latest robot technology, including ABB’s RobotStudio offline programming software, which helps to greatly reduce the time and cost of setting up a robot system by enabling robot cells to be modelled and tested off-line.

“UK manufacturers are struggling to keep pace with other leading nations that are able to quickly produce high-quality goods at low costs. For UK SMEs to remain competitive they must embrace digital technologies to increase their productivity,” says Mike Wilson, General Industry Sales Manager for ABB Robotics in the UK and Ireland. “Our Switch to Robots event has been designed to help businesses to easily identify whether a robot could be beneficial and explain the steps they need to take in specifying and installing the best solution for their requirements.” For more information please contact: Michelle Jocelyn ABB Robotics and Motion, Tel: +44 (0)1908 350 300 E-mail: michelle.jocelyn@gb.abb.com Process Industry Informer – October 2018

NEWS & EVENTS

CooperÖstlund Ltd awarded UK installation agreement by Bowman Power

Bowman Power Group Ltd (Bowman) has signed an agreement for CooperÖstlund Ltd(CooperÖstlund) to be their preferred installer of Electric Turbo Compounding (ETC) products for gas engines in the UK. CooperÖstlund will act as Bowman’s sole preferred UK installer of this energy efficiency technology for all Natural Gas, Landfill Gas and Biogas applications. In addition, CooperÖstlund will have the ability to sell and supply Bowman’s ETC products to their existing and prospective customer base. Bowman will continue to work directly with engine and genset original equipment manufacturers; and in cases where customers have existing UK installer partnerships, they can retain these if required. Installations outside of the UK will continue to be performed by Bowman or select partners. Paul Dowman-Tucker, CEO of Bowman, said “Thanks to CooperÖstlund’s highly capable and broad field engineering resources, they will play a key role in helping us fulfil the high levels of interest in our ETC technology in the UK. Their existing involvement with some of our customers, and first-hand experience of a wide variety of engine types, makes them the ideal partner to help us expand our UK operations.”

Dry hopper supplier launches lowinterest leasing to accelerate uptake by micro-brewers Hoptimiser, a business division of Torqueflow-Sydex Pumps, is now offering a low-interest leasing option on its Rolec DH/Hopnik® dry hopper technology.

The lease, which is usually in place over a period of 2-5 years, is a well-proven way to finance equipment purchases without the need for capital outlay.

By leasing the Rolec DH/Hopnik® dry hopper instead of buying it outright, brewers can immediately reap the benefits, without the capital cost. The Rolec dry hopper technology – which is now deployed at sites across the UK – enables brewers to deliver consistent flavour and quality, whilst using up to 40 per cent less hops.

David Lee, Managing Director of TorqueflowSydex Pumps and the Hoptimiser brand, comments: “This is a great opportunity for breweries that are struggling to find the funds to upgrade their equipment to put in place the latest technology without delay. We urge brewers to consider this route as a means of securing the operational savings enjoyed by so many of our Rolec DH customers.”

Duncan McPherson, CEO of CooperÖstlund Ltd, commented “We are very excited to have been appointed as Bowman’s preferred UK installer. The reliability and maintainability of their products is very high, and one of the reasons we feel comfortable taking on this role. Ultimately, we see huge potential for their innovative ETC technology to bring energy efficiency uplifts and reduce emissions for our customers.”

Brewers interested in making the transition to the Rolec DH technology can do at a low monthly cost to their business. For example,payments for the Rolec DH45 will start from as little as £243.53/month or £56.20/week.

Bowman is currently negotiating two major UK projects that CooperÖstlund will be central to delivering.

Finance is provided by leading provider Portman Asset Finance and is regulated by the FCA (Financial Conduct Authority).

For more information contact Bowman Power Group, Tel: 023 8023 6700 Email: MEssex@bowmanpower.co.uk Website: www.bowmanpower.com

Fish Lice Get a Battering With Help From Katronic Katronic non-invasive, clamp-on flow metering has been used to monitor water flow within a leading fish farm. Ocean Matters is a pioneering business, offering a sustainable and eco-friendly approach to minimise the use of medicinal chemicals in salmon farming. They breed lumpfish, or lumpsuckers, a ‘cleaner’ species that just loves to pick the sea lice from farm salmon, eating up to 100 at a time. They happily coexist with the farmed salmon, and significantly reduce the amount of chemicals required to successfully rear them. At Ocean Matters’ bio-secure facility in North Wales, nothing is left to chance, and the movement of water between the fish tanks and filtration systems is monitored using a portable Katronic KATflow 200 portable flow meter. Simply clamped on to the PVC pipes, the battery

For complete peace of mind, the Hoptimiser team will even provide a warranty for the length of the lease, in the unlikely event that any maintenance issues arise. The company provides full turnkey solutions for a range of pumping and process engineering requirements.

For more information contact Torqueflow-Sydex / Hoptimiser E-mail: info@hoptimiser.com Web: www.hoptimiser.com

powered KATflow 200 can be fixed and then moved so it both monitors and logs the flow of water throughout the process. Katronic equipment operates ultrasonically, firing an acoustic pulse through the wall of a pipe using a pair of compact transducers, comparing the time taken for the pulse to reflect from the pipe wall both upstream and downstream to derive a flow rate. Commenting, Ocean Matters Farm Supervisor Dave Jones, said, “We have been really pleased with both the simplicity of operation of the Katronic meter, and the support we received from the office in Coventry. Key for us was that the meter worked well on our PVC pipes, and it has been excellent.”

Katronic non-invasive clamp-on metering worked perfectly on Ocean Matters PVC pipes.

For more information contact Katronic Technologies Ltd., Coventry, West Midlands Tel: +44 (0)2476 714111 E-mail: info@katronic.com www.katronic.com

I/O FOR THE MOST EXTREME CONDITIONS WAGO’s I/O system, 750 XTR, is extremely weather resistant and can operate from -40 °C up to +70 °C, making additional heating or cooling equipment unnecessary. It is highly resistant to electromagnetic interference as well as insensitive to vibrations and impulse voltages up to 5 kV, ensuring secure communications in demanding applications. With up to 16 channels in a 12 mm wide housing it requires less space, and has lower energy and maintenance costs; taking automation into extreme environments. To request a catalogue call 01788 568 008, e-mail ukmarketing@wago.com, or visit www.wago.com October 2018 – Process Industry Informer

NEWS & EVENTS

WWEM 2018

to focus on the hot topics

The organisers of WWEM 2018, the water, wastewater environmental monitoring event, have published details of a comprehensive programme of conferences, seminars and workshops that will take place during the 2-day (21+22 Nov) event in Telford (UK). Covering testing issues such as microplastics, nutrients and herbicides, the event will cover all of the most topical subjects in water and wastewater analysis and monitoring. Many of these presentations are free to attend; as is the international’ exhibition that accompanies them. The main purpose of the WWEM events, which began in 2005, is to provide the latest information on the regulations, standards, methods and technologies that relate to the testing and monitoring of water and wastewater. By bringing the whole sector together, including laboratory, online and field monitoring, the WWEM events provide a unique learning opportunity. As a focused event, visitors are able to meet regulators, accreditation organisations, members of Standards committees, academics, researchers, method developers, instrumentation experts and a wide variety of monitoring practitioners with environmental responsibilities.

Registration for WWEM 2018 is now open All pre-registered visitors will benefit from free parking, refreshments and lunch, in addition to free entry to AQE 2018, the co-located air quality and emissions event. Visiting without pre-registration will cost £20/day. The WWEM 2018 Conferences are CPD certified and with such a large selection of Conferences, Workshops, Seminars and a major international Exhibition, visitors are advised to plan their trip in advance.

Day 1: 21st November 2018 An Analytical Conference, (£75 + VAT) organised by the Standing Committee of Analysts (SCA), will be introduced by Prof K Clive Thompson who will describe the history of the SCA and outline future potential. An impressive list of eminent and highly experienced speakers will then address some of the most topical analytical issues. In addition to sampling and information requirements, the presentations will address issues such as the analysis of inorganics and metals, as well as the stability and uncertainty in organics analysis. The chemical analysis of soils and associated materials will also be discussed. The evolution of drinking water microbiology will be described, in addition to the role of on-line water quality monitoring in the production of high quality tap water. The WWEM monitoring conference (£75 + VAT) will address some of the hottest topics in this sector, including on-line and at-site analysis, as well as the detection, counting and monitoring of microplastics. Following the ‘Blue Planet effect,’ the tide of public opinion on plastic waste and marine litter, is starting to turn, with inevitable political, and ultimately analytical consequences. Potential solutions to these challenges will be described in detail by Dr Andrew Mayes from the University of East Anglia, and Dr Claire Gwinnett from the University of Staffordshire. This will be followed by presentations covering online and at-site analysis in common environmental applications including, for example, real-time aquifer monitoring

for shale oil and gas extraction. Improved and novel analytical solutions will be described including automated on-line monitoring for laboratory-grade monitoring of pollutants, and buoys fitted with smart sensors. Some of the new analytical techniques being covered include ion selective field effect transistors, on-site spectrometry, droplet- based microfluidic sensors, trace analysis of engineered silver nanomaterials, simple techniques for N and P with TOC, and the measurement of 5-day BOD in just 48 hours. The Flow Forum Conference (free to attend) will include presentations from industry experts covering themes such as the maintenance of flow measurement equipment, and flow control and management, as well as providing an update on the latest developments in flow measurement. The Pump Centre Conference (free to attend) is entitled: ‘Delivering BIM – Using Product Data across the UK Water Industry for Enhanced Efficiencies in Capital Delivery and Asset Management.’ As the UK water industry increasingly embraces BIM Level 2 during AMP 6 and AMP 7, there will be an increasing need for bespoke water industry product data templates. These will allow manufacturers to transfer product information in a digital format and in turn allow owner operators to directly import vital product information into their asset management system. This conference will provide an insight in to how this process works and what data templates have been created.

Process Industry Informer – October 2018

NEWS & EVENTS The Engineering Futures Launch Initiative was created to help micro and small businesses to attract apprentices. The objective is to provide an affordable brokering service to partner enterprises with local schools, colleges and universities to help level the playing field. Effectively under the scheme, Engineering Futures becomes an extension to each micro or SME compiling and presenting on behalf of each company, thereby substantially increasing their chances of attracting the right candidates. It is believed that the initiative could save enterprises over £3,000 per vacancy fill, in comparison with traditional recruitment. A further 20% discount will be offered to companies that sign on at WWEM 2018. The WWEM Workshops (free to attend) on Day 1 have been mainly organised by WIPAC (Water Industry Process Automation Control). Running throughout the day in rooms located within the Exhibition Hall, the workshops will cover a wide variety of themes including the measurement of flow and water quality as well as communications and data management.

Day 2: 22nd November 2018 The WMSOC Conference (£75 + VAT) will run in the morning of the second day, and is entitled Rapid Microbiology Practical Applications. Organised by the Water Management Society, this conference will provide the latest advice on testing for Legionella and other waterborne pathogens. The speakers will share their experience in testing and monitoring techniques as well as outbreak management, with real-world case studies. The WWEM monitoring conference (£75 + VAT) on day 2 will address a number offield and laboratory sampling and analysis themes. The first speaker, for example, will be Prof Gary Fones of Portsmouth University, who will describe the use of a passive sampler for monitoring pollutants such as herbicides in rivers. This will be followed by a presentation on automated sample preparation and GC-TOF for SVOC and pesticide analysis.

The flow monitoring themes will include primary measurement devices, electromagnetic sensors, area velocity, radar, ultrasonic level and thermal mass flow measurement. Chemical analysis presentations will include ammonia, chlorine, turbidity, dissolved oxygen (and aeration control) and free cyanide detection in effluents. A PROFIBUS Workshop is being organised by PI UK, an organisation which[ promotes the use of PROFIBUS in the UK. More recently it has added PROFINET and IO-Link to the range of technologies supported by the group and is now known as PROFIBUS and PROFINET International UK, or PI UK for short.

The SWIG conference (£75 + VAT) is entitled: Industrial discharge monitoring Smart water: extracting value insights from data. There has been increasing awareness of the work by the Environment Agency to implement the polluter pays; principle, which is also at the heart of current government plans for a green Brexit. The aim of the morning session is to provide industrial dischargers, water companies, contractors and instrumentation providers with an update on systems which ensure compliance and deliver benefits from discharge monitoring. For example, Matt Dibbs from Meteor Communications will demonstrate remote water quality monitoring systems that can be deployed on sites without the need for power or data connection. The afternoon session will explore the way that insights and value can be extracted from the huge amounts of data that is either already available or that will be generated by future deployments. The presentations will include an outline of a large scale water quality monitor deployment in Southern Water’s clean water distribution network. The PROFIBUS Workshop (free to attend) will continue on day 2 as outlined above, and some of the WWEM Workshops from Day 1 will be repeated on day 2 – see www.wwem.uk.com for details.

International Exhibition The WWEM 2018 Exhibition will feature organisations from around the world, offering an opportunity to see the whole sector in one place. There will be almost 150 stands representing more than 300 of the world’s leading providers of testing, analysis and monitoring equipment, and related services. Organised by the Environmental and Food Analysis Special Interest Group (EFASIG) of the BMSS, a series of presentations will address the screening of wastewater. Speakers will cover recent advances in Ion Chromatography, Mass Spectrometry and online monitoring of VOCs from waste effluent by GC-FID and GC-TOF MS. Advanced deconvolution tools will be described for improved GC/MS identification rates. The screening of pharmaceutical and other medicinal compounds within environmental samples will be explained in addition to a rapid measurement of FOG (Fat, Oil and Grease) from wastewater using bench-top NMR. Later in the afternoon, taste and odour challenges will be addressed, with a description of the worlds most sensitive detector, and then speakers from IME, University of Chicago will describe a ‘cyberphysical’ sensing system in India monitoring high frequency temporal and spatial variation in river water quality parameters. October 2018 – Process Industry Informer

The WWEM exhibition offers free entry for pre-registered visitors, but for the first time, it will be co-located with AQE 2018, which means that visitors will be able to walk freely between the two events. Commenting on the 2018 line-up, WWEM Event Manager David Hellyer says: “It is difficult to think of any major brand in this sector that is not represented in the Exhibition Hall. However, it is also very gratifying to note the number of new and emerging companies that are also participating, so this will be a great opportunity for WWEM visitors to find out about all of the latest technologies, methods and techniques that have been developed since the last WWEM event in 2016. In addition to the updates on regulations that will be provided by many of the conference speakers, both the WWEM and AQE exhibitions will feature a ‘Regulators Stand’ providing help and advice from the regulators of England, Wales, Scotland, Northern and Southern Ireland.

A SWAN Workshop (Smart Water Networks Forum) will bring together key players to collaborate and accelerate the use of data-driven solutions in water and wastewater networks. Visitors to this workshop will: gain insights on the most pressing, water service challenges; learn about the latest, integrated smart water and wastewater solutions; hear real-life water company case studies and engage with water company and industry leaders through interactive roundtables.

A Gala Dinner for both AQE and WWEM will take place on the evening of 21st November. The winners of various competitions will be announced at this event – such as the SWIG Early Career Poster Competition, the SWIG Photography Competition and the WIPAC Instrumentation Apprentice Competition. The Instrument Users Group will present two awards, both voted for by the water companies. These will be for: ‘The best after-sales service’ and ‘Breakthrough product.’ The guest speaker for this black tie event will be Mr Brian Blessed.

WWEM co-located with AQE 2018 Explaining the reasoning behind the decision to co-locate the two events, organiser Marcus Pattison says: “Many of the visitors to these events are responsible for environmental monitoring generally, rather than just water or air. Similarly, environmental researchers and consultants take a holistic approach to environmental monitoring, and water companies have to address issues such as confined space gas analysis and emissions from generators and incinerators.”

“We have therefore made it free and easy to pass between the two events, but I would strongly urge those visitors that would like to attend both events to plan a 2 day visit, because it would be impossible to visit both exhibitions and attend the workshops or conferences of interest in just one day.”

“In summary, for those visitors that come for both days and plan their time carefully, this is a unique opportunity to meet people they wouldn’t normally meet; learn things they didn’t realise they needed to know; and to see a world of environmental monitoring in one place.”

NEWS & EVENTS

A world of environmental monitoring under one roof

According to the World Health Organisation 4.2 million people die every year from exposure to outdoor air pollution, and a further 3.8 million die from indoor pollution - 91% of the world’s population lives in places where air quality exceeds WHO guideline limits. Clearly, concerted international action is necessary to reduce the emissions of harmful pollutants and to lower exposure levels. This would not be possible without accurate, reliable monitoring, and AQE 2018 (the Air Quality Emissions event) was created to underpin that requirement, and is the latest in a series of events that began in 2003. AQE 2018 (www.AQEShow.com) will take place in Telford (UK) on 21st and 22nd November, and is comprised of Conferences, Seminars, Workshops and an International Exhibition. In combination, these will provide visitors with the latest information on testing, analysis and monitoring of industrial emissions, ambient air quality and workplace exposure; including regulations, methods, standards and technologies. Registration for AQE 2018 is now open and all pre-registered visitors will benefit from free parking, lunch and refreshments, as well as free entry to WWEM 2018, the co-located water, wastewater and environmental monitoring event. Visiting without pre-registration will cost £20/day. The AQE 2018 Conferences are CPD certified and combine with the workshops to provide visitors with an opportunity to tailor their visit in order to access the most relevant information whilst also leaving time to browse the exhibitions.

A Gala Dinner for both AQE and WWEM will take place on the evening of 21st November. The winners of various competitions will be announced at this event, and the guest speaker will be Mr Brian Blessed.

Day 1: Wednesday 21st November The STA (Source Testing Association) Conference will focus heavily on the Medium Combustion Plant Directive (MCPD), which will come into force on 20th December 2018. The MCPD applies to generators and plants between 1 and 50 MW (net rated thermal input) and an impact assessment has estimated that between 30,000 and 35,000 of these plants are currently operating in the UK alone. The estimated number of MCPs in the EU is around 143,000. The Environmental Industries Commission (EIC) seminar on 21 st November will focus on the development of Clean Air Zones (CAZs). In particular, there will be specific focus on air quality monitoring, which provides the baseline data that is essential for finding pollution hot-spots and measuring the effects of improvement measures such as CAZs.

Day 2: Thursday 22nd November Ambient air quality will be the focus of the IAPSC Conference (Investigation of Air Pollution Standing Committee) on the second day. The main themes of this conference will be: sensor-based air quality monitoring techniques; engaging the public with air quality; and green infrastructure and its potential role in LAQM. This conference is administered by Ricardo Energy &amp; Environment, and booking can be made via www.IAPSC.org.uk. On the morning of Day 2, the Renewable Energy Association Conference is titled: Understanding emission risks from Organics Recycling activities. With the recent release of the Best Available Techniques for the waste sector now live in the hands of the regulator, there has never been a better time to learn about issues relating to emissions from biowaste. A programme of free technical Workshops will run throughout both days, offering visitors the opportunity to learn more about the latest methods

and technologies on show. A wide variety of themes will be addressed covering both industrial emissions and ambient air quality. Over 80 companies will participate in the AQE International exhibition representing all of the world’s leading manufacturers and service providers in the air quality and emissions monitoring sectors. Many of them will be launching new products and services, and the only ay to see them all is to be there.

With so much to see and do at AQE 2018, visitors are being urged to plan for two days at the event. “Last year, many of the AQE visitors were unable to find sufficient time to see the entire Exhibition and to attend some of the specialist Workshops,” comments AQE organiser, Marcus Pattison. “For example, the IAPSC Conference will run throughout the second day, but the EIC seminar on Clean Air Zones runs on the first day, and to complicate matters further, many visitors are also likely to want to browse the WWEM Exhibition – clearly forward planning is essential!”

Registration is now open at www.AQEshow.com. 08

Process Industry Informer – October 2018

APPLICATIONS

REDUCE MEASUREMENT COSTS WITH RUGGED PH SENSORS THAT ARE BUILT TO LAST Reliable pH measurement in pulp production can be problematic to maintain, with solid content in pulp and sulphides used as cooking chemicals quickly clogging the diaphragm, and poisoning the reference system on conventional pH sensors. Regular cleaning can extend the lifetime of sensors, but is time consuming and costly for operators. Seshasayee Paper and Boards Limited (SPB) has operated an integrated pulp, paper and paper board mill in Tamilnadu, India, since 1960. METTLER TOLEDO’s solution to SPB’s pH sensor problem was the implementation of a measurement system based around our InPro® 4801i sensor. This probe is designed for high performance and long lifetime in harsh environments, such as pulp production and offers extended sensor lifetime due to its long diffusion path and PTFE-coated diaphragm that reduces clogging. For sensor monitoring and control, an M300 transmitter was selected to combine convenience with ease of use, fast installation and user-friendly configuration in any convenient location. To simplify cleaning, an InTrac® 777 retractable housing containing a flushing chamber for easy and efficient sensor rinsing, without process interruption.

MICRONICS PORTAFLOW 330 USED TO BALANCE CHILLED WATER PUMP ON RN VESSEL Since installing the system, SPB mill operators can now use their PLC to operate the pneumatic InTrac housing, quickly and thoroughly rinsing process material from sensors. Due to the long sensor lifetime and greater reliability, mill managers calculate that operating costs for the new system are half of what they were prior to use, and are planning to convert all pH measurement points at the facility to METTLER TOLEDO sensors. Download the Reduce Measurement Costs With Rugged pH Sensor Success Story www.mt.com/ uk-paper-ph-success-story For more information contact Mettler-Toledo Ltd, Leicester. Tel: 0116 234 5095 Email enquire.mtuk@mt.com

A Micronics Portaflow 330 was used to balance a chilled water pump on a naval vessel undergoing a refit in Fife Dockyard. Sam Humphreys, Chilled Water Commissioning Supervisor for AERIUS Marine had used Micronics flowmeters very successfully on several occasions in the past so had no hesitation in choosing the Portaflow again. “The Micronics units are easy to work with as well as being lightweight yet very robust making them perfect for our requirements”. The German company with headquarters in Hamburg and with locations in the UK, India, France and Australia are specialists in the design, assembly, selection and supply of the components and commissioning of maritime HVAC solutions focusing on the passenger ship and navy vessel markets. “We will continue to use Micronics flowmeters in the future whenever we have a requirement for a flowmeter,” said Sam Humphreys. The fact that the Portaflow 330 is especially designed for liquids, is portable and simply clamps onto the pipe played a significant role in Sam Humphreys’ selection. The specialist Micronics product is used for clean liquid monitoring. It is fitted with an integral logger and software and, because there is no need to cut into pipes it delivers significant savings on installation costs and there is less disruption than when installing an alternative in-line meter. It is robustly constructed and provides a quick and reliable means of measuring flow accurately. For further information on this project or the Micronics range call Micronics on +44(0)1628 810456, or visit www.micronicsflowmeters.com.

Your Right Connection For Hygienic Process Systems Valves

Fittings

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Tel: +44 (0)1772 323529 Email: sales@dixoneurope.co.uk www.dixoneurope.co.uk October 2018 – Process Industry Informer

APPLICATIONS

Variable speed actuation for a large butterfly valve Electric actuator specialist, AUMA, has supplied leading British valve manufacturer KOSO Kent Introl with an AUMA SEVEN HiMod variable speed actuator and a large GS gearbox. The AUMA equipment will operate a 48 inch butterfly valve within a flagship new project for Danish utility supplier Hofor that will transfer the Copenhagen district heating system from steam to hot water. Copenhagen aims to become the world’s first carbonneutral capital by 2025, and utility company HOFOR owns the district heating scheme, supplying 98% of the heat to Copenhagen’s 562,000 inhabitants. The DKK 500 million project to develop the district heating system from steam to a more energy-efficient hot water strategy was initiated in the 1990’s and is expected to complete in 2021. The 48-inch butterfly valve supplied by KOSO Kent Introl is the largest they have supplied and has a Cv of 59,531. It features a profiled vane that dissipates the energy as a valve works across a large pressure drop, reducing the chance of cavitation. The AUMA SEVEN HiMod, in conjunction with the GS gearbox, delivers a torque of 90,000Nm. A variable speed (modulating) actuator means, clearly, that the speed of movement of the valve can vary throughout its travel, moving quickly throughout the majority of the cycle and slowing as it closes to reduce wear on the mechanical components. Variable speed also gives the opportunity for a ‘soft’ start, reducing energy usage.

Variable speed, high torque actuation for 48-inch butterfly valve

AUMA UK worked closely with KOSO throughout the delivery phase of the project, helping to design a mounting that allowed the 5.5 inch drive shaft of the valve to interface accurately with the AUMA gearbox. Commenting, Joanne Handley, KOSO Kent Introl Project Engineer, said, ‘This is the largest butterfly valve we have ever supplied, and we have worked closely with AUMA throughout the project. Their experience of mounting large gearboxes to large valves in particular was very helpful.’ AUMA Actuators Ltd is part of the global AUMA group. For more information, please contact: Auma Actuators Ltd, Clevedon, North Somerset Tel: +44 (0) 1275 871141 Email: mail@auma.co.uk

Food manufacturer adds ABB drive to the mix contacted ABB authorised value provider, Gibbons Engineering Group, for advice.

ABB drive and control package helps Baxters Food Group to increase production capabilities at its Colchester site. Baxters Food Group is using an ABB variable speed drive (VSD) to help ensure consistent mixing of its range of sauces, dressing and marinades. The drive is used to adjust the mixer motor’s speed based on requirements for a particular product. Installed on a 750 kg capacity holding vessel, the VSD is used to mix sauces and other products at an elevated temperature – a process known as hot fill. This process pasteurises the product, preventing spoilage and prolonging shelf life. Baxters Food Group produces a wide range of soups, sauces, condiments, dressings, preserves, pies and meal accompaniments in the UK and Poland. Previously, it had only produced cold fill products at its Colchester site, but wanted to expand production by manufacturing hot fill sauces and marinades. The tank, which had not been used for several years, was re-located to Colchester from one of the other manufacturing sites in the group. It featured a steam-heated jacket that made it suitable for the hot fill process, but had no controls or electrical supply. Baxters needed a power and control solution that would turn the vessel into a fully usable asset and

“The holding vessel is vital to the production of our hot fill sauces. Without its agitation and heating capability, we would struggle to meet the required levels of product consistency and thermal process. This would potentially compromise the high-quality standards of the product range,” says Tony Bellian, European Technical Director for Baxters. Gibbons designed, built and installed a stainless steel-enclosed control panel, which incorporates a 4 kilowatt ABB micro drive to control the speed of the holding vessel’s agitator via a door mounted potentiometer. The VSD enables the speed of the mixer to be adjusted from 30 to 80 rpm, ensuring the hot fill sauces are agitated at a consistently controlled speed to give the correct end product quality. The control panel also controls the temperature of the steam. This is adjusted to suit different product recipes. The project involved fitting associated cabling, along with setting up and testing the panel. The control panel took four weeks to fabricate and a day to install on site.

“We had a tight deadline of two months to produce, install and test the solution. Gibbons was ready to conform to all of the working requirements associated with a food production environment. In addition, they were very cost competitive.” Bellian adds. For more information please contact: Abb Ltd, Warrington, Cheshire Tel: 01925 741517 Email: layla.hewitt@gb.abb.com Web: www.abb.com

FIP Foam Gasket service delivers IP rated seal and productivity benefits for LED lighting manufacturer In this case study Techsil provided a bespoke Form-in-Place Foam Gasketing service to TRT Lighting to produce an IP rated seal for the lid of an outdoor lighting luminaire. The new process replaced a manual system of gasket application saving time and allowing vital resources to be used elsewhere. UK based, TRT Lighting Ltd (Thorlux Road and Tunnel Lighting) designs, manufactures and supplies energy efficient, environmentally friendly lighting products for exterior lighting markets. Involved in designing lighting for civil engineering projects such as roads, tunnels, airports, urban centres and amenity lighting. They are also very active in the high demand market of outdoor HID lighting replacement and retrofitting with LED luminaires. TRT needed to produce an exacting, inert seal on the top lid of an outdoor LED light fitting to meet IP66 requirements and lasting throughout the life of the product. The seal was being achieved by manually applying an adhesive backed pre-cut gasket on the production line. With high order demand and volumes of finished product significantly increasing, the need to expedite certain elements of the assembly process at TRT were paramount. After tests and trials on a sample lid Steve Green, Techsil’s Application Engineer recommended a bespoke FIPFG (Form in Place Foam Gasket) service where a sophisticated six axis robot dispenses a single-component liquid polyurethane foam bead onto a customer’s substrate. The PU cures forming a fine, uniform, closed cell foam structure. The FIPFG service not only allowed TRT to increase their productivity but also provided a high quality, reliable solution that passed all relevant testing and verification. Green explains, “The project was successful in 2 ways. 1) The lids from stock are being fed to the production line already sealed and 2) the labour utilised in hand applying the gasket is deployed elsewhere. The material performed very well under stress tests and provided a reliable, aesthetically pleasing bond.”

“Short cycle times save time and money. If a manufacturer produces small volumes or has intermittent production, then subcontracting their FIPG system can be very cost effective,” says Green. Dispensing of only one component ensures that even very small sealing gaskets can be produced accurately without any problems. However intricate the part, a perfectly engineered foam gasket can be applied; from micro-dispensing of gaskets to replace o-rings, to high volume applications of foam to doors of switch cabinets. Furthermore, the thixotropic properties of the foam ensure that very complicated tridimensional shapes and cross-sectional variations can be accommodated. For further information please contact: E-mail: technical@techsil.co.uk

Process Industry Informer – October 2018

FEATURED ARTICLE

By Jerome Jennings, Global Product Manager, Components, SPX Cooling Technologies

Pros and Cons of Cooling Tower Power Transmission Technologies Look for the right balance of initial cost versus lifetime cost Cooling towers can use several power transmission technologies, including a gear drive, belt drive, direct drive, and electronically commutated (EC) drive. Each has advantages and disadvantages. The proper selection strikes an appropriate balance of initial cost versus operating costs.

offers a smooth and effective transmission of power between shafts, even if they are at a considerable distance. Belt drives transmit motion from one shaft to another with the help of a loop of flexible material.

Overview of available power transmission technologies Gear drives offer moderate cost with low lifetime operating costs The gear drive is a common system used that transmits power and has been used for decades. A gear drive relies on internal gearing that meshes to transmit power. In a cooling tower application, the gear drive reduces the high-speed power from the motor to the lower speed required to power the fan. The induction motor is relatively small because the gearbox multiplies torque. Gear drives are effective at all cooling tower power levels. Their thick casted shells housing the gear teeth and oil bath can withstand the high heat and humidity inside the cooling tower. Gearboxes require additional “no load” power to overcome the friction of internal components and oil viscosity. Net efficiency of the gearbox varies per application, but is generally near 96 percent.

In a cooling tower application, the size of the sheaves determines the speed; different sized belts provide the speed reduction required. The smallest sheave connects to the motor, while the larger fan sheave is connected to a fan shaft. The ratio between those sizes dictates the speed reduction. Belts matching the profile and length requirements of the sheaves transmit power. Unlike gears, belt drives are exposed to the cooling tower’s hot, moist environment. The initial cost of a belt drive is low, but ongoing maintenance costs grow over time. Sheaves and other components corrode; belts stretch and lose tension. Starting at about 95 percent efficiency, belt drives can drop to the low 90s or even lower as the belts stretch and wear. Maintenance includes regular belt replacement and fan shaft bearing lubrication several times a year, contributing to its higher lifetime operating cost. Belt drives are often employed in cooling towers with lower horsepower requirements. Like a gear drive, the belt drive does not require a VFD. Direct drive motors have low maintenance requirements but initial cost is typically much higher than other alternatives

The gear drive reduces the high-speed power from the motor to the lower speed required to the power the fan.

The gear drive requires little maintenance. For example, some gearboxes using synthetic oil do not require an oil change for five years, but cooling tower owners and service contractors should be diligent about inspecting for potential leaks. Another positive feature of the gear drive is that it runs off direct online power. A variable frequency drive (VFD) is not required, but may be included for added motor speed control and energy use benefits.

Belt drives feature low first cost but higher operating cost Belt drives have been around even longer than gear drives. They are used to transmit motion from one shaft to another with the help of a loop of flexible material that runs over two sheaves (also called pulleys) to link the rotating shafts. This technology October 2018 – Process Industry Informer

There are multiple direct drive options in which the motor directly drives the cooling tower fan. The direct drive motor offers reliability with minimal maintenance requirements. A common direct drive option uses a permanent magnet motor. This is a type of electric motor with rare earth permanent magnets incorporated into the rotor. Use of this technology has grown over the past decade and is now widely used in vehicles, drones, computers, and numerous other applications that need powerful but relatively compact motors. The permanent magnet motor directly drives the fan, eliminating a number of components, including gearbox, driveshaft, pillow block bearings and couplings. This in turn eliminates the need for alignment of the mechanical components, speeding installation, reducing installation costs and increasing system efficiency.

One disadvantage of the permanent magnet option is initial cost – a direct drive with a permanent magnet motor is often the highest cost of all power transmission options. For the torque requirements of cooling tower applications, permanent magnet motors become heavier and taller than standard induction motors, due to the gear drive being eliminated. Permanent magnet motors require a VFD to operate. Although an extra initial cost, the VFD lets operators control speed and conserve energy.

The permanent magnet motor directly drives the fan, producing a magnetic field.

Ensuring safe operation is a potential concern. With other power transmission options, when the motor is disconnected there is no power to it, making it safe to service. The permanent magnet motor can generate electricity even when power is shut off, potentially creating a dangerous situation. If, for example, wind turns the fan and fan shaft, electricity could travel to where a technician is working on the equipment. Another safety concern is the magnetic field produced, which could impact anyone wearing a pacemaker working near the motor. A direct drive typically has the lowest maintenance cost over its lifetime because there is no need to replace the oil, no oil seals that can wear, and no need for routine alignment. Annual lubrication is recommended. Initial costs can be two to three times more than a gearbox. Due to the high first cost, payback can extend to ten or more years. Electronically commutated motor combines motor, controller and fan

speed controller into one package. The rotor portion of the motor typically uses rare earth permanent magnets and the integral speed control eliminates the need for an external VFD. For cooling tower applications, the fan, fan shroud, and fan guard are often incorporated to provide a complete mechanical drive package. This provides a simple and compact arrangement that is easy to install in the factory and to replace in the field as needed. Cooling towers that use EC motors are usually of smaller capacity and footprint with a maximum application size of 10 hp or one-meter fan diameters. Compared to belt drives and other low-horsepower motors (less than 5 hp), EC motors are consistently more efficient. In small-hp applications, the EC motor presents no power transmission loss while other low-hp motors and belt drives can experience power transmission losses from 5- 20 percent. Because EC motors use sealed bearings, there is virtually no maintenance. The use of this technology for cooling towers is new and currently lends itself only to low-hp, small fan diameters. Table 1 provides an overall comparison of available power transmission technologies. Belt drives have low initial cost but high operating cost. Direct drives have high initial cost with lower operating cost. Gear drives usually fall somewhere in between. EC motors offer low operating cost, but sizes and applications are more limited.

Selecting the right option is a balancing act

When choosing among power transmission technologies, cooling tower specifiers, contractors and owners must evaluate costs across the entire cooling tower lifecycle. Factors such as energy efficiency, ease of maintenance, reliability and service life must be balanced against initial investment, installation costs, operational complexity and environmental impact.

References The high-efficiency electronically commutated (EC) motor is a newer technology that combines a small DC motor and an inverter/

A Look at Belt, Chain and Gear Drive Technology, Power Transmission Engineering, www.powertransmission.com/blog/a-lookat-belt-chain-and-gear-drive-technology/, retrieved 5/17/18

WELDING & CUTTING

Test & Measurement

HBM EXPANDS ITS RANGE OF STRAIN GAUGES WITH NEW KFU SERIES FOR HIGH TEMPERATURES Through its collaboration with the Japanese manufacturer Kyowa Electronic Instruments, HBM – a market leader in the field of test and measurement – is pleased to announce the arrival of its new KFU series of strain gauges for high temperatures of up to 350°C. Suitable for structural tests at exceptionally high temperatures, the latest series of KFU strain gauges are pre-wired and come equipped with a 1 meter long, high temperature protection cable. Available in grid lengths of 2 mm and 5 mm as well as in different versions, such as linear, T (with two measuring grids) or R (with three measuring grids) rosettes, depending on the application’s requirements, the KFU strain gauges are also available with temperature responses matched to steel, austenitic steel, and aluminium.

The latest series of strain gauges can be used at high temperatures for specified durations; at 350 °C for 72 hours or at 300 °C for 360 hours. Typical applications include strain measurements in autoclaves or environments with steam. The KFU strain gauge series are the first products manufactured by HBM in collaboration with the Japanese manufacturer Kyowa Electronic Instruments. This cooperation of two technology leaders enabled HBM to complement its range of products with additional, fascinating sensors, such as those for very high temperatures, and offer these to clients in future. For further information, please contact HBM on +44 (0) 1525 304980 or via email: info@uk.hbm. com or visit the HBM website at www.hbm.com

ESAB CHANGES SANDVIK WELDING CONSUMABLES NAME TO EXATON™, AN ESAB BRAND For more than 80 years, Sandvik Welding Consumables has been a world-leading developer and manufacturer of advanced stainless steels and nickel filler metals for demanding environments. To broaden and enhance its portfolio of specialty alloys,ESAB Welding & Cutting Products acquired the Sandvik welding consumables business, finalizing the transaction earlier this year. Beginning November 1, these products will go to market under the name Exaton™, an ESAB brand. As part of the brand update, the following changes will occur: • P roduct packaging will be updated to reflect the new Exaton brand and logo. • The product itself will retain current labeling. • T he contents of the Sandvik website, including specifications and Material Safety Data Sheets, will be transferred to the ESAB website. • T he Sandvik Welding Handbook mobile app, which features all in the information in the Welding Handbook PDF and useful calculators, will be transferred to the ESAB site.

“While Sandvik will move forward as Exaton, customers can be assured that the most important factors will remain the same: the excellent performance, metallurgy and weldability of our consumables,” says Shyam Kambeyanda, President, ESAB. Performance, Metallurgy and Weldability The Exaton portfolio includes solid welding wire and rods, Flux-Cored wire, MMA electrodes, strip electrodes, flux, thermal spray wire and weld finishing chemical products. Exaton works directly with fabricators and end users in the world’s most demanding segments, such as oil and gas, chemical processing, power generation and cryogenic applications.

“Our first-hand application knowledge enables us to continuously improve welding consumable performance,” says Henrik Calander, General Manager Specialty Alloys, ESAB. ESAB Welding & Cutting Products is a recognised leader in the welding and cutting industry. For more information contact ESAB Group (UK) Ltd Tel +44 1992 702442 E-mail: cheron.robinson@esab.co.uk Web: www.esab.com

Process Industry Informer – October 2018

FEATURE / ADVERTORIAL

By Keith Atkinson, EMEAI Sales Manager at Gardner Denver

A smart approach to compressed air maintenance

Keith Atkinson, EMEAI Sales Manager at Gardner Denver, advises on the most effective predictive and preventative maintenance strategies for compressed air users. Businesses of all sizes have become increasingly wary of purchasing a compressed air system that’s available for a lower upfront cost, only for issues to arise further down the line that means any savings originally realised have been lost on service and maintenance costs. As a result, owners are moving away from considering the initial purchase price for a piece of equipment alone and starting to focus more on whole life costs. Servicing and maintenance costs are no longer seen as separate entities, but rather parts of a greater whole. Effective maintenance strategies can help businesses save money, improve operational efficiencies, reduce downtime, increase productivity and deliver peace of mind. What, then, are the most effective strategies that compressed air users can implement? The real cost of using non-genuine parts

Non-genuine filters are more likely to have a reduced dust and dirt-holding capacity, resulting in more contaminants entering the system. Meanwhile, seals are designed to handle compressor oil, high temperatures over prolonged periods and varying pressure levels. These provide protection against the ingress of dirt and other contaminants, and therefore should be selected carefully to ensure efficiency levels are maintained. The same is true of genuine lubricants, which are formulated with additives to improve performance and optimised to work with all of the system’s component parts. This ensures that the correct lubrication, cooling and anti-wear qualities are maintained. If specified incorrectly, the lubricant can place extra demands on the filter element, which can result in dust and other particles coming into contact with internal compressor components. Furthermore, using the right lubricants and filters can help to extend oil change intervals. This not only reduces the cost and frequency of oil changes but helps to, reduce the environmental impact associated with oil disposal too.

It might also be worthwhile carrying out an energy audit, which can deliver a range of benefits to help ensure compressed air operations are maintained to a suitably high standard. A pre-assessment survey would be undertaken in the first instance, which would consider a range of variable factors that might affect compressed air usage. This would include: compressor kW sizes; the flow, pressure dew point, pressure and temperature required; the time needed to perform a leak survey; shift patterns; cost of electricity on site; and any obvious signs of leaks. From here, it can be assessed whether an energy audit would be worthwhile undertaking. For an example, a typical report from we would include an overview of the compressed air system, a power and flow report, temperature data, an air leakage survey, a report on any pipework issues, potential energy-saving opportunities, and a proposal on how to implement these recommendations. Smart digital insights

Minimising leaks, maximising profit

Non-genuine spare parts and lubricants are typically cheaper than a manufacturer’s original parts and, when trying to cut back on costs, it can be tempting to opt for these. Nevertheless, it is widely accepted that using non-genuine parts can be detrimental to a compressed air system’s overall performance and can have a negative impact on a machine’s efficiency and energy consumption. In some cases, the wrong spare part can cause real damage. This can potentially result in the system failing completely. The outcome? Not only an expensive repair bill, but costly unexpected downtime too. Of course, any compressed air system – whether a new or existing one – will need components such as filters, valves, seal and oil to be periodically replaced. But by replacing these with a non-genuine alternative, there can be no guarantee that the manufacturer’s warranty will be upheld. Genuine parts will have been manufactured to meet the same standards as the compressor that they are intended for. So, they will have passed the manufacturer’s stringent testing regimes, in a quality-controlled environment, to ensure your system continues to operate reliably. Components to be particularly mindful of are filters and seals. Filters ensure dust and particles cannot enter the compressor system, helping to protect components from unnecessary corrosion and wear. This encompasses everything from the pipework that carries the compressed air around the plant to the equipment at the point of use.

Did you know industry averages suggest energy costs represent over 80 per cent of a compressor’s whole life costs? As such, operators need to make sure performance is not being affected by any issues such as pipework leakages. Pipework leakages are a large factor in compressed air energy wastage, accounting for 35 per cent of total air consumption. There are many reasons for leaks in a compressed air system, including shut-off valves and manual condensate valves being left open, and leaking hoses, couplings, pipes, flanges and pipe joints. Such oversights and deterioration can be expensive. According to the Carbon Trust, just one 3mm leak could cost a company over £700 a year in wasted energy. Data-logging equipment can help pinpoint inefficiencies, identify any compressed air leaks and manage equipment performance. In the case of pipework leakages, using a flow meter is a reliable method of evaluating compressed air generation and downstream inefficiency costs. Indeed, finding and repairing one 3mm leak could potentially save enough money to cover the cost of purchasing one.

With Industry 4.0 driving companies to share and analyse data every step of the way, this is creating a real opportunity for compressed air users to consider how data can improve performance and help identify and inefficiencies. One of the biggest changes in Industry 4.0 is the move from closed, proprietary products to open ones. Traditionally, a product operates and connects to a brand’s own proprietary protocols and data transfer mechanisms. This closed system can be problematic for those using compressors. Most businesses, over time and throughout various product lifecycles, will have purchased units from a range of brands. To meet this need, we have introduced a new digital platform, iConn. iConn is a cloud-based, air management platform, which has been developed to deliver advanced analytics, enabling you to stay in control of your compressed air installation. The system provides historic, real-time, predictive and cognitive analytics, allowing users to rectify potential issues before they happen. Crucially, iConn is an open platform, supporting ancillary and compressed air products from other brands. iConn can help provide a platform that delivers truly meaningful compressed air insights, no matter who the manufacturer is. Process Industry Informer – October 2018

FEATURE / ADVERTORIAL By Tom North, Senior Service Business Engineer for HBM

Regular Calibration Keeps Quality High and Costs Low in the Food Industry Manufacturing standards within the food industry are among the most heavily regulated in today’s market, and it is essential that calibration forms an integral part of a food processor’s quality and safety programme. With this in mind, HBM discusses how regular calibration can help to reduce overall costs and minimise error to ensure accurate, traceable and repeatable measurements throughout the food production process. Split into two distinct categories, food quality is determined by subjective and objective testing. Whilst subjective testing evaluates product based on sensory tests, such as sight, smell and taste, the latter focuses on the characteristics that can be measured, recorded and analysed with instruments. This is where calibration is important. The purpose of calibration is to determine if an instrument is still measuring within manufactures specification. Without properly calibrated instruments, the reliability & accuracy of data gathered is highly suspect. A valid calibration of your transducer is a prerequisite for certification in compliance with ISO9000 requirements. You should decide to calibrate your transducer, particularly if the calibration is no longer valid or an imminent monitoring audit of your measuring tool is due. Calibration helps to obtain measured values that are demonstrably reliable. However, like most good things in life “Nothing worth having comes free” and unfortunately, this activity can often become neglected or the interval between calibration checks on instruments can be extended in order to cut costs. Neglecting calibration can have detrimental effects on a production process. Greatly dependable on weighing accurate masses within the food industry, calibration can help to avoid potential recalls or legal action due to ‘bad batches’ and reprocessing, all of which could result in damage to the reputation of a business, which is an invaluable asset. So quality assurance is key, as even if no associations or guidelines were in place, the same commitment to quality would still play a critical role in achieving market success.

In order to achieve this goal, the following needs to be performed: • Develop effective procedures for calibration; • Document those procedures; • Maintain records of calibration activities, including corrective actions; • Review records to ensure that procedures are being followed; Regular Calibration helps to ensure that equipment performs at optimum levels and the data measured is reliable. This, in turn, enhances efficiency, uptime and cost savings, should when you calibrate the instrument you find it to be suspect, the time period of potential suspect data has been kept to a minimal if calibrating on a regular basis. In addition, with equipment running at optimum performance levels, there is less wastage of raw material, as well as lower pollution which assists in minimising manufacturing expenses, without affecting product quality. In short, putting off calibration can ultimately cause a variety of quality and compliance issues which can involve heavy costs in more ways than one. So how often should devices be calibrated? Due to drift, all instruments require calibrating at set intervals. How often they are calibrated depends on a number of factors. Firstly, the manufacturer of the instrument will provide a recommended calibration interval. HBM – a market leader in the test and measurement market - recommends that calibration is undertaken approximately once a year for electronic devices and at a maximum interval of two years for transducers although; ultimately the end-user is responsible for determining calibration intervals. This interval may be decreased if the instrument is being used in a critical process or application. Quality standards may also dictate how often a pressure or temperature sensor needs calibrating. However, the most effective method of determining when an instrument requires calibrating is to use some sort of history trend analysis. The optimal calibration interval for different instruments can only be

determined with software-based history trend analysis. In this way, highly stable sensors are not calibrated as often as those sensors that are more susceptible to drift. Another misconception is that new instruments do not require calibration. This is not true. Just because a sensor is newly installed does not mean that it will perform within the required specifications. By calibrating an instrument before installation, a company is able to enter all the necessary instrument data to its calibration database or calibration management software, as well as begin to monitor the stability or drift of the instrument over time. When it comes to deciding who should be responsible for calibration, food processors are faced with a further decision of whether to choose a OEM or a third party provider? Previously opting for an OEM could have meant excessive downtime and loss of production as the measuring equipment was removed and sent to a calibration laboratory. However, with HBM, it is now possible to have most data acquisition equipment calibrated on site, and all transducers calibrated at HBM’s DaKK’s Standard calibration laboratory in Darmstadt. Once equipment has been properly calibrated a digitally signed electronic copy of the calibration certificate is sent by email directly to the customer. The security of every customer’s data is very important to HBM and for traceability all calibration data is saved on central servers in both company’s UK headquarters in Millbrook and its international headquarters in Darmstadt, Germany. In addition to calibrating HBM equipment in the field, the HBM’s on-site service is an extension of one of the bestknown and most capable DAkkS standards calibration labs worldwide, which is based at HBM in Darmstadt. Founded in 1977, the HBM Calibration Laboratory is one of the most prestigious facilities in the world. Regardless of whether calibration and validation activities are performed on-site or in a laboratory, the benefits of making sure that test devices are recalibrated on a frequent schedule are clear. For more information, please visit www.hbm.com

However, luckily for the consumer, there are industry regulations in place and almost all regulations and management standards that address food quality and safety stress the importance of calibration: Hazard Analysis and Critical Control (HACCP) regulations that are mandated for meat and poultry, seafood and juice reference:

“Records that document the calibration of process monitoring instruments” Whilst ISO22000, the food safety management system’s requirements for any organisation in the food chain, states in Section 8.3:

“The organisation shall provide evidence that the specified monitoring and measuring methods and equipment are adequate to ensure the performance of the monitoring and measuring procedures”. October 2018 – Process Industry Informer

October 2018 â&#x20AC;&#x201C; Process Industry Informer

PROCESS MEASUREMENT & INSTRUMENTAL

A British firm has devised a device to save time and money for thousands of companies Adding water to powder or granule mixes has long been done using pails or hosepipes. Time consuming, open to accident and operator error, there has never been a viable alternative. Aquameter Ltd looks set to change that. Their micro-controlled Abacus system delivers exact, pre-selected quantities of water from a single pipe -straight into the mixing vessel. This precise metering of the water means the operator can recreate batch consistency each time.

Beverage Dispensing Flowmeters

Operation is simple - the quantity of water required is programmed in, the RUN button pushed, and the water flows. A solenoid valve located in the water pipe closes the flow at the completion of the cycle - when the pre-set quantity has been reached. The unit is already in use world wide. Derek Baxter, International Projects Director with Filtrona International in Jarrow, says of the system: “We use the unit for metering water into a carbon-powder mix. Were it not for these units we would be using buckets of water, a line of hose, or a constantly changing mark on the tank - not that convenient.” He goes on: “With this thing we just dial new numbers in, and away we go - it’s obviously more accurate; using the meter than relying on staff to put it in by pail. “

Based upon a unique Pelton wheel design, Titan Enterprises beverage dispensing flowmeters are inherently reliable and proven in tens of thousands of installations around the world.

For further information please contact; John Morton aquameter limited 8 Woodlands Drive HODDESDON EN11 8AZ Tel: 01992 442 861 E-mail: john@aquameter.co.uk Web: www.aquameter.co.uk

At the heart of each beverage flowmeter is a precision Pelton wheel turbine that rotates freely on robust sapphire bearings and contains over-moulded magnets that are detected through the chamber wall by a Hall effect detector. The output from the beverage flowmeter is a stream of NPN pulses that are directly interfaced with the electronic display. This combination of materials and technology ensures a long-life product with reliable operation throughout. Constructed from totally non-metallic wetted components and offering a flow range of up to 10 litres per minute - Titan’s NSFaccredited beverage dispensing flowmeters

are the product of choice for precise metering of lower viscosity beverages including coffee, wine, beers, spirits and soft drinks. For further information on flowmeters for your beverage dispensing application please visit: www.flowmeters.co.uk/beverage-flowmeters-drinks-dispensing-flow-meter-forbeer-wines-and-spirits/ or contact Titan Enterprises on +44-1935-812790 E-mail: sales@flowmeters.co.uk. To review a beverage industry case study on this topic please visit: www.flowmeters.co.uk/beer-flow-sensorstitan-supply-600000-flow-sensors-beerindustry/.

Process Industry Informer – October 2018

PUMPS & VALVES

P&M PUMPS PROVIDE VITAL SUPPORT IN DEALING WITH GIBRALTAR’S SEWAGE

NEW THERMODYNAMIC PUMP MONITORING SYSTEM MONITORS PUMP PERFORMANCE AND EFFICIENCY Corroserve has just announced further major investment in its Thermodynamic Pump Monitoring (TPM) System. As a result, the Leeds based corrosion protection and engineering services specialist can now monitor the performance of any class C industrial pump over its working life and as a result highlight significant cost saving opportunities for the user. Calibrated and certified by the Yamari Standard Laboratory in accordance with relevant Japanese standards, the updated TPM system calculates pump efficiency by the thermodynamic method based on the first law of thermodynamics. The effect is that energy losses in the pumping process are transferred to the pumped liquid in the form of heat energy, causing a rise in temperature. The TPM unit measures temperature and pressure at the pump suction and discharge and by inputting the motor power consumption, the system calculates the flow rate and actual pump performance and efficiency.

TPM identifies pump wear and measures changes in performance and efficiency, allowing the customer to make informed decisions about refurbishment and the optimum time for any work to be carried out. It also identifies the most efficient pumping conditions providing customers with a detailed & accurate report. The financial investment in TPM testing will be quickly recouped in savings made by reduced energy costs from running a more efficient pump - savings that might be increased even more by using the company’s Fluiglide coatings to further enhance pump efficiency.

For more information contact: Simon Cappleman; E-mail: simonc@corroserve.com Tel : +44 (0)113 2760 760 Mob: +44 07800 587007 or Web: www.corroserve.com

Over the last decade, AquaGib, the local water utilities company in Gibraltar, has continued to work with its long-standing partner P&M Pumps, specifically with the supply of Vaughan Chopper Pumps. Since 2007 and following the successful trial of a standard Vaughan self-priming chopper pump that was installed at AquaGib’s Waterport sewage pumping station, over twenty self-priming Vaughan Chopper Pumps have now been installed across the Rock. These pumps have become a standardised feature in many of AquaGib’s pumping station and are now a standard requirement in any future station. A problem unique to Gibraltar is the use of sea water for sanitary purposes, as well as street cleaning and firefighting. All this sea water ends up flowing into the sewage network, which ultimately increases the salinity of the sewage making it that more corrosive. The combination of the high salinity as well as the high solid content offers a challenging scenario to any pump. However, following the successful trial back in 2007 and the subsequent year in use, the Vaughan Chopper Pumps have shown how effective they are in dealing with high solid contents especially when those contents are non-degradable

in combination with the high salinity. AquaGib’s team where able to learn additional maintenance techniques on the Vaughan that will hopefully make them that more effective and extend their operating life, as well as providing their own experience in using these pumps on location back in Gibraltar. Further information on Vaughan Chopper Pumps and associated mixing systems is available from: Andy Parr, P&M Pumps, Sawtry, Huntingdon. Tel: 01487 830123. E-mail: andy@pumpmix.co.uk Web: www.pumpmix.co.uk

Process Industry Informer – October 2018

FEATURED ARTICLE By Malcolm Walker, Product Manager Centrifugal Pumps, AxFlow

The argument for Canned and Mag drive pumps Magnetic drive (mag drive) and canned pumps offer numerous advantages over traditional mechanical sealed process pumps. In fact there are few reasons not to use a mag drive or canned pump. In this article, we take a look at the advantages of mag drive and canned pumps and explore why they aren’t used more. The benefits Mag drive pumps (Fig.1) transfer power using a drive magnet attached to the motor shaft which rotates an internal magnet (attached to the impeller) using the magnetic field that exists between the two magnets. This means that the motor shaft does not pass through the rear pump housing, eliminating the need for any seals. As a result they offer many advantages across a wide spectrum of industries over traditionally sealed pumps.

+350 o C and -150 o C and contain very high system pressures. For many API (American Petroleum Institute) applications they are cheaper than mechanical sealed pumps containing expensive seal support systems (Fig.3). If a mag drive pump requires maintenance the pump chamber assembly can be easily disengaged from the motor bracket. Should the pump become jammed, the magnets de-couple thereby protecting the motor. The pumps can be manufactured from wide range of chemically inert plastics preventing metal from coming into contact with the liquid.

(Fig. 1) Mag drive pump

Canned pumps (Fig.2) integrate with the motor itself thereby utilising the electromagnetic field between the motor stator and the rotor (which is positioned within the rear pump chamber) to turn the impeller. Canned pumps are therefore also “seal-less” and can offer additional benefits over magnetically driven pumps.

(Fig. 3) Mechanically sealed pump

Canned pumps offer double liquid containment because the liquid is contained within the pump chamber which is surrounded by the motor casing. With the rear pump chamber being contained within the motor casing noise is reduced, plus the pump’s footprint is much reduced because the pump is incorporated within the motor itself. Although usually more expensive than other pumps, mag drive and canned pumps offer much lower total life time costs, reduced maintenance and provide a safer option than mechanically sealed pumps. So why aren’t they used more? There are several reasons why these pumps are not used more, with ignorance being the main one.

(Fig. 2) Canned motor pump

As there are no seals, mag drive and canned pumps require little maintenance, offer complete containment of the liquid, can handle temperatures ranging between

October 2018 – Process Industry Informer

Many people believe that mag drive and canned pumps are by definition centrifugal pumps. This is not the case as the term only applies to the coupling and the nature of the construction. At AxFlow our pump portfolio incorporates rotary vane, gear and regenerative turbine pumps. In fact any pump that uses a rotating shaft (nonelliptical) could be mag drive or canned.

The second reason is a belief that both pump types are new and relatively untested technologies, where in fact they have been around since the mid 1950’s. Virtually every home has a canned pump in the guise of the central heating circulator pump, whilst mag drive pumps have been used by NASA on all space missions. Most nuclear plants use canned pumps as the main pump type, and they are generally used for the most toxic of applications. An inability to handle solids of any size is often cited as a generic disadvantage of mag drive and canned pumps. True, there is a need to have close tolerances at the rear of most pump types so they can’t be considered as “solids” handling pumps. However, they can cope with a small degree of solids and are no less susceptible than mechanically sealed pumps – that is unless the solids include ferrous particles. Slightly higher energy costs are a valid down side due to the losses across the magnetic and electromagnetic couples, but for most applications these are trivial and far outweighed by the maintenance and reliability savings which are largely ignored. The point is that, unless there is a reasonable amount of solids in the media, they are better across the board than traditional mechanical sealed pumps.

Summary That leaves us with the age-old obsessions of finding the lowest initial cost and an inability to consider the long term direct and indirect costs of a product. If reduced breakdowns and their associated costs, plus negligible maintenance are considered, then mag drive and canned pumps win hands down. The truth is that in most situations mag drive or canned pumps offer easily the best solution, yet many people try everything to avoid their use. Perhaps we should move to an environment wherein people have to justify why they haven’t used a mag drive or canned pump.

PUMPS & VALVES

NEW TEFC MOTOR OPTIONS FOR FTI DRUM PUMPS Pumping specialists MICHAEL SMITH ENGINEERS have introduced new TEFC (Totally Closed Fan Cooled) IP55 motor options for their range of Finish Thompson drum and barrel emptying pumps. This type of pump is the most reliable and efficient method of transferring a wide range of fluids from container-to-container compared to hand pumps, and these new motor options extend their capability to an even wider range of applications. The new motors include a powerful 1000 Watt continuous duty universal motor providing 0-12,000 rpm variable speed operation. The variable speed TEFC versions feature solid state control with chemical resistant touch pad for precise fluid dispensing and superior motor protection against overload and over temperature. These motors provide 10 selectable speeds which can be easily controlled up or down by pushing appropriate key on the keypad. The motors also recall the last running speed when the power is switched on. LED lights provide useful feedback about the motors state – a blinking green light indicates the motor is in standby mode, a solid green light indicates the motor is on, a blinking red light indicates over-temperature and a solid red LED indicates over-current. These motors also incorporate a zero voltage safety release feature which prevents the motor from turning back on after a power failure. The option of a lower cost, fixed speed version is also available.

Getting the Proper Spec in Electric Actuation Actuated Solution Ltd (ASL), one of the UK’s leading valve automation providers is encouraging specifiers of electric actuation products to keep it simple while sourcing automation for their valve installations. With over 15 years expertise in electric valve automation and a portfolio of over 200 products, ASL’s market leader position in provision of mid-level electric actuators, has been built upon sound technical knowledge and a pragmatic approach.

Both the fixed speed and variable speed versions of these new motors are available for the best-selling PF series of drum pumps – available in polypropylene, PVDF or stainless steel in a choice of different lengths – as well as for the TB, TT and HVDP drum pumps and the TM drum mixer unit.

Although the actuation market is advancing in technological leaps and bounds in line with other industrial electrical equipment - ASL is encouraging buyers not to succumb to the impressive displays of automation wizardry when it comes to actuation, and ultimately not to be tempted to over-spec on their installations. This is on the basis that over-specification can be as troublesome in the longer term as underspecification.

Paul Slaughter, Managing Director of ASL commented; “Technology can be a doubleedged sword, new gadgets and special features are always attractive whether it’s a new phone, car, laptop or in our business an actuator. However, we often find engineers in a whole raft of trouble because an installation hasn’t been fitted with the appropriate actuators and the equipment specified is too complicated for the job in hand. In our experience, the majority of electric actuators are perfectly suited for simple applications requiring open/close operations, other features are often left redundant and as with anything, the more complex the equipment is the more chance there is of going wrong and more chance you’re paying for features you don’t need or will use. That is why we believe, to save both money and time, it is important to develop the specification detail from the outset to ensure products are fit for purpose.” To find out more about Actuated Solutions visit: www.actuated-solutions.co.uk/

For more challenging environments the motor’s IP55 design ensures superior protection in corrosive, damp or dirty environments and downdraft cooling directs corrosive vapours away from the motor.

For more information contact: Michael Smith Engineers Ltd, Woking, Surrey Tel: FREEPHONE: 0800 316 7891 Email: Info@michael-smith-engineers.co.uk Web: www.michael-smith-engineers.co.uk/

SENSORS

NEW BAUMER ENCODERS COMBINE ULTIMATE DURABILITY & PRECISION The tough demands of industrial environments and challenging outdoor applications inevitably tests the durability and reliability of components such as sensors and encoders. Furthermore, for some applications the challenge is also for more sophisticated and specialised control, resulting in the need for components which offer the vital combination of robustness AND optimum precision. The MAGRES range of ABSOLUTE ENCODERS from sensor experts BAUMER is proven around the world in the harshest environments and industrial applications, such as utility vehicles, cranes, wind energy plants, steel and metal processing plants. The new generation of Baumer encoders, such as the MAGRES EAM580 and EAM360, successfully combine proven robustness with ultimate precision. Their angular accuracy of up to ±0.15º ensures absolute reliability and precise positioning for process control applications which previously required optical sensing. For ultimate reliability, the MAGRES EAM encoder hardware has been developed on the EN 13849 standard which means they can be integrated as standard components with embedded software in overall certified systems up to PLd. They are also available with redundant sensing where the position is transmitted via 2 Node ID’s which have to be checked for plausibility in the control system.

mobile automation. Furthermore, their 0.5mm² wire core cross-section means they are fully compatible for the latest automotive connection technology. The EAM580 with PROFINET option supports the latest communication standards while OPC UA is ideally prepared to make IoT a reality. The broader Baumer range of encoders includes options in 58mm and 36mm sizes along with an extensive variety of mechanical designs, mounting and interface options which provide users with maximum flexibility so they can choose the best encoder for their application. Also, thanks to their compact size MAGRES encoders are ideal for applications where space is limited. Further details available at: www.baumer.com/ch/en/product-overview/rotaryencoders-angle-sensors/industrial-encodersabsolute/c/313 For more information contact: Baumer Ltd. Swindon, Wilts. Tel: +44 1793 783839 E-mail: sales.uk@baumer.com Web: www.baumer.com/ch/en/

An integral part of the new generation of encoders is the R Series (EAM580R & EAM360R). These are designed to be E1-compliant to ensure high electromagnetic compatibility, combined with IP67 protection and C5-M corrosion resistance. The result is uncompromising durability for the most demanding outdoor applications such as

Process Industry Informer – October 2018

Heat Transfer & Energy

Evaporative cooling listed as new category on the Energy Technology List (ETL), entitling buyers to claim an Enhanced Capital Allowance Seeley International are proud to have all three Breezair models listed on The Energy Technology List (ETL), a government list of energy-saving products used by businesses. Breezair products are the first evaporative coolers to be listed on the UK’s Carbon Trust Energy Technology List. The ETL (or Energy Technology Product List, ETPL) is a government-managed list of energy-efficient plant and machinery, such as boilers, electric motors, air conditioning and refrigeration systems that qualify for full tax relief. With over 17,000 listed products the ETL is one of the world’s largest databases of top performing energyefficient products. UK businesses that purchase products listed on the ETL can claim an Enhanced Capital Allowance (ECA), a first year 100% accelerated capital allowance that delivers all available tax relief in 1 year. At the end of 2017, the Chancellor announced a number of changes to the technologies supported under the ETL and those changes have been published as The Capital Allowances (Energy-saving Plant and Machinery) Order 2018 No. 268. The Order came into force on 22 March 2018. The changes include the addition of 3 new

sub-technologies for Evaporative Air Coolers, Saturated Steam to Electricity Conversion Equipment and White LED Lighting Modules for Backlit Illuminated Signs.

To get more information about Breezair, you can browse www.breezair.com/uk or write an email to uksales@ seeleyinternational.com

Seeley International was part of the working committee to establish the new energy technology list criteria for evaporative air coolers, with the Carbon Trust and a number of different stakeholders in the industry.

What is evaporative cooling?

The benefit that businesses can get from choosing a product from ETL is equivalent to approximately 5.5 times the benefit of standard tax relief in the year of purchase. Businesses that purchase products listed on the ETL can also make significant energy savings. Considering embedding the ETL into procurement processes will reduce the time it takes the business to find good quality products, and can deliver resource, energy and financial savings.

The specific Seeley International products that have listed on the ETL are as follows: • Breezair TBS 580 • Breezair TBSI 580 • Breezair EXS 220

Evaporative cooling is the only viable option when cooling large industrial or commercial areas, including semiopen spaces. Evaporative air cooling uses between up to 87% less energy than conventional A/C; it brings in 100% fresh outside air and utilises water for cooling instead of synthetic chemical refrigerants. That all adds up to very responsible environmental and energy saving characteristics. Very easy to install and maintain, evaporative coolers are a great solution to improve air quality, especially in production areas where fumes and germs are involved: in fact, cooled air is never recirculated, doors and windows can be left open or extraction fans need to be installed.

For more information contact Seeley International Europe, Hucknall, Notts, Tel: 0115 963 5630 E-mail: uksales@seeleyinternational.com Web: www.breezair.com/uk

BABCOCK WANSON EXPANDS ITS “OFF THE SHELF” PREMIUM RANGE TO COVER COIL TYPE STEAM BOILERS Following the launch of its new Premium Range of fire tube steam boilers in 2017, Babcock Wanson has expanded the range with the addition of coil type steam boilers. The Premium Range is designed to provide customers with a boiler that meets the very latest safety and operational guidelines at an “off the shelf” price and with shortest practicable delivery time. The latest addition is the VAP Premium Range of fully automated coil type steam boilers with standard outputs from 150 to 1500 kg/h at a 12 barg design pressure. They are available with a range of control options. VAP Premium Range Coil Type Steam Boilers all feature three full gas passes, plus an in-built combustion air pre-heater to give high operating efficiency. With availability of steam from a cold start in as little as three minutes and a low volume of water under pressure VAP boilers combine efficiency with safety, even at high working pressure.

flow and combustion air, which means optimum performance and lowest electrical consumption. Premium Range boilers are highly competitively priced and are aimed at the steam user who wants fully automated control with the minimum of boiler house manning Packages of ancillary equipment – including feed water tank, blowdown tank, softener and chemical dosing – are available. For more information, please contact Babcock Wanson on 020 8953 7111 or info@babcock-wanson.co.uk or go to www.babcock-wanson.co.uk

VAP Premium Range boilers use natural gas fired two stage or fully modulating burners, with the latter featuring digital HMI touch screen control plus remote monitoring via ethernet. They feature the same rugged construction as Babcock Wanson’s standard VAP range, but with the added benefit of the feed water pump being mounted to the side of the unit for quick assembly and ease of servicing plus variable speed drive for both feed water

October 2018 – Process Industry Informer

PIPING SYSTEMS

EXPLOSION SAFETY

PSRE Co. Announces New Version of PASS/ HYDROSYSTEM Affordable, smart simulation has been extended to include three-phase oil/gas/water flow and multi-parameter optimization for automatic sizing of piping systems PSRE Co., the leading developer of smart simulation and sizing tools for every piping and equipment engineer/ designer, is pleased to announce the new version 4.1 of PASS/HYDROSYSTEM scheduled for release beginning of October 2018. This new version contains two big improvements, which are expected to considerably extend the applicability of this versatile simulation and sizing solution helping users to efficiently design complex piping systems that meet all requirements while minimizing design and operational cost. First, PASS/HYDROSYSTEM users can now analyze three-phase gas/oil/water flow typical for oil and gas field piping systems, including automatic calculation of flow rates for each phase in any part of a complex piping network. To enable this, PASS/ HYDROSYSTEM takes into account the mixing of 3-phase flows with different phase flow rates. Preserving its renowned easeofuse and affordability, the PASS/HYDROSYSTEM GUI has been extended to provide different convenient options for setting each phase flow rate at source (oil well) nodes. In this new version, gas/oil/water flow is analyzed as twophase gas/liquid flow whereby the liquid oil/water emulsion is simulated using the HEM model for density and Brinkman – Roscoe generalization of the Einstein formula for viscosity. The program monitors inversion points and defines which type of emulsion takes place in each specific part of the piping network – water in oil or oil in water. Further, integration of the new TUFFP Unified Model Library for 3-phase flow occurs as soon as this library is ready for usage – currently expected during 4Q 2018 – 1Q 2019. The second important improvement allows analyzing and optimizing piping networks containing multiple arbitrary control valves, orifices or other elements with controlled parameters. The parameter selection feature initially introduced in version 3.88 is now capable to support any number of parameters. Unlimited parameters in connection with a modern, derivativefree optimization method (by Powell) enables PASS/ HYDROSYSTEM users find optimal combinations of valves and orifices parameters for complex piping networks. The PASS Suite is already successfully used by more than 2000 customers around the globe to efficiently engineer complex piping systems and related equipment. Please check out the PASS software at www.passuite.com

Fluidwell launches the E126 Explosion-Proof Flow Computer Unequalled safety and ease of use Fluidwell introduces the E126 explosion-proof flow computer for corrected gas and liquid volume measurement. It measures the actual flow, temperature and pressure and converts it with an ideal gas formula to gas volume at reference conditions. It saves time, money and hassle; is designed to withstand the toughest conditions and is simple to use. Daily operations and plant operations for running work permit procedures are no longer interrupted and even (partial) plant shutdowns can be avoided as the covers do not need to be opened to operate, set and modify the display functionalities thanks to the through-glass keypad. This unequalled flow computer delivers user-friendliness in the toughest conditions.

Above and beyond requirements Housing

Operating

The robust stainless steel 316L E-Series housing is designed to guarantee safety. It takes the E126 flow computer beyond the legislative requirements for hazardous areas. In the harshest conditions of punishing weather, desert and maritime climates and extreme temperature fluctuations, the durable E-Series consistently delivers accurate measurements. A solid die cast aluminum housing with the same ingress protection rating is available for cost-effective applications.

The E126 is extremely practical in use. The throughglass keypad enables safe and effortless operation of all functionalities without having to open the cover. The menu, display and navigation structure are designed according to the Fluidwell “Know one, know them all” principle, which enhances easy and intuitive control of various Fluidwell totalizers, flow computers and other displays.

Overview features Advantages

• Saves time and improves flexibility with the through-glass keypad: no need to open the front cover • F amiliar easy operation with the Fluidwell “Know one, know them all” configuration structure, saving time, cost and aggravation. • Easy installation in spacious chamber and plug & play connectors. • Reduces costs with the easy to install 1” NPT thread for direct flow meter mounting. • Durable high-grade stainless steel 316L Ex d enclosure withstanding extreme (maritime) conditions. • K ey information at a glance: flow rate, total, temperature, pressure, measuring units and a flow rate indicating speedometer. Hazardous area information

The E-Series are ATEX, IECEx, FM and CSA C-US certified for an ambient temperature range of -40°C to +70°C (-40°F to +158°F). The ATEX markings are: G as: II 2 G Ex d IIC T6 Gb Dust: II 2 D Ex tb IIIC T85°C Db The IECEx markings are: Gas: Ex d IIC T6 Gb Dust: Ex tb IIIC T85°C Db The FM and CSA C-US markings are:

X P (Explosion-proof): Class I, Division 1, Grps A, B, C, D. DIP (Dust-Ignition-proof): Class II/III, Division 1, Groups E, F and G. Gas: Class I, Zone 1, AEx d IIc T6 Gb. Dust: Zone 21, AEx tb IIIC T85°C Db.

Fluidwell bv

Fluidwell’s mission is to be the premier supplier for display and calculating solutions wherever process variables need to be measured, converted, monitored or otherwise processed. We develop, produce and sell reliable and safe signal processing equipment. We work in close cooperation with our customers and support them in finding the right product for their applications. Your success counts! For any specific customer request, there is a Fluidwell product available or one can be developed. This provides our customers with the best equipment to suit their needs and requirements, with a familiar and intuitive user-friendly interface. Know one, know them all! Further information contact: Fluidwell Group, The Netherlands Tel: +31 (0)413 343 786 E-mail: mail@fluidwell.com Web: www.fluidwell.com.

Process Industry Informer – October 2018

TANK CLEANING By Graeme Shaw, Technical Application and Academy Manager, Zumtobel Group

TANK CLEANING PRESSURE LOSS PROBLEMS SOLVED BY SIMPLE RECONFIGURATION The Problem Tank cleaning applications can be adversely affected by pressure loss problems which can have a direct impact on cleaning efficiency. A good example of this is where cleaning heads were installed and then subsequently found to be having very little impact on the tank walls. The tanks in question were large 10 meter diameter storage vessels that required periodic, as opposed to regular cleaning. In theory the 4 nozzle rotary jet heads should have had sufficient reach to provide adequate cleaning but, when observed, the jets were barley reaching the walls. The Cause Following the investigation it was found that frictional pressure losses were causing a significant pressure drop between the pump and the cleaning head. The pipe run was quite long with an effective length of 50 meters and in addition, there was a 12 meter climb. Also, the tanks were larger than before so a natural conclusion would be that a larger tank cleaning system would be needed. However, what was not accounted for was the additional flow in the existing pipework, which then caused an increase in pressure losses. The result was that the cleaning heads only ‘saw’ a 4 bar pressure drop, as opposed to the 8 bar required. The Solution As the cleaning required on this particular application was only periodic the time taken to clean was not critical. Therefore, swapping the cleaning heads from a 4 nozzle to a 2 nozzle configuration meant that the cleaning time was doubled, but crucially the flow rate was lowered. This reduced the frictional pressure losses incurred and allowed the new 2 nozzle configuration to ‘see’ the higher pressure drop and therefore, delivered a more powerful cleaning jet. The Benefit This relatively simple reconfiguration meant that the time, expense and inconvenience of having to upgrade existing pipework was avoided and enabled the existing tank cleaning system to deliver the higher flows required for more effective cleaning. Spray nozzle specialists THE SPRAY NOZZLE PEOPLE (SNP) have established themselves over the last 18 years as leading experts in spray nozzle technology. They have advised a wide range of food process, manufacturing and chemical companies on correct nozzle selection and spray process optimisation, as quite simply the control of the fluid supply to their nozzles is of vital importance. The new SNP product range includes hygienic fluid regulators, filters, air regulators and valves for use with SNP’s air atomising nozzles. The Spray Nozzle People are part of the Spray People Group. More details at: www.spray-nozzle.co.uk/spray-nozzles Or contact: ivan@spray-nozzle.co.uk Tel: +44 (0) 1273 400092

Manufacturing

switches on to light as a service

Analyst insight into the UK manufacturing sector paints a picture of strong current performance ahead of critical strategic challenges. Brexit dominates the headlines, but it is far from the only hurdle on the horizon. In its recent report ‘Pressure on the production line - Working capital in global manufacturing’ PwC dissects the way in which companies in the sector are managing and using working capital. The report points to the need for businesses to invest continuously in their plant and operations in order to remain competitive and to secure long-term stability. The report reveals that the sector’s rate of investment has seen a steady decline over the last five years and now sits at its lowest point during that period, concluding that better management of working capital is key to generating the necessary cash for investment.

Maintaining excellence The future-proofing advantages of light as a service are critical. Without such a model in place, every new technological advancement would require significant capital expenditure. Light as a service provides buyers with the necessary consultative expertise to enable them to stay a step ahead. Additionally, any decision-maker will surely welcome the prospect of dealing with just one supplier contact (safe in the knowledge that the system is being monitored and maintained in the background) rather than having to deal with multiple maintenance, management and sales personnel. Such a service enables the sector to benefit from LED technology – and from future developments without the hassle of owning and operating the lighting solution themselves.

As we enter the much-discussed ‘4th industrial revolution’ there is clearly pressure on manufacturing businesses to assess legacy operations and re-think legacy processes. Historically, lighting has not been a major consideration for the sector.But a new mindset is emerging. The sector’s leaders are embracing the new idea of light as a service, whereby the future performance of the lighting solution is ensured by the supplier, and where no capital outlay is required.

Not only is electricity getting more expensive every year, maintenance costs are also increasing. Every day an obsolete lighting system is operating it causes unnecessary extra costs - through excessive electricity consumption, high failure rates and high maintenance charges. Doing nothing is expensive.

The light as a service model enables manufacturing companies to look far beyond what would otherwise be possible without such a financing model in place. Put simply, businesses can upgrade the way in which light is used within their environment and pay for it using savings generated from day one of installation.

Changing any purchasing and business model will always require careful assessment, and moving to light as a service will be a step change for many. However, taking the decision now can lead to immediate savings and can result in a model that normally pays for itself from day one.

Tailored for purpose Certainly, the cost-savings and energy efficiencies delivered by today’s LED lighting systems are compelling. But undertaking to buy light as a service rather than a commodity moves the conversation way beyond simple savings. Manufacturing covers a broad array of processes, many of which impact – or are impacted by - the operational environment. Our dealings with the sector have revealed a number of specific lighting challenges. The pharmaceutical industry provides an obvious case in point. Many pharmaceutical products are light sensitive and will degrade under the wrong kind of light. In turn, lean manufacturing processes place the emphasis on increasing efficiency and reducing waste. Here, high-quality LED lighting is assisting with product inspection and quality control. Food manufacturing presents another challenging environment. We have seen examples of dispersed sausage fat eating into the plastic lighting surrounds. The same issues are present in environments dealing with ammonia or chlorine. The light as a service model delivers immediate and ongoing access to lighting industry experts, individuals who are trained to assess the operating environment and who have the experience and depth of knowledge to suggest best-fit lighting

October 2018 – Process Industry Informer

solutions. Light can be tailored and controlled to suit a client’s specific needs.

Time to switch

Everything associated with lighting - from design via installation and commissioning through to regular maintenance – will be handled by the expert provider, enabling manufacturing leaders to focus on core tasks. Once installed, transparent remote monitoring helps to achieve the agreed aims regarding illuminance and energy efficiency and – with expert guidance - to quickly identify opportunities to adapt and enhance usage patterns. Adjusting lighting to individual specific needs and implementing new functions isn’t a one-off task performed when installing the lighting, but rather continues throughout operations. In this way, possibilities for optimisation – in the areas of quality, efficiency and functionality – are constantly monitored. Light as a service arrangements allow future cost avings to be harnessed to pay for today’s digital technology upgrade. Such arrangements are gaining attention precisely because they enable investment without capital commitment, moving the business model from buying technology, to paying for access to that technology. It is the combination of smart financing and smart technology that can accelerate investment in the smart manufacturing environment.

FILTERATION & FABRICATION

PIONEERING FILTRATION TECHNIQUE CAPTURES “ELUSIVE 80%” OF SOLIDS

HYGIENIC FABRICATION CAN BE EXOTIC

The European process industry now has access to a pioneering form of thermal fluid filtration technology, capable of removing the 80% of particulate matter too small to be captured by conventional techniques, so improving the cost-efficiency of thermal oil systems across the continent.

Bespoke stainless steel fabricators, Axium Process, specialise in hygienic engineering design, fabrication and system solutions utiilising a wide range of corrosion resistant superalloys including exotic alloys; Hastelloy®, Duplex®,, Inconel®, and Monel® as well as high performance engineering plastics such as PEEK®,, used in the company’s CNC operations for applications where weight, heat resistance and strength are paramount.

UK-based provider of thermal fluid system support, maintenance and risk management services to the global process industry, Thermal Fluid Solutions (TFS), has launched a new depositional filtration service, the first to remove particulate matter measuring less than 20 microns.

Selecting the right material for the right application is crucial to the success of any design project particularly for challenging applications such as those associated with high salt concentrations and where system integrity and optimum plant design life is critical. Axium Process’ bespoke design and fabrication expertise has been built on years of diverse and practical experience supplying custom filtration systems and components for the most challenging of applications across a wide range of industries. The company’s welders and Procedures are Notified Body approved to ASME IX, BS EN ISO 9606-1, BS EN 15614-1; engineering design, procurement and fabrication is carried out in accordance with EHEDG and ASME BPE prinicples and FAT/SAT testing and training is carried out to the highest levels.

TFS estimates that approximately 80% of particulate matter measures less than 20 microns, the minimum size addressed by conventional full flow filter mesh filtration techniques traditionally used throughout Europe. Carbon solids are formed due to the oxidisation of thermal oil operating at high temperatures. They abrade components such as pumps, seals, bearings and valves, compromising their performance. They form deposits, restricting flow and reducing the

heat transfer capability of the system. If left unchecked, systems can become completely blocked and cease to function. TFS’ new depositional filtration units re-route oil from live thermal fluid systems, running it through fine filters to remove solids without incurring any down time. Systems are left free from particulate matter, and so able to operate efficiently. The company’s continuous thermal fluid risk assessment and management service, of which regular fluid testing and analysis forms an integral part, enables it to spot when customers’ oil requires filtration. Said TFS’ managing director, Richard Franklin: “Our work with process manufacturers worldwide demonstrated that, while growing numbers were adopting ongoing risk management policies to ensure that their thermal fluid systems complied with health and safety legislation, many systems were operating inefficiently due to a build-up of matter that escaped conventional filtration. For further details, please visit www.thermalfluidsolutions.com.

Axium’s design expertise is backed up by its team of qualified engineers who routinely offer advice and cost effective engineering solutions ensuring the best value for money in terms of process development, efficiency and on time delivery. For further information please contact: Axium Process Ltd, Hendy, Swansea Tel: +44 (0) 1792 883 882 Email: info@axiumprocess.com Web: www.axiumprocess.com

FREE FLUID FILTRATION AUDIT SERVICE FROM ECLIPSE MAGNETICS Feedback and advice will be given regarding your current method of fluid filtration, the levels of ferrous contamination circulating in your system, and ways to improve your current system, and highlighting any potential problem areas. With the recent publication of the Good practice Guide for Safe Handling and Disposal of Metalworking Fluids from The United Kingdom Lubricants Association (UKLA), in conjunction with the Metalworking Fluid Product Stewardship Group (MWFPSG) and the Health and Safety Executive (HSE), the correct management of fluids has never been so important to minimise health risks. Filtration specialists at Eclipse Magnetics are offering free fluid filtration audits to companies across the UK. No obligation visits are carried out by an experienced, qualified engineering professional, and include a free of charge assessment of a business’ fluid filtration practices. One of our fluid filtration experts will visit your site at a time and date convenient to you, and asses your current methods of managing ferrous contamination in your oils, coolants and lubricants. Where required, a more detailed laboratory analysis and report service is offered, including an ISO cleanliness code to determine the solid particulate count (as stated by ISO 4406:1999). In addition to contamination testing, full chemistry tests can be carried out including foaming, PH testing and bacterial count.

David Buchan, UK Sales Manager for Filtration at Eclipse Magnetics Ltd said: “Businesses are quickly realising the importance of the strict management of metalworking fluids, not only to reduce the risk of ill health in operators and meet health and safety directives, but also to improve accuracy and quality in their manufacturing processes and meet environmental directives. The launch of the Free Fluid Filtration Audit Service from Eclipse Magnetics is a direct response to the increasing demand for safe, efficient, and clean fluid filtration systems, and our experts have extensive experience in improving fluid quality in a variety of applications.”

Effective fluid filtration improves the surface finish and accuracy of manufactured components, extends the life of machinery and the oil, coolant, or lubricant itself, and improves production rates. Eclipse Magnetics patented magnetic filtration systems are the ultimate in filtration technology, providing cost, quality, environmental, and health benefits. Unlike some traditional filters which use replaceable media such paper, magnetic filters require no consumable items thereby presenting significant cost savings, and reducing the amount of waste sent to landfill. To book a free Fluid Filtration Audit Service from Eclipse Magnetics, please contact us on 0114 225 600 or email: info@eclipsemagnetics.com. For more information about filtration systems for metalworking fluids, oils and coolants, please visit www.eclipsemagnetics.com/row

Process Industry Informer – October 2018

PRODUCT & SERVICES DIRECTORy BUTTERFLY VALVES

CONSULTING

DUST CONTROL

LIQUID RING VACUUM PUMPS

162 CHILTERN DRIVE, SURBITON, SURREY KT5 8LS TEL.: 0208 399 9991 FAX: 0208 390 2004 www.dustengineering.com

EXPLOSION PROTECTION

Nylon Screens

Industrial Datacoms

VALVES

MIXERS & BLENDERS

PIPE COUPLINGS

PIPEWORK SYSTEMS

SIEVING

TRAINING

Water AnalysiS

Sifting Machines

WEIGHING SOLUTIONS

To advertise here: email info@piimag.com or call 01428 751188

The Pitreabie Business Park, Queensbury Road, Dunfermline KY 8UL TEL.: 0333 300 1851 FAX: 01527 590310 EMAIL: sales@preciamolen.co.uk web: preciamolen.com