Process Industry Informer Magazine Sept 2013 Edition

PROCESS INDUSTRY INFORMER.

SEPT 2013 Volume 9 No. 5

THE UK’S BIGGEST PUBLICATION SERVING THE PROCESS INDUSTRIES

In this issue...

• 9 Editorial Features • News & Applications • Product Introductions • BPMA News

Catch up with robotic automation, understand the role of maintenance & asset management in optimising plant management, check out pressure transmitter materials, find the right float switch, understand the new REACH regulations, avoid gas hazards and update yourself with ATEX.

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

NO COMPROMISE BETWEEN FREE PASSAGE AND HYDRAULIC EFFICIENCY

Innovative technologies mean we can offer you the highest total efficiency yet in a wastewater pump – the Grundfos SE and SL ranges GrundfoS S-TUBE Groundbreaking impeller design: The S-tube impeller offers world class hydraulic efficiency without compromising free passage

GrundfoS iSOLUTIONS Our total system approach: Customised technologies allow the pump system to adapt dynamically and intelligently to changing operating conditions

GrundfoS BLuEfLux® High motor efficiency: Grundfos Blueflux® guarantees IE3 motor efficiency, maximising electrical efficiency in the pump

GrundfoS SmarTDESIGN User-driven design: Trouble-free installation, operation and maintenance of products through functional design

The SE and SL ranges of wastewater pumps provide the highest total efficiency currently available. Innovative technologies from Grundfos bring together intelligence, motors, hydraulics and functionality to meet the challenges of modern wastewater, maximising the hydraulic, electrical and mechanical efficiency of your pumps.

See more at http://uk.grundfos.com/no-compromise.html

Contents

editorial features

News & Events 4-6

Premium Conveyor Lines 38

Applications 7-9

Bulk Bag Fillers 38

Transforming your sustainability with robotic automation 10 The role of maintenance and asset management 13 Sweating your assets – MORE! 14

Process Control 11

Grinding, Classifying & Drying 38

Health & Safety 12

Instrumentation 40

A Guide to Pressure Transmitter Materials Selection 16/17 More Efficiency from Motors 18 A Guide to Selecting

Network & Communications 15

Control & Power Distribution 40

BPMA News

Multi-pin Connectors 41

from The British Pump

Manufacturers Association

19-26

the right Float Switch 28 REACH Regulations update – Time is running out 31 CO2 Gas Hazards in the Brewing Industry 34

Fluids & Liquids Handling inc. Pumps & Valves 32-36

Enclosures 41

Keep up with ATEX and stop dust fires 39

Stainless Steel Tube & Pipe Fittings 36

Set Point Generators 41

Spray Nozzles 36

Air Powered Equipment 42

Materials Crushing 37

Range of Transmitters 42

Filtration & Separation 37

Suppliers Directory IBC

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

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

All product announcements published in Process Industry Informer are paid for. All copy submitted for publication in Process Industry Informer must be legal and must comply with the British Code of Advertising Practice and is accepted for publication, or not, at the publishers’ absolute discretion. When deemed necessary all copy may be edited and classified at the publishers’ discretion.

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News & Events

Axion Consulting adds expertise to resource recovery team Axion Consulting has added further project management and marketing expertise to its Bramhallbased team of resource recovery and recycling specialists.

Jessica Stewart brings a wealth of waste management experience to her new job as Project Consultant working across a range of initiatives, from carpet and WEEE recycling to broader research contracts and an internal environmental management system.

Commenting on her new role, Jessica says: “Axion takes a dynamic and highly-innovative approach to the resource recovery and recycling of a variety of materials. It’s an inspiring environment and I’m looking forward to developing my skills and helping to expand Axion’s services further as part of this great team.”

As Marketing Assistant, Manchester University graduate Callum Moran has joined the marketing team with a remit to further develop social media, online and promotional activities across both Axion Consulting and Axion Polymers.

“This role at Axion presented a great opportunity to expand my expertise in Marketing whilst being a part of a very exciting company with a friendly, hard-working team,” adds Callum.

For more information, contact Axion Consulting, Bramhall, SK7 2DG Tel: 0161 426 7731 Fax: 0161 426 7732 E-mail: info@axionconsulting. co.uk Web: www.axionconsulting.co.uk.

Sponsored by

RECOVINYL RECYCLERS SUPPORT BPF PVC SUSTAINABILITY EVENT Recovinyl-accredited PVC recyclers will again be exhibiting at a British Plastics Federation one-day seminar on October 3rd, in support of the UK forum’s emphasis on sustainability within the UK PVC industry.

Innovative applications for recycled PVC, including its use in new windows, flooring and building products, will be presented by VEKA Recycling Ltd, part of the VEKA UK Group, PVC Recycling Ltd, Polyflor and Recofloor, the UK’s vinyl flooring recycling scheme, at the event in the Etihad Stadium, Manchester.

Recovinyl’s achievements and the contribution of PVC products to the success of the 2012 London Olympics will be among a broad range of subjects covering how the PVC industry can enhance and promote its cost, energy and resource-saving potential.

Entitled ‘PVC Products: Promoting Social Responsibility in Procurement Decision Making’, the day offers scope for specifiers, PVC converters, PVC product sales and marketing professionals to learn about the future opportunities and challenges facing the industry.

Jane Gardner, Senior Consultant at Axion Consulting and the UK agent for Recovinyl, says: “The success of the Recovinyl scheme and its PVC recyclers is testament to the on-going industry commitment to more sustainable practices, as well as meeting growing demand for greater recycled content in new PVC products.”

For more information contact: Axion Consulting, Bramhall SK7 2DG Tel: 0161 426 7731 Fax: 0161 426 7732 E-mail: info@axionconsulting.co.uk Web: www.axionconsulting.co.uk and www.recovinyl.com

Demag tandem hoists promote workplace safety ■ New concept for working beneath suspended loads ■ Lifting solution for a wide variety industrial processes Hot-galvanising company, Helling & Neuhaus, in conjunction with Terex Material Handling and with input from the industrial employers’ mutual insurance association, has developed a solution which allows operators to work beneath suspended loads. The lift and lower sections of the two Helling & Neuhaus conveyor lines have each been equipped with two Demag double chain hoists, which are connected by means of a tandem control system. According to the manufacturer, this concept, which satisfies the requirements of BGV D8 Plus hoists, is an innovative solution, which provides maximum safety for a wide range of industrial applications.

In many production facilities, including galvanising plants, it is necessary for operators to work beneath suspended loads, which are held by chain hoists. Applications such as these are subject to special safety requirements, which are laid down in the BGV D8 safety regulations.

Michael Rother of Helling & Neuhaus GmbH, Engineering Director, stated: “Together with Terex Material Handling and the industrial employers’ mutual insurance association, we first carried out a risk assessment and analysis. On the basis of the results, a concept was developed to satisfy the requirements of the BGV 8 Plus regulations, allowing operators to work beneath the trolleys.”

For more information contact Demag Cranes & Components Ltd, Banbury, Oxfordshire Tel: 01295 676100 Fax enquiries to: 01295 271408 E-mail: bnb-help@terex.com Web: www.demagcranes.co.uk

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CERAM TO

HOST ‘SURFACE ANALYSIS WORKSHOP’ ON 22 OCTOBER 2013 Ceram, the international materials technology company, will be holding a ‘Surface Analysis Workshop’ on Tuesday 22 October at its headquarters in Stokeon-Trent.

As experts in surface, near surface and interface analysis, with state-of-the-art equipment and a wide range of techniques, Ceram will provide an introduction to various surface analysis techniques.

The Workshop will be split into a morning of presentations around the main techniques and industry applications, and an afternoon of laboratory demonstrations.

Delegates will have the opportunity to take a sample along for the technique demonstrations and/or for a one-to-one discussion with a member of Ceram’s surface science team.

The workshop will run from 9:30am - 5:00pm and has a registration fee of £150.00 + VAT (this will include refreshments and a buffet lunch).

For programme/further information and to register, visit www.ceram.com/workshop.

Reliable measurement of oxygen in thermal oxidisers METTLER TOLEDO has launched a new online webinar reviewing the function of thermal oxidisers. The short presentation discusses how oxygen measurement at the exhaust outlet allows optimisation of the combustion process, reducing fuel costs and ensuring high VOC destruction.

Watch the Webinar ‘Reliable Measurement of Oxygen in Thermal Oxidisers’ and discover why in-situ tunable diode laser (TDL) oxygen analysers are an excellent tool for monitoring oxygen levels. The presenter outlines the benefits of the probe-style GPro 500 TDL oxygen sensor including: • Easy one-flange installation • Virtually no maintenance • Withstanding thermal oxidiser environments • Built-in Intelligent Sensor Management (ISM®) • Reduced operating costs Watch the Webinar at www.mt.com/uk-combustion-webinar For more information contact Mettler Toledo, Beaumont Leys, Leics.

Tel: 0116 234 5095 E-mail: enquire.mtuk@mt.com Visit: www.mt.com/o2-TDL

Process Industry Informer September 2013

News & Events

Sponsored by

BARTON OPENS ABB wins $27 million THE DOOR TO offshore automation contract EXCLUSIVE SPARES Barton Fabrications, the largest aluminium silo manufacturer in the UK, has been successful in obtaining a consignment of moulded blue plastic silo doors before tooling was scrapped. The doors are an exact replacement for damaged doors fitted to existing Braby storage Replacement Braby plastic door fitted to a silo silos.

Commenting on the purchase, Mark Barton MD of Barton Fabrications said: ”Since Braby closed its doors in 2011 we have had requests from a number of companies to provide spares and a refurbishment service for its silos. We have been fortunate in obtaining what we believe are the only replacement Braby silo doors in Europe.”

The doors are supplied undrilled ready for customer fitting to replace existing damaged doors.

Safety and automation systems from ABB will contribute to the efficient and safe operation of Statoil’s Heimdal platform.

ABB’s scope comprises a new human-machine interface (HMI) for the control system, control room modifications, simulator, fire and gas detectors, integration of telecommunication in the control room and information management systems (IMS).

Following the upgrades, the Heimdal platform will have ABB’s modern 800xA Extended Automation platform as the main control system, adapted to comply with Statoil’s guidelines for workstations layout and design of process graphic. According to the agreement, ABB will have the complete engineering, procurement, construction and installation (EPCI) responsibility.

Today the Heimdal field has reduced its own production and the platform is now primarily a hub in the central North Sea for the processing and distribution of gas. The platform receives gas from the Huldra, Oseberg, Skirne and Vale fields and exports it via Vesterled or Statpipe pipelines for processing. At its peak the amount of processed gas in Heimdal represents 15 to 20 percent of the total Norwegian gas production.

The agreement strengthens ABB’s position as a supplier of maintenance, modification and service of existing fields and confirms its ability to manage complex projects involving core areas: automation, power, telecommunication and instrumentation.

For more information on spares and silo refurbishment contact Barton Fabrications via its website www.bartonfabs.co.uk or Tel: +44 (0) 1275 845901.

For more information contact ABB Ltd, St Neots, Cambs.

Tel: 01480 475 321 E-mail: oilandgas@gb.abb.com Web: www.abb.com/oilandgas

Safety and sustainability go hand-in-hand KIMBERLY-CLARK PROFESSIONAL* is urging manufacturers to consider safety and sustainability as inextricably linked in order to maximise their performance in both areas as many companies in the industrial world treat safety and sustainability as separate areas of focus altogether.

However, according to Alison Cook, End User Marketing Manager UK, Ireland & Benelux at KIMBERLY-CLARK PROFESSIONAL*, “A fresh perspective is always helpful and we have helped many of our customers in this way through our Efficient Workplace programme, which has been designed specifically to help companies in a range of industries eliminate hazards and enhance the sustainability of their operations by boosting their efficiency and performance.”

The Efficient Workplace initiative helps companies identify hazards and unsustainable practices and root them out using targeted, tailored solutions. It’s an innovative strategy focused on maximising safety, sustainability and profitability through finding the right solution for each individual company.

For more information contact Kimberly-Clark Limited West Malling, Kent. Tel: 01732 594000 or visit www.kcprofessional.co.uk

Process Industry Informer September 2013

PUMPING Plating Solutions, Acids?

3M Magnetically driven, sealless pumps are perfect for safe and reliable transfer of the most challenging fluids in surface treatment, finishing applications.

• Sealless design and corrosive resistant materials

• Wide range of models,

flow rates up to120 mc/h, heads up to 44 metres, system pressures to 6 bar

• From 3M, the experts in

mag-drive, sealless pumping

Pick the perfect pump – from Pump Engineering

PUMP ENGINEERING Tel: 01903 730900 sales@pumpeng.co.uk

www.pumpeng.co.uk

5

Introducing our 2 new regular website sections: In the Hot Seat & Top 10 Tips To make sure you don’t miss each update register to receive our weekly E-newsletter Process Industry Update and keep up-to-date with all the latest news & gossip. Simply log onto www.piimag.com or email philblack@piimag.com

The best bits from In the Hot Seat…

Likes: Dedication, Trying something new, Snowboarding, Clever humour, Time with family Dislikes: Lack of Commitment, The M62, People who take themselves too seriously, Jobsworths

Best & worst business decision you have made Best: To bring in a non-executive Business Director, a decision triggered by attending the Cranfield Business Growth Programme in 2001. It’s a strategy I’d particularly recommend to small/medium sized companies looking to instigate significant change (Peter Guttridge, Chairman Guttridge Ltd) Worst: Attempting to build an internal ERP system!

(Roger Gallo, CEO EquipNet Inc)

What has been the most important advancement in technology for your business?

The introduction of CNC (computer numerical control) machines for manufacturing. I remember my father purchasing our first CNC punching and nibbling machine in 1979 for the princely sum of £85,000 and how it began a transformation in manufacturing practice. Today computers have changed almost every aspect of daily business, but I still find the CNC machines especially compelling. By taking instruction directly from plans on the PC they cut steel to impressive tolerances while at the same time minimizing waste and the manpower needed for construction. It’s fascinating to watch them in action. (Peter Guttridge, Chairman Guttridge Ltd)

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

I was sponsored by Rolls Royce at university and went to work for the Rolls Royce Industrial Power Group in Sheffield as a Quality Engineer. (Simon Nadin, General Manager, Siemens Mechanical Drives)

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

As part of our services package we launched a Smart Auction platform to help manage online sales. This offers both buyers and sellers additional benefits over a traditional auction, as it takes on a completely different

Get involved!

6

approach. For buyers, the Smart Auction platform offers multiple chances to win equipment and sellers gain a higher level of flexibility to approve bids in real time. (Peter Guttridge, Chairman Guttridge Ltd)

What can’t money buy?

Trust. One of the most challenging things industry faces at the moment is around quality of leadership, and trust is the essence of good leadership. It has to be earned. (Simon Nadin, General Manager, Siemens Mechanical Drives)

Best advice you have ever been given and what advice would you give to aspiring engineers?

“Numbers set you free.” If you can hit your figures/ targets, that frees you up to do other things. My advice to aspiring engineers? Be acutely aware of the business of engineering, not just the excitement of the technology or the product itself. All too often in the UK this is the thing we lose sight of. (Simon Nadin, General Manager, Siemens Mechanical Drives)

What has been the most unusual project your company has undertaken?

We were asked to sell a golf course. A large pharmaceutical company in the Midwest via an acquisition became the owner of an 18-hole golf course. (Roger Gallo, CEO EquipNet Inc)

What has been the most embarrassing moment at work?

General Manager BEKO Technologies)

In 140 characters tell people why they should ‘Tweet’ or ‘Like’ this post Peter Guttridge, chairman shares the good, the bad, the comic and the pretty unpleasant! A great 5 min, thought provoker.

I’m not a celebrity or a personality but ordinary working people have interesting lives too. (Steve Riley, General Manager BEKO Technologies) The shower may make them laugh but as an engineer I try to make Britain better. I’m proud of my team and the processes we’ve improved so far. (Simon Nadin, General Manager, Siemens Mechanical Drives) Do what you love doing and other #GoodAdvice from @EquipNet CEO Roger Gallo

Log onto http://www.piimag.com/ in-the-hot-seat to read the latest ‘In the Hot Seat’ Most recent Top 10 Tips: Top Tips: For buying a Level Switch from a supplier that offers multiple technologies Top Tips: For Temperature/Humidity Data Logging Top Tips: For Maintaining your Storage Tank

I took a hot shower at our new offices and the steam triggered a fire alarm. The sensor had been incorrectly fitted, but I had to exit the shower with a tea-towel round my waist and stand in the car park - in January.

Very humiliating for me but amusing for my work colleagues! (Simon Nadin, General Manager, Siemens Mechanical Drives)

If you were invited to appear on Mastermind what would be your specialist subject and why?

The life and works of Pink Floyd. I have their entire catalogue, read the books, got the DVDs. (Steve Riley,

Top Tips: When selecting Mixers for Powder Blending Top Tips: When choosing a Water Purification System in the Food & Beverage sector TOP TIPS: For Nozzle Selection and Spraying System Design TOP TIPS: For Industrial Staff Training TOP TIPS: For Preventative Maintenance on Variable Speed Drives

Log onto http://www.piimag.com/ top-tips/ to read more

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

Process Industry Informer September 2013

applications NOV MONO EZSTRIP™ TECHNOLOGY HELPS IMPROVE BIOGAS PRODUCTION EFFICIENCY

HIRE STATION MOVES LOW-LEVEL ACCESS OUTDOORS

The ability to reduce the average maintenance time from 1 day to just 1 hour was a key reason why a NOV Mono EZstrip™ maintain-in-place, progressing cavity transfer pump was selected by a large wastewater treatment plant in Germany.

Installed at the Karanlage Plön site in Schleswig-Holstien, the pump transfers sewage sludge to an anaerobic digester for biogas creation. Operating at 294 rpm, the pump transfers the sludge at 15m3 per hour, lifting it 18 metres into the digester.

“Whenever the previous pump needed maintenance it took 8-hours to strip, maintain and rebuild,” says the plant’s Abwassermeister, Andreas Laatsch. “The ability to do this to the Mono pump in one hour has cut our maintenance times dramatically and also helped reduce the associated costs.”

Mono’s innovative EZstrip™ technology allows the pump to be disassembled without removing any associated equipment or pipework. By simply removing a few screws, the suction chamber is dismantled giving access to remove any rag buildup. The EZstrip™ transfer pump can be installed into new plants, or retro-fitted into existing NOV Mono Compact C installations. No electrical disconnection is required and suction and discharge pipes remain untouched “There are increasing instances where customers are realising the tremendous time and cost savings which our EZstrip™ pumps offer,” adds Mono’s Area Sales Manager in Germany, Werner Potrafke. “The EZstrip™ technology represents the biggest leap forward in progressing cavity pump design for 30 years.”

Hire Station, a member of the Vp Plc group of companies, displayed its ingenuity in providing low-level access solutions at the recent Network Rail track and plant show.

Showcased on the Vp group stand was a variant of the PecoLift which has been specifically designed for outdoor use. The compact PecoLift is the first ‘non-powered’ powered access platform. It does not use batteries – so no charging requirement or mains power consumption – just step on and turn the handle.

Using a unique winding mechanism, the access platform requires minimal effort from the operator to attain a safe working height of 3.5 metres, and its wheels are automatically braked on elevation.

Graham Haigh, who is Business Development Director for the specialist Hire Station division that deals with low-level access for sectors such as facilities management, petrochemical and rail, explains: “Like many low-level access products, the standard PecoLift is not wind-rated and is therefore only suitable for use indoors, on a flat level surface.

However, at Hire Station, we could see great potential for this product in outdoor maintenance applications. Together with the manufacturer, we came up with a wind-rated PecoLift which has all the necessary attributes for working in the open. The newly-designed PecoLift provides excellent stability, can be operated on gradients up to three degrees and has a wind rating of 12.5m/s.”

Hire Station reports that it has now taken delivery of the initial batch of production machines, with further units ordered to complete the hire fleet, and has already placed equipment with clients. Initial contracts for the new PecoLift include 10 units on hire to Hertel (UK) Ltd – a leading maintenance and facility management services provider.

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

For more information contact Hire Station Ltd, Trafford Park, Manchester Tel: 0844 8920137 Web: www.lowlevelaccess.co.uk

Pulsar’s non-contacting control for the Mersey Estuary pollution alleviation scheme Pulsar Process Measurement have supplied non-contacting ultrasonic level measurement instruments that have been incorporated into United Utilities flagship project, the Mersey Estuary Pollution Alleviation Scheme (MEPAS), providing key control and monitoring functions throughout the network of CSO/SSO chambers, vortex and interceptor sewers that form the MEPAS network.

When the major Sandon Dock Wastewater Treatment Works was expanded during the 1990’s, the scheme included a substantial network of interceptor sewers and CSO, designed both to separate out solids and particulates before the main Works and to manage storm surges. Some of Pulsar’s earliest equipment was used as the project went live, including the unit that bears the serial number 0001. The Mersey is now so clean that, within a few hundred yards of the sewage treatment works itself, a scuba diving centre is flourishing, and many species of fish have re-established themselves in the river.

However, following major and damaging floods in 2010, it became clear that the existing control and monitoring regime that controlled the flow to the WwTWwas not operating as it should. The new control systems contractor, Ramptec, along with UU’s modelling team, redesigned the system operation through the 39 CSO’s within the network. Pulsar Process Measurement supported, ensuring that the ultrasonic level measurement instruments at each location were performing correctly.

Under the new control arrangement, the holding capacity of the system is maximised, so storm flows to the works are better managed, discharges of untreated and semitreated sewage to the Mersey are minimised, and limits are in place and controlled accurately to avoid any risk of further flooding arising from overflow of the system.

Each CSO includes three or more Pulsar units, at measurement points to maintain control and flows – within the chamber, at the outfall end, measuring river levels and within the vortex chamber feeding on to the

Process Industry Informer September 2013

wastewater treatment works. Some of the applications were challenging, including measurement down narrow pipes that was previously undertaken using pressure transmitters. Pulsar remained involved throughout the project to re-establish control, providing service and commissioning support to Ramptec.

As Ray Watts of Ramptec put it: ‘We have a very good relationship with Pulsar. The fact that we have their first unit, dating back to 1997, and also some of their latest equipment, proves that they supply good equipment and are able to back it up effectively’ The sternest test of the operation of the new system came in September 2012. The 25th September saw some of the worst storms on record, and the effluent height in the culvert reached 4.5m AOD (metres above ordinance datum), a volume of water that would have potentially resulted in devastating flooding if it had not been properly controlled. Both the control system and the CSO’s worked perfectly, however, releasing the excess water safely away from habitation.

For more information contact Pulsar Process Measurement, Malvern, Worcs.

Tel: 01684 891371 E-mail: keithf@pulsar-pm.com

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applications

Ultracoat helps stop the rot in food and drink processing A proven and accredited epoxy coating system, Ultracoat from Fernco Environmental, has become the champion of the food and drink manufacturing industry, as it provides the ultimate in repair, rehabilitation and protection of grease traps, settlement tanks, manholes, and all other trade effluent chambers.

Due to the chemical composition of the trade effluent, chambers traditionally built with concrete and brick will become corroded over a period of time. Effluent may then leach out into the ground, and groundwater will also infiltrate into the drainage network. As a result, the structure may become unstable, maintenance becomes more expensive and the facility may experience downtime. Furthermore, environmental issues may become legal issues.

Thanks to the highly chemical resistant (pH 2-14) Ultracoat epoxy spray applied coating system, these structures can be efficiently repaired and permanently protected, extending their life by up to 50 years.

Graham Howard, Technical Sales Manager at Fernco Environmental comments: “Ultracoat has been used by the food and drink industry worldwide for over 20 years and having been applied to over 50,000 infrastructure projects, the system can still claim zero failures. In addition to its excellent chemical resistance, maintenance and cleaning schedules are reduced – virtually nothing sticks to it!”

Graham adds: “Ultracoat also delivers structural reinforcement, and provides excellent bonding

adhesion to damp substrates – in all pull off tests, the substrate comes off with the coating.”

Containing no VOC’s (Volatile Organic Compounds) and addressing many health and safety issues, Ultracoat is also particularly suitable for application in those corroded chambers and settlement tanks that are located underground or in confined spaces. To ensure the highest standards, Ultracoat is only used by licenced applicators who have completed Fernco Environmental’s rigorous training scheme.

Graham concludes: “The food industry faces ongoing pressure to cut costs and to reduce its environmental footprint from trade effluent. As many are being hit by increased effluent charges and carbon taxation, Ultracoat provides a costeffective and permanent solution for all trade effluent chambers, avoiding the disruption of replacement.

In terms of whole of life costs, it is reduced to a minimum.”

In addition to settlement tanks, Ultracoat is suitable for bunds, manholes, grease traps, reservoirs, tunnels and a whole host of other structures at risk from corrosion.

Independently tested and approved according to a range of international standards, Ultracoat is an ideal solution for the permanent protection of chamber infrastructures.

For further information on Fernco Environmental, visit www.ultracoatsystem.com or call +44 (0)1226 340 222. You can also call Graham Howard directly for more technical details on 07852 196430.

SPIRAX SARCO DELIVERS TOTAL STEAM SOLUTION FOR PIONEERING CARBON CAPTURE PROJECT Spirax Sarco has delivered a comprehensive steam-driven heat exchange solution for a ground-breaking carbon capture project at Ferrybridge coal-fired power station in Yorkshire. The Spirax Sarco system is a key element in the success of this cutting-edge project to develop large-scale technology to mitigate the environmental damage from burning fossil fuels.

Carbon Capture and Storage (CCS) technology aims to capture carbon dioxide from the flue gas of major emitters such as power stations and store it out of harm’s way, possibly by burying it in exhausted oil and gas reservoirs or saline aquifers.

The Ferrybridge project demonstrates the “capture” part of the process at a much larger scale than previous pilot schemes, using an amine-based solvent to absorb up to 100 tonnes of carbon dioxide per day. Spirax Sarco’s steam system is used to re-boil and regenerate the carbon dioxide saturated solvent for reuse by stripping the carbon dioxide out under carefully controlled high-temperature conditions.

The temperature and pressure in the clean-up column, or stripper, has to be controlled precisely. If the temperature is too high, the amine solvent breaks down. If it’s too low, the pressure in the column drops, which means it subsequently takes more energy to compress the carbon dioxide ready for transport and storage.

According to project partner Doosan Power Systems, Spirax Sarco was the right choice to provide the steam system.

For more information, please contact: Spirax Sarco, Cheltenham, Glos. Tel: 01242 521361 Fax: 01242 573342 E-mail: webenquiries@spiraxsarco.com Web: www.spiraxsarco.com

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SINE PUMPS HELP TRANSFER 2 TONNES OF HAZELNUT SPREAD EVERY HOUR AT KESSKO • MasoSine SPS pumps vital to production at German sweet treat specialist • 160 containers of hazelnut spread filled every 60 minutes The Kessko factory in Bonn, Germany is using four MasoSine SPS series pumps supplied by WatsonMarlow Pumps Group to help deliver high quality ‘sweet’ products to customers in the bakery, confectionary, ice cream, biscuit and soft drink trades. At the heart of this effort, the SPS pumps offer reliable service that includes the transfer of up to 2 tonnes of hazelnut spread (containing soft solids) every 60 minutes.

Inside the production hall, one of Kessko’s 180 employees enters the exact weight of 12.5kg of hazelnut spread per container into the filling system. He actuates the foot pedal and the sweet chocolate and hazelnut mixture that children so enjoy spreading on their toast, flows quickly into the containers courtesy of a MasoSine SPS pump.

“We fill 160 containers in this process every hour,” says technical manager Reiner Liffmann, “which is the equivalent of 2 tonnes of hazelnut spread.”

Viscous substances

With their powerful suction, the MasoSine SPS pumps are ideal for viscous substances such as the chocolate spread being handled at Kessko. They provide a particularly gentle, virtually pulsation-free pumping operation. This is what distinguishes MasoSine pumps from other positive displacement models such as gear pumps, for example.

The sinusoidal design of the rotor creates four chambers with each turn, through which the medium – in this case the sweet spread – is pumped from the inlet port to the higher-pressure discharge port. The rotor, unlike on rotary lobe pumps with multiple shafts, is powered by a motor via just one shaft. The scraper gate prevents any liquid from flowing back from the discharge side to the lower-pressure suction side of the pump. Since the chamber volume does not change, the system is perfect for pumping liquids containing soft solids or viscous media.

A heated jacket for the housing is used especially for this type of application, while other pumped liquids require a cooling jacket in order to keep the temperature of the product constant. This is also available for MasoSine SPS pumps.

Thorough cleaning Even the cleaning of the SPS pumps is a straightforward process. The pump is stripped down in 10 minutes. Once the pumphead front cover has been removed, all the internal parts that come into contact with the product can be removed (without tools) and cleaned. The SPS pumps are also suitable for CIP and SIP cleaning processes.

“Our four MasoSine SPS pumps are good, fast and extremely reliable,” concludes Mr Liffmann. “When it comes to acquiring our next pump, Watson-Marlow will definitely be the first port of call. We’re extremely satisfied with what they have to offer.”

For more information contact Watson-Marlow Pumps Group, Falmouth, Cornwall Tel: 01326 370370 Fax: 01326 376009 E-mail: info@wmpg.co.uk Web: www.wmpg.co.uk

Process Industry Informer September 2013

applications

AXFLOW SOLVES A STICKY PROBLEM FOR TOFFEE MANUFACTURER Walkers Nonsuch of Stoke–on–Trent has been making traditional toffees for over 100 years and exports its high quality confectionery to over 35 countries. The recipes may be as old as the family business, but the same cannot be said about the processing equipment.

One of the company’s recent investments has been the installation of six Waukesha Universal 1Series rotary piston pumps from AxFlow to replace rotary lobe pumps which were plagued by mechanical seal failures.

The toffee production cycle starts with uncooked toffee mixture at a temperature of between 40 and 50ºC and this has to be pumped around the factory to various points where it is drawn off for the addition of ingredients that go into formulating the toffee mix. At this temperature the sugar is abrasive and viscous. Once a toffee mix has been produced, the sticky liquid is transferred to the dissolver where it is raised to 85ºC in order to dissolve the sugar. Both operations use the Universal 1 Series 60 pumps.

Once the sugar has been dissolved, it is transferred by four Universal 1 Series 15 pumps to the individual cooking ovens. These pumps are governed by flow meters as it is critical that the speed of the pumps is accurately controlled to ensure a smooth production flow. Cooking is a continuous process, but the individual products are manufactured on a batch process, so there has to be a constant availability of the toffee mix into which the various additives, such as flavourings and colours, are fed. The number of hours that any of these Waukesha Universal pumps run does vary according to production requirement, but as a minimum, the pumps are run eight hours a day.

Walkers Nonsuch switched to the Waukesha pumps after consulting AxFlow, the UK distributor for this pump brand, about the sealing problems that they were experiencing with the existing rotary lobe pumps.

“There were two reasons why the Waukesha pumps were selected, the first being down to efficiency of the design and the second was the elimination of replacing mechanical seals,” says Production Director, Edward

The pump in the foreground is pumping raw toffee to the cookers and the pump in the background is pumping sugar and water to the initial holding tank where the raw toffee ingredients are mixed.

Walker. “It was costing us around £2,000.00 every time seals needed replacing. The attraction of the Waukesha pump is that it contains a self-lubricating double ‘O’ ring seal, so the problem of costly mechanical seal failures is eliminated. In reality, the initial outlay on a new pump can be recovered in around a couple of years.”

The Waukesha Universal 1 Series is a rotary piston pump that employs an operating principle known as the external circumferential piston (ECP). In this design the arc-shaped rotary pistons, or rotor wings, travel in annular-shaped cylinders machined in the pump body.

The resulting long sealing path reduces slippage and produces a smooth product flow without destructive pulses or pressure peaks, and without the need for valves or complex parts.

However, unlike progressing cavity and rotary lobe pumps, the Universal pump is not adversely affected by varying or viscous products that may settle in the pump.

Because the rotors produce a scooping action, they do not squeeze and compact the medium being pumped.

The Waukesha Universal 1 pump is ideally suited to

Site completed Niplast Tanks replace originals after 25 years Simpson Thomson Filtration (STF) Ltd, manufacturers of Niplast Storage Tanks, have replaced two bulk storage tanks, in situ, for NGF EUROPE Limited 25 years after the originals were first installed in the company’s St. Helens site.

Niplast bulk storage tanks were originally installed at the NGF EUROPE’s St Helens site in 1988 and the replacement tanks will continue to store latex solutions for the company, part of the NSG Group, one of the world’s leading manufacturers of glass products.

However, the contract brought new challenges. The original tanks were installed as part of the site construction, being lifted into place before the plant roof was assembled. Hence, 25 years on, STF were required to undertake the demolition of the redundant tanks and complete the construction of the new tanks in situ, within the plant. STF also undertook the licensed disposal and 100% recycling of the original polypropylene tanks.

The two 30,000 litre Niplast tanks have been designed and manufactured to British and European Standard BS EN 12573 Welded Static Non-pressurised Thermoplastic Tanks which was adopted by the BSI in 2000. The key tank components were manufactured at STF’s Stockport factory, primarily the tank roofs, base sections and wall cylinders.

STF Managing Director, Adrian Greenwood said, “The 25 year’s service provided by the original Niplast tanks demonstrates the excellent service life achieved by thermoplastic tanks constructed to BS EN 12573. The provision of the new tanks shows the flexibility of this design standard and the manufacturing and testing techniques.”

For further information about Niplast contact Storage Tanks Tel: 0161 477 6777 E-mail: info@niplast.com Web: www.niplast.com

Process Industry Informer September 2013

confectionery manufacturing because it can handle both thick and thin fluids without causing any damage to the pumped product. It combines a very gentle, pulse-free pumping action with the high suction capacity necessary for allowing the thick mix to be drawn into the pump without any separation of the ingredients. The pump uses double ‘0’ ring self-lubricating sealing system for all applications, which allows high vacuum to be developed on the inlet side.

Manufactured from stainless steel and suitable for CIP cleaning, the pump’s close clearances allow the pumping of water against back pressures, whilst its simple design enables operators to completely strip it down for inspection in situ without the need to remove connecting pipework. Where high viscosity fluids and solids are involved, the large fluid cavities of the rotors, together with the large easy-entry anti-cavitation ports enable efficient pumping. Maximum service life can be achieved even under severe operating conditions where fluids are non-lubricating or abrasive because there is no contact between the bearings and the pumped fluid, nor is there sliding or rolling contact and rotor-to-rotor contact.

According to Edward Walker, it is now about two years since the first of the Waukesha pumps was installed and following on from the success of the pump the other five units have been installed as required. Should there be a need to shut one of the Waukesha pumps down, it can be quickly removed and flushed out in a very short period of time in situ. “When you are making up to as much as 40 tons of toffees a week and having to satisfy orders from customers from all over the world, minimising downtime is a key issue,” comments Edward Walker. “The removal of the old pumps and their replacement with Waukesha Universal 1 Series pumps has removed the uncertainty and costs of mechanical seal failure, and at the same time is contributing to efficiency.”

For more information contact AxFlow Limited, Ealing, London Tel: 0208 579 2111 E-mail: info@axflow.co.uk Web: www.axflow.co.uk

EMERSON WINS $17 MILLION USD CONTRACT TO AUTOMATE PREMIER OIL PLATFORM ON UK CONTINENTAL SHELF Premier Oil has awarded Emerson Process Management, a $17 million USD contract to automate a new offshore production platform in the Solan oil field on the UK Continental Shelf. Emerson’s technologies and services will enable Premier to safely and efficiently manage the platform 160 km west of Scotland from an onshore operations centre in Aberdeen.

Designed for unmanned operations, the platform could serve as a model for future developments in marginal fields, where such operations can help increase profits as well as worker safety.

As the project’s main automation and electrical contractor, Emerson will provide full project services including project management, detailed design, configuration, acceptance testing, commissioning, and start-up support, all as part of a complete solution For more information E-mail: InfoCentral@EmersonProcess.com or visit www.EmersonProcess.com

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Transforming your sustainability with robotic automation Sustainability has become something of a buzzword in modern manufacturing processes. Often requiring investment to bring about the changes needed, it presents something of a double-edged sword for companies seeking to enhance their reputation through sustainable practices

whilst enhancing their competitiveness through reduced costs. With the potential to completely transform production processes, robotic automation is a good example of an investment that can yield improvements in both sustainability and cost performance that can greatly improve competitiveness.

Few would argue that these are tough times for manufacturing and processing companies. As well as having to contend with the toughest set of economic conditions in living memory, there are the added pressures of spiralling energy prices, rising input prices and fragile consumer demand. Not only that, but today’s companies are subject to increasingly stringent legislation governing everything from product quality through to minimising the environmental impact of their operations.

energy is now by far the most significant overhead for any company. It is therefore imperative to find ways to use it more efficiently.

For many companies, the concept of sustainability is the latest addition to this list. The idea has been gathering momentum in recent years, as consumers have become more aware of the environmental issues associated with manufacturing processes and produced goods. Basically defined, it promotes the idea of shaping our activities so that we can enjoy the materials and resources, including water and energy, that we need both now and in the future.

Although it often requires associated changes and investment, acting sustainably can invariably have a positive impact on consumer demand that can lead to improved sales, making it a valuable differentiator and competitive tool.

As a means of reshaping production processes to become more efficient, reliable and less prone to problems caused by wastage and poor quality, modern robotic automation can deliver major benefits for companies that often see investment being recouped within just 18 months.

The following are some examples of how introducing robotic automation can help companies to improve their performance in some key areas associated with sustainable performance.

Energy Energy represents the most vital resource for every manufacturing process. Yet with supply being steadily outstripped by demand, it is no longer a resource that can be taken for granted. The United Nations Industrial Development Organisation’s (UNIDO) recent ‘Industrial Development Report’ points to the need for investment in energy efficient technologies at all levels in order for sustainable growth to be achieved.

To paraphrase UNIDO Director General Kandeh Yumkella, industrial energy efficiency is a key issue that needs to be tackled in order to ensure continued growth, employment and mitigation of climate change.

The knock-on effect of shrinking supplies is already being felt in rising energy prices in the UK. With energy prices having risen by well over 50% in the last 10 years,

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With no requirement for minimum lighting or heating levels, robots offer a great opportunity to cut energy bills.

Current estimates point to a potential saving of 8% for every 1°C reduction in heating levels, while savings of up to 20% can be achieved by turning off unnecessary lighting. Aside from their ability to work in unlit and unheated environments, robots also present massive opportunities to help save energy through longer-term productivity improvements, particularly in the area of reduced wastage, as I shall show below.

Wastage Closely linked to the inefficient use of energy is wastage.

Every product that has to be reprocessed requires additional energy, materials and cost to make it. Not only that, but there is the additional cost and environmental impact associated with disposing of the ruined product and / or any associated waste. As a means of producing and handling hundreds of products quickly, repetitively and accurately, robotic automation has been proven to virtually eliminate product wastage.

As such, reduced wastage can make a major contribution to more sustainable production practices, by enabling products to be produced correctly first time, optimising the use of materials, and reducing the amount of energy, with less capital spent.

Flexibility One of the biggest areas that companies need to address to improve their sustainability performance is product and process innovation.

In essence, this focuses on the need for companies to find new ways to remodel their production processes and find ways to reduce the environmental impact of their product offerings, both during production and after, at the disposal stage.

Robotic automation can help in both these areas. For one, robots offer a very high level of flexibility as they can be programmed to handle a large number of product variations and sizes.

With the availability of simulation and offline programming software suites, programming the production line in advance can increase overall productivity and enable shorter change-overs between products. The ability to produce a greater range of products without causing considerable downtime can not only increase profitability

Mike Wilson, General Industry Sales and Marketing Manager for ABB’s UK robotics business, explains how.

but enable tasks such as training, programming and optimising plant processes to take place without disturbing production.

A real life example of how flexible robots can be in production is the Youngman Group. The manufacturer of micro powered access, Ecolite lighting towers, ladders, steps and mobile access towers introduced two of ABB’s IRB 1600 robots to dramatically improve flexible production and reduce stockholding. The answer was to install two fully, automated welding cells. The welding cells were programmed to operate around the clock, six days and a week. The labour-saving benefits, improved flexibility and safety aspects of the new system are impressive in their own right, but the proven capabilities of the system ensures products can be quickly and perfectly handled with a high level of precision and consistency.

Summary For many manufacturing processes, robot-based automation offers improved flexibility, productivity and reliability, helping manufacturers to meet ever shorter product life-cycles, multiple product variants and rising energy and material costs. As demonstrated, the tangible benefits of robotic solutions have become ever more apparent and it is widely accepted that robots will be adopted at a much higher rate across the manufacturing industries where long term sustainability and reputation are paramount.

The challenge for manufacturers now is to reassess their strategy to identify the opportunities and exploit the sustainable and environmental advantages of integrating robot-based automation into modern manufacturing processes. With the potential to completely transform production processes and introduce sustainable production, there is no longer a reason to avoid an investment that is widely proven to also greatly improve your competitiveness.

ABB Robotics, Rooksley, Milton Keynes, Bucks Can be contacted on: Tel: 01908 350 300 E-mail: robotics@gb.abb.com, ref:IT/robots

Process Industry Informer September 2013

pROCESS CONTROL Rugged plc simplifies control in extreme environments ABB’s ‘extreme conditions’ AC500-XC PLC is protected against a wide variety of threats including high and low temperatures, high humidity, low air pressure, salt mist and hazardous gases, and vibration and shock. This typically reduces system building costs by eliminating the need for sophisticated protective enclosures with special seals, HVAC, shock absorbers, EMC protection, etc.

The embedded protection features ensure that AC500XC PLC based control systems stay functional and reliable even when operating in hostile environments.

Such conditions can be found in many common automation applications including mines, tunnels, vessels, cranes, water and wastewater plants, offshore platforms, wind turbines, solar trackers and weather and navigation stations.

Extended temperature operation allows the PLCs to operate in temperatures from -30 to +70 0C, with reliable system start-ups in temperatures as low as -40 0C. It has extended immunity against salt mist and atmospheres with corrosive gases.

For more information contact ABB Ltd, Warrington, Cheshire.

Tel: 01925 741 111 Fax: 01925 741 212 E-mail: energy@gb.abb.com Web: www.abb.co.uk/energy

Wonderware InTouch Access Anywhere AllowsRound-the-Clock Access to Industry-leading HMI • Invensys extends mobile offerings to real-time visualization from any device at anytime and from anywhere • Invensys, a focused supplier of state-of-theart industrial software, systems and control equipment to the world’s major industries, has released its Wonderware® InTouch Access Anywhere™ software solution.

The new solution enables users to access plant-floor data via Wonderware InTouch® software, the world’s leading human machine interface software. It runs entirely and securely inside a web browser so users can connect to other InTouch applications at anytime from anywhere, using any mobile device, including Microsoft Surface tablets, iPads, iPhones, Androids and others. The software also supports Macintosh and Linux-based computer systems, as well as Microsoft Windows PCs and laptops. And because users are not required to install any software on their mobile device, the offering is remarkably easy to deploy, manage and maintain.

“This new offering complements Invensys’ broader mobile strategy to provide and improve real-time visualization, collaboration and execution at multiple levels of an organization,” according to Craig Resnick, vice president, ARC Advisory Group.

InTouch Access Anywhere software is the newest capability in the company’s progressive suite of mobility solutions, which now includes workflow, reporting, analytics, visualization, maintenance management, operator training, data gathering and procedure management. In 2010, Invensys released its IntelaTrac offering, a mobile reporting and decision support system that enables workflow, data collection and general task management. In 2011, Invensys released its SmartGlance solution, an industrial reporting application that delivers secure, on-demand access to rich, graphical reports from any operations data source via mobile devices. In 2012, the company released its Work Tasks mobile offering, enabling plant personnel, regardless of their location, to respond immediately to assigned work tasks via the company’s ArchestrA Workflow software.

“InTouch Access Anywhere software emphasizes the depth and breadth of our capabilities when it comes to mobile and web-enabled solutions,” said Norm Thorlakson, vice president of HMI and supervisory software products for Invensys.

The software, along with the Invensys’ entire suite of complementary mobility offerings, will be on display and demonstrated at the company’s customer conference covering its Avantis, SimSci and Wonderware software offerings. The event will be held October 15 through October 17 at the Hilton Anatole Hotel in Dallas, Texas.

For more information about the new software, please visit the InTouch Access Anywhere HMI site or contact a local Wonderware distributor. For more information about the company’s customer conference and to register, please visit http://ourevents.invensys.com/SoftwareCustomerConf/pages/home.aspx.

Process Industry Informer September 2013

Locate process information in seconds?

Certainly.

ABB’s distributed control system, System 800xA, is based on Aspect ObjectTM technology which means all information associated with a drive, motor, valve or instrument can be accessed with minimal engineering. From video camera monitoring, shift handover and LOPA displays through to entire documentation libraries, everything can be instantly seen.

Maintenance teams can access electronic work orders (CMMS functions) and asset management information directly, allowing them to see the complete history of an object. Tracking and monitoring of operation actions is easy, regardless of where they occur in the system. To learn more about information navigation visit: www.abb.com/800xA or scan the QR code using your smartphone App.

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

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health & safetY

CASTELL’S NEW RANGE OF PADLOCKS NOW EVEN SAFER

New truck mounted static ground verification system improves safety

Improved differ code delivers higher level of complexity

Newson Gale’s award winning “Earth-Rite® MGV” enhances the protection of personnel and equipment during vacuum tanker and road tanker transfers of flammable or combustible materials by preventing uncontrolled electrostatic discharges.

With the operation taking place in a hazardous area, the need to control all types of ignition sources is absolutely paramount however the vacuum transfer process can generate large amounts of static electricity, requiring confirmation of proper bonding to a verified grounding point.

The new truck mounted Earth-Rite® MGV derives its power source from the vehicle battery, and uses certified Intrinsically Safe monitoring techniques to not only indicate a good bond to a static grounding point, but more importantly verification that the ground point to which it is attached represents a satisfactorily low resistance to true earth.

Units have obtained Intrinsically Safe certification for use in the Global Petrochemical Industries, according to the requirements of IECEX, ATEX, CSA/US and NEPSI (China), and may be used in all common gas, vapour or dust explosive environments.

To learn more about the Earth-Rite MGV or the dangers of static electricity in hazardous areas please contact Newson Gale. www. newson-gale.com

Industrial safety specialist Castell has launched an enhanced version of its Iso-Lok padlock range. The new range features a more complex differ code system, increasing the overall safety level offered to customers.

Castell’s tracking system already ensures that each padlock supplied to a site is unique. This removes the issue of keys fitting multiple padlocks and therefore reduces risk in lockout / tagout procedures. The company’s enhanced range of padlocks now takes the separation of differ codes one stage further.

“The quality of the Iso-Lok range is very important to our client base,” said David Hughes, Castell’s sales director.

“By increasing the integrity of our padlocks we have effectively increased the safety of the Iso-Lok range.

This product improvement - coupled with our ability to track differ codes, paint and engrave padlocks - delivers substantial value to our customers.”

For more information contact Castell Safety International Ltd, 217 Kingsbury Road, London, NW9 9PQ Tel: +44 (0)20 8200 1200 Fax: +44 (0)20 8205 0055 E-mail: dhughes@castell.com Web: www.castell.com

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

Pocket-sized electronic listening stick for acoustic leak detection The new Tmic from HWM is a highly cost effective monitoring tool for identifying leak noises on the water network that would otherwise be inaudible to the human ear.

The lightweight and portable device allows operators to hear amplified sound via high quality, rechargeable wireless Bluetooth headphones, while an LED display simultaneously shows a clear visual representation of noise levels – all in a package small enough to fit in a shirt pocket.

By storing the previous reading in its built-in memory, Tmic allows the operator to visually compare current and previously recorded noise levels. This lets the user quickly determine whether a noise is caused by a leak and, if so, where the most likely position of the leak is. The high quality digital sensor can be placed directly on the pipe or coupling and provides levels of sensitivity and noise quality far beyond what is possible with mechanical listening sticks. An additional magnetic attachment is available if required and the Tmic can also be connected to a detachable metre long extension rod to access congested or difficult to reach areas.

An ergonomic, robust design and long battery life from standard alkaline cells mean that Tmic is always ready to use in any situation. Weighing just 180 grams, it can be easily carried in a shirt or trouser pocket, and a bright LED torch is built into the head for use at night or to investigate dark chambers. For additional convenience, the wireless headphones ensure full freedom of movement with no risk of tangled cables, and the unit is supplied with its accessories in a durable carrying case with precision cut foam compartments to protect all components in transit.

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

NEW TECHNOLOGY FROM 3M TRANSFORMS SAFETY EYEWEAR FOR MANUFACTURING INDUSTRY Extensive scientific research by diversified technology company 3M has led to a ground-breaking development in safety eyewear and the launch of a new product range ideal for manufacturing and general industrial workers.

SecureFit Protective Eyewear by 3M is the first range to feature Pressure Diffusion Temple Technology, designed by 3M to provide noticeably higher levels of personal comfort and security of fit.

Incorporating flexible ribs into the temple area of the frame, 3M Pressure Diffusion Temple Technology allows SecureFit eyewear to self-adjust to the size and shape of the wearer’s head, reducing slippage and movement while in use. It also enhances comfort by dispersing

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pressure across the temple area.

Nikita Shah, technical engineer from the Personal Safety division of 3M, explains: “3M understands how challenging it is to fit a diverse workforce with safety eyewear that provides effective protection and comfort to all.

“Our research has shown that 71 per cent of the health and safety officers we surveyed put non-compliance down to discomfort*. 3M undertook comprehensive research into face shapes and sizes throughout the world including detailed digital modelling.

The result is the development of Pressure Diffusion Temple Technology which, without the need for any adjustment by the user, helps to diffuse pressure across the temple while holding the frame securely in place for a

secure and comfortable fit.”

Featuring a stylish, lightweight design weighing only 18g, SecureFit Protective Eyewear is available in three lens colours (clear, grey or yellow) with anti-fog and antiscratch coatings.

SecureFit Protective Eyewear meets the requirements of EN166:2001 and also absorbs 99.9 per cent of UVA and UVB radiation thanks to its polycarbonate lens. * 2Europe, UK, September 2010 3M and SecureFit are trademarks of 3M Company.

For further information on the full range of Personal Protective Equipment and safety solution services available from 3M, visit the website www.3M.co.uk/ safety or call 0870 60 800 60 in the UK or 1 800 320 500 (Ireland).

Process Industry Informer September 2013

The role of maintenance and asset management in optimising plant performance

By Ian Ritchie, Managing Director, Brammer UK

Irrespective of the economic situation, the key drivers of manufacturing competitiveness and profitability remain the need to optimise production output and efficiency whilst reducing operational costs. If an efficient and reliable plant is the key driver of success, then the way in which a company approaches its maintenance and asset management strategy is critical.

A best-in-class approach to optimising manufacturing plant performance will align the strategies, goals and metrics of the production and maintenance teams, fostering collaboration between these teams to aid effective prioritisation and decision making.

a general reduction in capital investment in new plant and equipment. Many companies are instead focused on driving existing assets over an extended lifespan, frequently while working within reduced operating budgets.

should always focus on the total cost of ownership, rather than the initial purchase cost, with factors such as component lifespan, spares criticality, reliability, reduced maintenance and service intervals all contributing to the purchasing decision.

Common objectives should be standardised around typical metrics used by best-in-class manufacturing companies such as Overall Equipment Effectiveness (OEE) – measured as a percentage by multiplying plant availability, performance and quality – and asset downtime, measured as the amount of time the asset is offline against total asset availability.

An effective maintenance and asset management strategy is absolutely critical to meeting these challenges while delivering on operational performance, service levels and overall company profitability targets.

Ultimately, the strategy should concentrate on identifying the most common and machine-specific spares, and ensure that critical spares are always available.

Wherever possible, stock value and the number of stockkeeping units held should be minimised, with the number of suppliers minimised to reduce inventory and working capital tied up in maintenance spares as well as the transactional costs associated with maintaining duplicate suppliers of the same thing.

In order to maximise OEE and minimise asset downtime, plant must be both well operated and well maintained, with vital spares available when needed and unscheduled downtime minimised.

This is brought firmly into focus by the fact that unplanned production downtime can throw manufacturing schedule adherence into disarray. It can often cost many thousands of pounds per hour, and can be commercially damaging for companies in asset intensive industries.

Lost production time can mean a failure to meet a tight order deadline and even the consequential loss of one or more highly valuable customers.

It can also be further complicated by the issues brought on by ageing plant and equipment. This is becoming an increasingly important factor since the recent recession as economic and financial pressures have influenced

Developments in maintenance strategy A best-in-class approach to maintenance and asset management strategy is to move from a reactive approach – where plant is run to failure, often supported with high levels of engineering stock and characterised by unreliable performance and frequent breakdowns - to proactive and condition-based maintenance management.

A reliability-centred approach goes a long way in helping companies to avoid asset failure and to fix potential problems relating to production assets before they actually have an impact on unscheduled plant downtime.

Making effective asset maintenance decisions requires organisations to equip their employees with the right data at the right time and in the right format. This may include the adoption of condition monitoring techniques such as vibration analysis, thermographics, oil sampling and acoustic analysis to assist in the monitoring of plant performance.

While this approach requires a significant evolution in maintenance strategy and execution for many manufacturers, its impact is being widely proven in safeguarding production schedules, adding new efficiencies to operations, reducing maintenance costs, improving spares management and even lowering energy consumption.

For example, scheduled maintenance to a motor or compressor whose energy usage has been monitored and identified as exceeding the level expected, can help identify the contributing factors and allow a programme of corrective action to be developed and implemented reducing both energy usage and future asset downtime.

This is just one instance of how energy consumption data can be highly valuable in informing operational decisionmaking and contributing to OEE. Whatever approach to maintenance is adopted, its goals and metrics should always be closely aligned with those of production and procurement teams to ensure a consistent and collaborative approach to the spares purchasing and management process.

Best practice in maintenance management Maintenance spares management also plays a significant part in achieving the goal of improving overall efficiency in manufacturing operations, helping to maintain continuity of production and avoiding costly downtime.

A successful maintenance spares sourcing strategy

Process Industry Informer September 2013

The maintenance management strategy should also focus on an engineering spares standardisation programme, which has the potential to significantly reduce inventory and the cash tied up in stock, while ensuring a consistent standard of components is used across the asset base.

The benefits of outsourcing The purchasing of spares for the daily maintenance and repair of production and manufacturing equipment is often a complex, time and resource consuming activity for most organisations. When well managed, however, this is an operational area that can provide considerable added value with major cost savings generated through demand reduction, reduced inventory, production and maintenance improvements.

Where the procurement and spares management process is large-scale or complicated, there is much to be said for outsourcing part or all of the function to a specialist MRO partner. The right partner should be able to offer a strong combination of procurement and supply chain management expertise, combined with valueadding services such as condition monitoring, energy audits, drive system design and lubrication programmes to support the maintenance and asset management strategy. This enhanced level of support can free up valuable in-house procurement, production and maintenance capacity to focus on improvement projects to increase production output and efficiency.

Outsourcing of some, or all, aspects of MRO spares management is consistently proven to reduce total acquisition costs and working capital, while the right partner can also add value to the engineering team to support the goal of optimising plant uptime and production output. In the current economic climate, where capital investment is being restrained, and therefore plant asset life is being extended, an effective maintenance strategy is the key to improved manufacturing plant reliability and higher operational and financial performance.

Brammer UK Ltd, Wythenshawe, Manchester Can be contacted on: Tel: 08447 36 36 65 Web: www.brammer.co.uk

13

Sweating Your Assets –

More!

Throughout industry, pressure to squeeze maximum return from each and every asset is intense. This principle drives the focus on process simplification, and on maximizing efficiency in production. Such strategies have become vital for day-to-day operations in most sectors, and return considerable value. However, business leaders targeting the very highest levels of excellence are now extending this rigour to other aspects of their companies and, for example, are recognizing the additional value that proactive management of idle and surplus analytical, plant and packaging equipment can deliver.

In this article Ben Potenza, VP Marketing, EquipNet, examines emerging best practice in this area, pointing out what to look for in the solutions offered, and illustrating what proactive asset management is delivering to the pharmaceutical, biotech, chemical, food, beverage, and personal care companies that are their clients.

Significant asset base idle and underutilized Today’s companies hold enormous value in the form of equipment and plant. Keeping an accurate asset register provides a solid basis on which to make management decisions, but research suggests that on average, 5% of a manufacturing company’s global asset base is idle, with most not having good visibility of these underutilized assets.

Of course, businesses have always traded surplus assets, and equipment dealers and auctioneers have been there to help. But increasingly, more sophisticated tools – tools that can develop a comprehensive inventory of assets and support their utilization across multiple sites as needs change – are being systematically implemented. In parallel, there has been significant growth in the market for the sale and purchase of surplus equipment.

Challenges and opportunities Progressive businesses strive constantly for an efficiency edge, but in recent years, the tough economic climate has driven consolidation, relocation, mergers & acquisitions, outsourcing and plant closures in almost every sector and company. The result? More executive teams see that a focus on managing assets can deliver directly to the bottom line.

Once a decision has been taken to proactively manage the asset base, a company must consider a series of choices. For many, the variables are clear – redeployment vs. disposal, or realizable value vs. available time, for example. But every situation is different – reusing equipment within an organization always delivers the highest value and, with time available to do this, some companies will have this as the sole focus. Disposal is a secondary consideration that only comes into play if redeployment is not needed. For other organizations, perhaps where a site or line is being closed, time may be short and releasing as much value as possible within the available window is the overriding factor.

Whatever the goal, the process is logical, and straightforward, but like much in business it needs to be carefully planned, and rigorously executed in order to maximize returns. For most executive teams asset management is a ‘non core’ activity, so contracting with an external specialist that can bring industry expertise and experience to bear, whatever the size and shape of the project, is an attractive option.

The right tools for the job As noted above, auctioneers and equipment dealers offer their services in many industrial sectors. However, there is a view evolving of what best practice in asset management looks like, and specialist companies (such as EquipNet) have become established leaders.

A holistic approach that balances the needs of a company can be developed. EquipNet describes this with its ‘Value Control Model’.

Figure 1 shows how redeployment, negotiated sales with managed pricing through an on-line marketplace, competitive auction events and clearance programs fit together to deliver a consolidated service, whatever the individual needs of a company.

Fig 1. Assets are liquidated using a range of strategies

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We can pull this apart to consider the key components. Importantly,

what ties the redeployment part of the model together is the availability of an asset tracking platform that can be installed across multiple sites. Users should be able to post, track, identify and internally redeploy equipment that is not being used in its present location, ahead of moving to external sale. An established example is EquipNet’s ARMS™ (Asset Redeployment Management System) platform. This simple, yet robust program sits behind the company firewall, and features workflow management, multiple access levels for plant managers and executives across the business, in-depth search functionality, and comprehensive listing specifications, providing information that lets the company know what they have and where it’s located.

The rise of the internet has seen the development of online marketplace products.

Innovative features to look for here include: • ‘Top-down’ offers rather than the more usual ‘bottom-up’ bidding model • Expert evaluation of goods offered for sale, and accurate setting of sale prices • Concentrated promotion of the marketplace platform and, within it, advertising of specific equipment • Payment by results Auctions are another dependable channel but the competitive nature of auction events can produce wildly differing results, designing and managing a successful auction event depends on many factors. A specialist partner should advise on the right approach in each case; your options might include online auctions, live/webcast auction events, sealed bid and private treaty sales.

Innovation should be at work here too, look out for active marketing by the auction provider, expert knowledge of the equipment being offered for sale, and a flexible approach to managing bids close to, but under any reserve set. Figure 2 shows how bids that most auctions would ignore are picked up and processed

by EquipNet. There are those assets that hold very little value and are best dealt with through clearance, by donations, scrap and environmental Fig 2. Flexible management of bids close recycling. Working with to any reserve can deliver higher ROI your chosen expert, you should expect to be advised of the scrap value of your idle equipment, presented with a comparison of that amount against the market value to sell it, together with a recommended strategy that will generate the highest rate of return for your company.

In summary Pursuing a proactive asset management strategy is not without its challenges. It requires formalised processes, specialist knowledge of the industry and its equipment, dedicated resources, and a concerted effort to change management. Many companies lack the time or resources that are necessary to establish a successful program themselves. For this reason, the majority of companies that are succeeding in this area are relying on a partnership with a specialist service provider. They are enjoying the clear benefits of cash release, reduced costs, and increased efficiency.

EquipNet, Inc., Grove House, Wargrave Road, Twyford, Berkshire, RG10 9NZ Can be contacted on; UK Tel: +44 (0) 118 901 6161 Fax: +44 (0) 118 901 6162 E-mail: sales@equipnet.com

Process Industry Informer September 2013

network & communications

Available on iPhone BULKHEAD-MOUNTED and Android devices INDUSTRIAL CONNECTOR HOUSING FOR PROTECTION LEVEL UP TO IP 67

HARTING has introduced a bulkhead-mounted version of its proven Han® B industrial connector housing providing improved protection against water ingress up to protection level IP 67.

The new housing incorporates a special flange which prevents water from penetrating into the connector and consequently offers ideal protection for the contact points in the housing interior. A circumferential collar also prevents the seal from sliding off inwards or outwards, and consequently offers solid support.

The use of a stable seal offsets the effect of uneven sections and provides additional protection against water penetration.

No extra costs are incurred when the IP 67 bulkhead-mounted housing is installed, as the cutout corresponds to the dimensions of the existing Han® housing portfolio. The new bulkhead-mounted housing is locked with the HARTING Han-Easy Lock® levers, which allow a high contact pressure level when closed and also provide optimal sealing between the hood and the bottom housing.

The new IP 67 flange is the latest addition to HARTING’s comprehensive range of housings for use in industrial environments. Potential applications are in any industrial sectors where operational reliability is required under extreme conditions, such as wind turbines, cranes, electricity substations and the rail industry.

For more information contact Harting Ltd, Northampton, NN4 7PW Tel: +44 (0) 1604 827500 Fax: +44 (0) 1604 706777 E-mail: gb@harting.com Web: www.HARTING.com

Process Industry Informer September 2013

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A guide to pressure t materia

The risk of corrosion presents a serious threat to the long term operation and accuracy of pressure transmitters, particularly in critical measurement applications. One way of minimising this risk is to ensure that your pressure transmitter is made from the correct materials to enable it to withstand the rigours of your application. Trevor Dunger, Product Specialist for ABB’s UK Measurement Products business, explains the various choices on offer and how to choose between them.

When selecting a material for a pressure transmitter it is necessary to consider both their resistance to corrosion and their suitability for the specific application in question. For example, the filling fluids used in a pressure transmitter mean that they cannot be used in direct contact applications such as in the food and beverage industry, as any leakage could corrupt the process.

Corrosion is a major challenge in many pressure measurement applications. Corrosion is the gradual destruction of a metal either by chemical or electrochemical means. The speed and aggression of corrosion can be determined by a variety of factors, ranging from different types and combinations of chemicals through to temperature, particularly in high temperature applications. For example, temperatures above 40°C (104°F) in seawater can increase the risk of corrosion of stainless steel components through pitting.

Where materials selection is concerned, it is important to remember that there is no ‘catch-all’ solution that will be suitable for all types of application and process conditions. With the onus sitting squarely on the user to make the right selection, it is therefore essential that you make a careful and detailed analysis of your process in order to correctly specify the materials for your device.

If in doubt, it is always best to consult a pressure measurement expert, who can suggest possible solutions.

The following section contains advice on some of the most common materials used for the wetted parts of pressure transmitters, these being the components that come into direct contact with the process.

316L Stainless steel 316L SST offers good resistance against corrosion, including low concentrations of nitric acid and most salt solutions and as an example it is used as the standard material for the wetted materials of our 2600T pressure transmitters. When it comes to alkaline solutions, organic acids and other organic compounds, the resistance of 316L SST against corrosion may depend on temperature.

Certain halide salts, including fluorine, chlorine, bromine and iodine, can also cause severe pitting and stresscorrosion cracking.

For oil and gas applications, where hydrogen sulphide is often present, 316L SST may be available with specific NACE MR0175 certification. This standard defines the types of corrosion resistant materials that can be used in various oil and gas industry environments. As such, it covers most types of stainless steels, including 316L SST. By setting criteria both for the hardness of the material and the process by which it is manufactured, the standard helps to reduce the risk of sulphide stress corrosion cracking. The standard also covers non-wetted parts such as bolts, as they also have a bearing on the instrument’s overall containment effectiveness even if they are exposed to corrosive environments far below the limits of the standard.

The NACE certificate is also available for other materials including Monel and Hastelloy C.

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Monel Monel offers good resistance against the corrosive effects of most of the non-oxidising acids, such as hydrofluoric, sulphuric and phosphoric acids, at ambient temperatures.

Monel is also considered the prime choice for applications where components are in contact with sea water. Despite its general high resistance to corrosion, Monel is not suitable for contact with acid and alkaline oxidising sales, which can cause severe corrosion damage.

Applications with a high hydrogen concentration may also affect Monel’s effectiveness as a material of construction.

Especially where Monel is used as a diaphragm material in hydrogen gas processes, hydrogen atoms may permeate the diaphragm, leading to hydrogen bubbles forming within the fill fluid.

Hastelloy C Hastelloy C is comprised of chromium and molybdenum added to nickel to improve the alloy’s resistance to oxidising conditions. As such, Hastelloy C is well suited for protecting against the rigours of alkalis, organic acids and other organic compounds.

Hastelloy C also offers good protection against oxidants such as phosphoric acid as well as acid salts including nickel and copper chlorides. At moderate temperatures, Hastelloy C is able to withstand hydrochloric and sulphuric acids in most concentrations. Like Monel, Hastelloy C also affords good protection against atmospheric conditions and fresh water.

Gold plated Hastelloy C, Monel or SST Hastelloy C, Monel and SST can all be permeated by hydrogen, meaning that they should be avoided as a diaphragm material for use in applications where hydrogen is present. Hydrogen atoms can diffuse through the very thin transmitter diaphragms into the fill fluid, whereupon they can combine with the fluid to form molecular hydrogen. This is particularly a problem at elevated pressures and temperatures, which increase the permeation rate.

As molecular hydrogen is too large to permeate back through the diaphragm, it becomes trapped and forms bubbles in the fill fluid. As these bubbles form and accumulate, they can severely affect transmitter performance.

One way to prevent this problem is to plate the diaphragm with gold, which prevents hydrogen permeation at high process temperatures and pressures.

Another form of protection available from ABB is a corrosion resistant hydrogen preparation gel, which can be applied to a pressure transmitter’s diaphragm to reduce hydrogen permeation.

Tantalum Tantalum is an ideal alternative to 316L SST in corrosive applications featuring a range of chemicals including hydrochloric, hydrobromic, boiling hydrochloric, nitric, phosphoric and sulphuric acids. It has a high melting point and good strength even at elevated temperatures.

With the exception of aluminium fluoride, potassium carbonate and sodium sulphide, to which Monel is more suited, Tantalum offers a good resistance to most acids, chemical solutions and organic compounds, as well as liquid metals.

Despite this, Tantalum can suffer severe embrittlement if used with high temperature oxygen or nitrogen, or with hydrogen at any temperature. It is also prone to attack by strong alkaline solutions and by fused alkalis such as sodium hydroxide.

PFA (Teflon from DuPont) PFA (Teflon) coating offers outstanding protection against corrosion and anti-stick properties, with even a 0.2 to 0.3mm coating capable of providing a cost effective alternative to more expensive methods, such as the use of specialised materials.

A limitation of a PFA coating is its recommended temperature limit of 200°C (392°F) and a minimum increase of the temperature effect on accuracy. Also, if the diaphragm is subject to mechanical abrasion (rapid flows with solids) it can become punctured, allowing corrosion to penetrate the area below the coating.

Other points to consider Aside from the materials of construction, there are also other factors that can affect the operation of a pressure transmitter.

One important aspect is the selection of the appropriate fill fluid. Making the correct choice is especially important as the type of fill fluid can limit the working temperature that the transmitter can stand.

Process Industry Informer September 2013

transmitter als selection

For this reason, it is advisable to choose a fill fluid that can be used over the widest possible range of operating temperatures. The most widely used is Silicone Oil DC200, which offers high stability over temperatures ranging from -40°C to 200°C (-40°F to 392°F).

Alternatively, other fluids may be selected whenever their temperature range is compatible with the application, in order to take advantage of a lower viscosity or thermal expansion factor. This is especially useful where faster response times are required in remote seal applications with long capillaries.

In some applications, such as food and pharmaceutical production processes, it may also be undesirable for certain fill fluids to be used, in order to prevent potential product contamination caused by a ruptured diaphragm. Where this is the case, a food sanitary fill fluid should be selected.

An alternative fill fluid should also be used for transmitters used for oxygen rich applications , where leakage of a silicone oil fill fluid could cause a fire. For this reason, an inert fill fluid should be selected.

Another important aspect concerns the selection of the appropriate material for the transmitter gasket. The most widely used material is PTFE (Teflon), due to its general corrosion suitability with several materials.

However, a potential drawback of PTFE arises in processes subject to periodic variations in temperature.

Particularly in processes where the temperature varies by several degrees, the limited elasticity of PTFE can compromise its tightness. In these instances, it would be wise to consider the elastomer Viton.

Special requirements may also arise in food or pharmaceutical applications, which frequently call for an approved material listed by the US Food and Drug Administration (FDA) or other national equivalent organisations.

Summary As one of the most ubiquitous process parameters, pressure measurement needs to be conducted across a wide range of operating environments and process conditions. Given the wide variety of pressure ranges and operating conditions, having a good understanding of how to specify a device can be a useful first step in ensuring it fully meets the requirements for a particular application.

ABB UK – Measurement Products Division, St. Neots, Cambridgeshire Can be contacted on: Tel: 0870 600 6122 E-mail: moreinstrumentation@gb.abb.com ref. ‘Pressure’ Web: www.gb.abb.com

Process Industry Informer September 2013

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More efficiency from motors An accurate calculation of motor efficiency opens the door to long-term savings and backs up any initiative to improve plant profitability with a reliable set of data. And what’s more, explains Phil Burge, Country Communication Manager, SKF, even manufacturers with a relatively small number of motors in operation can achieve measurable payback.

As long as environmental and economic needs stay at the top of the agenda for modern businesses, a more reliable, safe and beneficial method of enabling efficiency will always be vital to reduce energy demands and the impact on global warming. As one of the biggest energy consumers in industry, motors must be scrutinised to ensure that they are running as efficiently and smoothly as possible. By determining the efficiency of a motor, users can then correct the issues that directly affect energy usage, such as cavitating pumps and improperly tuned drives, and start increasing the efficiency and service life of the motor while also reducing maintenance costs, downtime and production losses.

Industrial motors have something had a bad reputation, which is hardly surprising when you consider the statistics. Indeed, they are responsible for consuming about 65% of all generated electrical energy, account for up to 75% of the total electricity costs in industrial plants and use 50% of the total electricity consumed by commercial buildings. In addition, it has been said that the annual cost of operating an electric motor can reach a staggering 25 times its original purchase cost.

Nevertheless, there is great potential to further reduce energy use in most sectors and economies. Many analyses have demonstrated that the total overall efficiency with which we use energy to provide the final demand of energy services in society is as low as 10-15%. This means that we as society “waste” as much as 85% of all the energy we consume. An even more striking case in point is lighting; an incandescent light is less than 5% efficient- and if you include in your calculations all the system inefficiencies inherent in generating, transporting and transforming electricity, the overall efficiency becomes – believe it or not -less than 1%.

Take account of statistics…

The statistics can be daunting, but they also underline the importance that we work together as a coherent force with a consistent approach.

A large amount of waste can be converted into a correspondingly large energy saving if attitudes to energy efficiency are transformed. We are in this together; and together is the only way we are going to solve the problem.

A systems approach will help claw back some of the staggering amount of electricity consumed across industry by electric motors, and this begins with the calculation

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of motor performance. The effort will be worthwhile; a systems approach will enable operators to capitalise on significant savings and rest assured that they are truly maximising their energy efficiency, not just solving a part of the problem.

By correctly matching load and energy use, ensuring proper sizing of all components, improving the efficiency of the end-use devices such as pumps and fans, and reducing electrical and mechanical transmission losses, inefficiency can be significantly curtailed. In fact, by addressing each issue it has been estimated that the electricity use of industrial motor systems can be reduced by as much as 30%.

When making that initial calculation of motor efficiency, the Instantaneous Current Method is considered the most accurate and less intrusive of the options available, and looks at output power rather than trying to estimate losses. As this element is less sensitive to the efficiency of the predicted motor, the margin for error for estimating lower end efficiencies is smaller and ensures maximum precision.

In essence, the Instantaneous Current Method requires a measurement of the motor input power and a calculated estimate of the motor output power, with current and potential transformers being used to gather incoming rotating voltage and currents for all three phases. Calculations are then made based on these values for speed and torque, while air gap torque is worked out using the Park’s Vector, or 2-Axis Theory.

Friction, stray load and windage losses are estimated and then subtracted from the air gap torque calculation to get an estimate of the output torque, while speed is estimated through the gathered currents and voltages.

For example the EXP4000 Dynamic Motor Monitor from SKF uses the proven Instantaneous Current Method to give users a comprehensive look at overall motor performance and integrity.

This instrument calculates the operating efficiency then extracts a comparable efficiency from a motor database that contains over 22,000 different NEMA design motors from numerous

motor manufacturers. The percentage difference in the losses between the tested motor and a comparable motor with the target efficiency is then evaluated with respect to the thresholds. Ultimately, it identifies motors that are performing under par and calculates the payback period if replaced by a new motor.

Making the case...

In response to a sharp rise in local energy costs, Indonesian textile plant PT. Leuwijaya Utama implemented an urgent cost-saving programme, and discovered that 30% of the factory’s energy consumption was consumed by the twisting machines, which are critical in ensuring fabric quality. So, as well as taking measures to correct electric motor energy losses and optimising frequency converters for the overall electricity supply, the energy consumption of the twisting machinery was examined in closer detail.

Inside the Leuwitex twisting machines, lines of high precision spindles are driven by two powerful motors.

As these machines operate 24 hours per day, frictional losses (and ultimately energy losses) occur in the rotational motion dependant on the quality of the bearings fitted at the ends of each spindle. With 176 twisting machines incorporating 256 spindles, this clearly presented an opportunity for a major energy saving. By installing our Energy Efficient (E2) deep groove ball bearings, frictional losses were reduced by 30% over a standard SKF bearing and achieved 10% total energy savings.

So, the means exists to conduct an evaluation of motor efficiency and the benefits can be considerable. All that needs to change is the attitude that accepts high energy consumption as an unavoidable fact and assumes that nothing can be done.

SKF(U.K.) Limited, Luton, Bedfordshire Can be contacted on: Tel: 01582 490049 Fax: 01582 848091 E-mail: marketing.uk@skf.com Web: www.skf.co.uk

Process Industry Informer September 2013

A change is as good as a rest…

Don’t wind your way to the St Johns Hotel in Solihull for the 2014 Pump Industry Awards – if you do you might find yourself alone as the venue for next year, by popular demand, has changed.

So make a note that the place to be is the Chesford Grange Hotel, Kenilworth in Warwickshire, ideally situated for access from the major road networks, including the M40, M42, M6, M9 and the M1 and in splendid landscaped gardens bordering the River Avon.

Now that you know the place it is important to jot down the event date of March 27th and if this year’s success is anything to go by it wise to make your booking as soon as possible!!!

PS: And don’t forget to make your nomination – the closing date is Monday 25th November (See page 4).

NEWS

SEPT 2013

M o to rs | A uto matio n|E nergy| T ransmissio n&D istributio n|C o atings

L o w e ring e ne rgyusage isn’ t just abo ut c utting c o sts.

Energy saving appears to be the theme…

Between the covers you will find that energy saving is an important subject, both from the BPMA and its members inclusion and there is some really interesting reading material in the following pages for you to absorb.

If you have any comments about BPMA News please e-mail them to: peterullmann@piimag.com

FREE Energy Assessment

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

W ithth eh ighc o sts o fe ne rgy ,y o uc an mak esignifi c ant sav ings byre duc ing y o ur usage .I n te rms o fa mo resustainablef uture , th e sere duc tio ns c o uld me an a lo t mo rebe side s.A saw o rld le ade r in e ne rgye f fi c ie nc y ,W E G pro v ide s th epro duc ts and se rv ic e s toh e lp y o u tousee ne rgymo ree f fi c ie ntlyand sustainably .T h is is w h yw e ’ v ete ame d up w ithso lutio ns pro v ide r Sulz e r too f f e ry o uE ne rgyRe duc tio nA dv ic e ,a snapsh o to f e ne rgyusagew ith in y o ur applic atio ns and a f e wo fth eth ings y o uc o uld dotore duc ec o nsumptio n.

F o r adv ic eand te sting,v i si twegreduci ngenergy . co m

St rengt h,E f fici encyand R el i abi l i t y .

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NEWS BYTES   BPMA 2013/14  MDS Roadshow Directory and Motor Driven Systems Conference hits the Road in 2013 Buyers Guide 2013/14 now available Our every popular and much in demand Directory and Buyers Guide is now available from BPMA. Over 80 pages packed full of member articles, technical information, latest innovations as well as a comprehensive pump sourcing guide.

Apply direct from our website www. bpma.org.uk or simply email j.page@bpma. org.uk to request a copy.

 Training BPMA Lecture-based training courses scheduled for later this year are: Module 001, Part 1 (Pumping Fundamentals) – 9th October 2013 Module 001, Part 2 (Pump Selection) – 10 October 2013 Contact j.page@bpma.org.uk for further information or booking form.

The Motor Driven Systems (MDS) Conference takes to the road in 2013 with a series of regional events aimed at helping industry professionals generate huge savings from motor driven apparatus - pumps, fans and compressors. Now in its third year, MDS continues to break new ground by assembling some of the world’s most qualified experts to highlight the importance of adopting a systems approach to motor driven systems for optimum energy efficiency. Covering key areas of Regulation, Systems Engineering and Product Technology, MDS focuses on real life examples of how industry and commerce are delivering huge financial savings through the application of ‘energy efficient motor driven systems’. Plant managers, engineering staff and financial heads within end-user organisations find enormous value in learning how others are developing increased efficiencies across their operations, a theme that will form an important part of the 2013 Roadshow.

Each regional conference includes key representatives from UK government, end-user organisations, product manufacturers and technical experts, each expressing their views on the impact of electrical motor systems on energy and the environment. This year, in addition to our ‘founding five stakeholders’ we are delighted to have the support of the IET and EEF who will be helping to promote each event in the series to their respective memberships.

The MDS 2013 Roadshow will be stopping in: Scotland, Wednesday, 9th October – Broxburn – Hosted by Eriks North, Wednesday, 23rd October – Rotherham – Hosted by Rittal Midlands, Tuesday, 5th November – Redditch – Hosted by WEG South East, Wednesday, 20th November – Hatfield – Hosted by Mitsubishi South West, Wednesday, 4th December – Bristol – Hosted by ABB For further information on the MDS 2013 series of events, please visit the dedicated website at www.motordrivensystems.com or contact the Series Director Andrew Castle at andrew@touchwavemedia.co.uk.

Energy Savings Opportunity Scheme (ESOS) The Department of Energy and Climate Change published in July its ESOS consultation document which seeks views on the Government’s approach to implementing Article 8 of the EU Energy Efficiency Directive, which was agreed by Member States on 25 October 2012 and came into force on 14 November 2012.

Background 1. Article 8 of the EU Energy Efficiency Directive (‘the Directive’) requires all Member States to introduce a programme of regular energy audits for ‘large enterprises’.1 Audits must be undertaken by 5 December 2015, and then at least every four years from the date of the previous audit. Government believes that this programme offers a significant opportunity for the UK. It will help drive the take-up of cost-effective energy efficiency measures by participants, benefiting their competitiveness and contributing to the wider growth agenda.

2. The ‘Energy Savings Opportunity Scheme’ (ESOS) is the Government’s proposed approach to implementing this requirement. Under the scheme, approved assessors will carry out Article 8 compliant ESOS assessments to identify energy saving recommendations. While the Directive prescribes many of the key features that ESOS must include, there is some limited scope for flexibility and interpretation. This consultation document seeks views on a range of detailed issues around the implementation of ESOS. 3. Following this consultation, the Government will analyse consultation responses and then develop secondary legislation, setting out the legal framework for the operation of ESOS. The Government also proposes to develop good practice guidance to support organisations and ESOS assessors in conducting ESOS assessments.

4. The Government’s guiding principles for implementing ESOS are to: • ensure that ESOS provides high quality and well-targeted advice to large enterprises on cost-effective energy efficiency opportunities, driving significant net cost savings; • ensure a proportionate approach to implementation is taken, minimising the administrative burdens placed on UK businesses; 2

• ensure ESOS fits with and is complementary to the landscape of existing energy efficiency and climate change policy instruments; and • ensure our implementation of Article 8 avoids ‘gold plating’ that disadvantages UK businesses relative to their European competitors.

5. The Government’s Energy Efficiency Strategy set out the substantial, untapped and cost effective energy efficiency potential which exists in the UK economy.2 Through the right action we can unlock more of this cost-effective potential, and help to reduce energy bills at a time of increasing gas and electricity prices, balance the UK’s future energy demand and supply needs, and cut our carbon emissions.

6. The current economic climate makes it more important than ever for individuals, businesses and the country to realise the benefits available from reducing energy demand. Doing so will help support productivity of UK firms and improve the UK’s international competitiveness.

Who will this scheme apply to?

7. The proposed scheme would apply to all large enterprises in the UK (primarily businesses but also charities and any other UK organisations outside the public sector, if large enough).

8. Small and medium enterprises (SMEs) will not be required to participate, unless they are part of a large corporate group enterprise.3 SMEs will be able to carry out ESOS assessments on a voluntary basis and the Government encourages SMEs to consider such voluntary action.

9. To make it easier to determine whether a corporate group would be included in ESOS, the Government proposes that the scheme would only target those corporate groups where there are one or more large (i.e. non-SME) UK companies within the corporate group. If every UK company in the group enterprise was an SME, the group would not be covered by the scheme.

10. The scheme does not extend to public bodies.

NB. The consultation closes on 30 October 2013 and BPMA convened a meeting with its members on 4 September to consider the BPMA response.

NEWS BYTES   Europump General Assembly

 Pump Industry Awards 2014 We are pleased to announce that the prestigious Pump Industry Awards 2014 will take place at Chesford Grange, Kenilworth on 27 March.

For further details of categories, make your nominations or to book a table for the event please visit the dedicated website www.pumpindustryawards.com

It is with great pleasure we announce that in 2014, BPMA will be hosting the Europump General Assembly at the wonderful Fairmont St Andrews in Scotland from the 22 to the 24 May. With two championship golf courses, amazing countryside and steeped in history this premier destination will be the venue for the annual series of Europump Technical Standards, Commercial Marketing and General meetings.

A fantastic partner programme has been put together and coupled with a National Association dinner to be held at Guthrie Castle and a gala dinner on the final evening at Fairmont, this event is sure to be one not to be missed.

BPMA members are invited to join us at what should be a memorable few days. more visit Here is the new Advert weFor would like toinformation run.

Technical Innovation Finalists 2013 165mm by 225mm plus 3mm bleed and 20mm slug. www.europump2014.com

TM

Pumping The BoosterTechnology Set Experts

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Smedegaard offer what is Probably the most comprehensive range of Booster Sets in the UK. • • • • •

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Please contact Sean Austen for further information sean.austen@smedegaard.co.uk

3

WEG launches new energy efficient standard motor range with 40% less losses WEG, a global leader in electric motors, has launched a new range of motors that represents a major breakthrough in providing high levels of energy efficiency – the W22 Super Premium. The innovative electric motor is the only complete standard range available on the market worldwide that exceeds the yet-to-be-implemented IE4 regulations, enabling manufacturers to increase energy efficiencies significantly throughout their plants and processes, and reduce their total cost of ownership.

The W22 Super Premium gives outstanding performance across the full power range from 3 kW to 355 kW and presents up to 40% less losses compared to previous designs. The threephase induction motor is based on WEG’s popular W22 motor mechanical design and meets the requirements of the most demanding industrial users, giving reduced energy consumption, increased productivity, extended lifetime and lower maintenance. It is ideal for industrial applications including fans, blowers, pumps and compressors.

With features like an innovative aerodynamic frame, redesigned cooling system and unique insulation system, the W22 Super Premium range of motors is quieter, more reliable, easier to maintain and more cost-effective.

The motor has been designed to have low operating temperatures, which increases the

insulation time and results in a long service life.

The frame and cooling system of the motor has been optimised to deliver exceptional airflow to its components, improving operating efficiency even in tough environmental conditions.

It delivers increased lubrication intervals and therefore needs minimal maintenance and servicing. High performance rubber drains allow for easy motor drainage during servicing, and provide high protection at harsh conditions. Special bearing seals also extend the lifetime of the motor in aggressive environments by protecting it against the ingress of water and dust.

It has a flexible terminal box design for the 225 – 355 frame sizes, whereby the terminal can be positioned on the top or side to best suit the application. The W22 Super Premium range is modular, reducing inventory costs for manufacturers by enabling a common motor frame to be used with different types and sizes of terminal boxes.

The motor is robust with solid integrated feet, which provides a tough construction and enables easier installation and alignment. Motors in frame sizes 160 and above are fitted with flat surfaces which allow vibration detectors to be fitted easily, an important advantage for condition monitoring and preventative maintenance schedules.

Suitable for low voltage supplies, the W22 Super Premium motor range covers 2, 4 and 6-

pole motors in frame sizes up to 355. They are designed according to DIN EN 50347 Standard, which means that customers can replace an IE1, IE2 or IE3 motor with total reliability.

“As motors typically run for thousands of hours every year, any gain in efficiency by replacing motors with higher efficiency versions, equates into considerable savings which would pay for the investment in a few years, and in some cases even months,” says Marek Lukaszczyk, European marketing manager at WEG. “The new W22 Super Premium motors allow a low total cost of ownership thanks to its reliability, easy maintenance and energy savings, and enable users to reduce their carbon footprint.”

The introduction of the W22 Super Premium range means that WEG now has the widest range of energy saving motors for industry.

For further information about the W22 Super Premium range of motors visit www.weg-ie4.com

Calling for your Nominations The BPMA is delighted to announce that the call for nominations for the 2014 Pump Industry Awards is now open! The awards programme recognises individuals and companies who make exceptional contributions to the Pump Industry so if you or your company, or another that you know of or work with, is worthy of recognition for a ‘job well done’ why not put forward an entry?

Sponsored by some of the leading brands in the pumps sector and with ITV & BBC Radio Five Live Presenter Helen Fospero hosting and entertainment by ex England Rugby Player Martin Bayfield, this year's ceremony is set to be a very special night.

DART1

Wireless Machinery Monitoring System (ATEX Zone 1 Certified) As part of our commitment to continually reduce the cost of clients’ condition monitoring and improve safety in collecting data from hazardous or inaccessible areas, John Crane has developed an advanced technology, intrinsically safe wireless machinery monitoring system.

Specifically designed for condition monitoring of rotating machinery in hazardous areas (ATEX Zone1), the system is battery powered, designed to be easily installed and virtually maintenance free.

• Fit in a day • Easily moved from skid to skid for bad actor RCA • Up to 16,000 point data spectrum • Real time and long time trending graphs • Monitor in hazardous areas • Monitor in inaccessible areas • Monitor infrequently run equipment with “wake up” feature • Dashboard GUI with alarm function • Can run on standard PC • Free issued software and no annual charges • 3 to 8 year battery life John Crane UK Ltd Nash Road, Trafford Park, Manchester, M17 1SS

SUBMIT YOUR ENTRY

24hr Emergency: 0800 917 2408 Colin Ure T: 07786 727997

www.pumpindustryawards.com hannah@touchwavemedia.co.uk

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

www.johncrane.com

E-mail: hannah@touchwavemedia.co.uk

4 16617 BPMA 112x150mm Ad_AW 2.indd 1

28/01/2013 16:52

No pressurisation headaches with Grundfos COMpress Now part of the extensive portfolio of packaged pumps sets available from Grundfos Pumps, a new generation of specifically engineered COMpress pressurisation units will deliver improved system peace of mind.

COMpress is available in both single and twin pump options and these units are ideal for use in both sealed heating and chilled water systems.

These new top-up pressurisation specialists have a multifunction digital controller with a simple user

interface as well as having many useful features.

These include: flood monitoring protection, event logging and MODBUS communication protocol as standard. In addition COMpress units offer BACNET protocol and a high water alarm as additional options.

The range offers 12 variants and making the right selection is a simple process (once the vessel size has been calculated) of choosing the fill pressure required to top-up, and that’s it!

Pumps

ABB

So all and all, the Grundfos COMpress now has the answer to system pressurisation headaches.

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

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

Valves

Service

One goal

completes acquisition of

Dynamotive in the UK The acquisition strengthens ABB’s service offering in lowand medium-voltage motors and drives.

ABB recently announced that it has completed the acquisition of Dynamotive Ltd, which was announced on June 7th.

Dynamotive based in Coalville, UK, designs, commissions and upgrades systems of drives, controls and motors for industrial and marine applications and automotive test rigs.

The acquisition of Dynamotive strengthens ABB’s service operations including upgrade and retrofit capabilities in lowand medium-voltage drives.

Furthermore, it will help ABB to increase its sales of complete industrial motion packages, which include drives, motors, controls and related services.

ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 145,000 people.

For more information go to www.abb.com

On the mark for your success Two symbols, three letters: pumps, valves and KSB are all closely connected – thematically and visually. Wherever there are fluids to be transported, controlled or shut off, customers globally benefit from our expertise. And you too, can trust our products. The KSB brand stands for competent advice, excellent quality and top reliability. It also guarantees service you can count on worldwide. www.ourtechnology.yoursuccess.ksb.com

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

Our technology. Your success.

Pumps • Valves

• Service

5

Pump-attuned valves improve energy efficiency

By Uwe Herberger-Rosin – KSB Aktiengesellschaft

In actual practice, roughly one out of three check valves installed in pump systems is causing major losses due to improper selection. Particularly in connection with system conversions and overhauls, more attention should be paid to the proper selection and positioning of such valves.

Check (or non-return) valves are needed when a pump is stopped and the liquid column acting on the discharge nozzle or the pressure generated by other pumps operating in parallel could cause the impeller to reverse direction. Sensitive components like unidirectional mechanical seals could sustain damage as a result. If an appropriate valve is installed, any reversal of flow will close it, thus providing reliable protection against reverse flow.

Often, however, lift check valves and dual plate check valves are installed without first having examined the prevailing flow conditions and resultant energy losses.

BOA RVK wafer-type lift check valve

Frequently, the pump is the major point of focus at the time of installation, while the check valve is selected en passant, so to speak. Depending on the equipment constellation, this can cause serious wear and tear on the valve or even keep the system from achieving good performance.

The advent of speed control systems, though, has changed the situation for check valves. While pumps used to be either “on at full load” or “off”, many units are now operating at reduced speed in the partload range.

When lift check valves are used, low flow velocities can cause constant “opening and closing”, because, unlike dual plate check valves, they are unable to reliably maintain a partly open position. Consequently, they might use up their entire service life in terms of opening/closing cycles within a few weeks. High volume flows can also cause problems due to high flow velocities in the narrow gaps at the disc/seat interface. This can lead to such pronounced wear and vibrations as to cause the eventual failure of the valve. Indeed, resonant vibrations might even cause damage to the pump itself.

Frequently, the connecting piece between the pump and the check valve is too short. As a rule of thumb, the valve should be situated at least the equivalent of five nominal diameters away from the pump – a length referred to as the flow stabilisation distance.

In a study conducted by KSB, more than 30 percent of all check valves were found to have been incorrectly installed, poorly selected, or undersized.

There were even cases in which the installed check 6

valve consumed nearly half of the head generated by the pump! Considering the huge number of check valves now in service in industry, there is an equally huge potential for cutting costs.

Hydraulically efficient swing check valves Ever since the company was founded, KSB has been designing and producing a wide diversity of valves.

One particular model was known for closing so softly and reliably that it became the valve of choice for use in the exhaust systems of numerous dieselelectric submarines. Its job was to keep seawater out of the exhaust systems of snorkeling subs.

So what could have been more logical than to use SERIE 2000 check valves, with their dual plate valve disc, for less spectacular applications, too? The robust, maintenance-free valves have one-piece cast bodies with high mechanical strength and excellent corrosion resistance. Their spring assembly ensures reliable seating in situations where gravity alone would not suffice.

This type of valve can be installed horizontally or vertically with no special tools required. A wide spectrum of materials allows service at temperatures between -196°C and +538°C. Their main merit, however, is their low pressure loss coefficient.

The valve disc opens stably even at very low flow velocities.

Tests document high savings potentials In order to closely analyse the opening behaviour of SERIE 2000 valves, extensive tests were performed on one of KSB’s own test stands. The basic goal was to examine which kind of check valve – dual plate check valve or lift check valve – is most suitable for which kind of application. Both types were therefore tested in diverse situations.

In the first test set-up, the technicians installed a lift check valve with no flow stabilisation section. The results agreed with practical field data. At minimal volume flow, the opening behaviour was unstable, and the valve began to chatter. At maximum flow, the spring vibrated strongly due to the high velocity of flow through the valve. Even the subsequent installation of a flow stabilisation section failed to improve that behaviour.

In the second setTest set-up for examining up, the technicians the behaviour of check installed a SERIE valves in combination with 2000 dual plate check valve with, variable speed pumps

and then again without, a flow stabilisation section.

This time, the observed opening behaviour remained stable, even with the valve in a partially open position, and there was no chattering like in the case of the lift check valve. Any unsteady behaviour of the dual plate valve discs was remedied by installing a flow stabilisation section.

Under low flow conditions, the lift check valve remained very unsteady despite installation of a flow stabilisation section. Consequently, such valves should only be installed in cases where space constraints leave no room for any other choice, because its unstable opening behaviour can, under certain circumstances, result in a very high rate of wear. Nor is this kind of valve inherently suitable for use with a frequency inverter. This is also evidenced by a comparison of head losses calculated for both types of valve.

The individual loss coefficient, , of a wafer-type lift check valve is approximately 4.5. With a SERIE 2000 valve, the situation is intrinsiccally more favourable, because there is no change in the direction of flow in the valve, so its value, at 0.4, is much better.

This can also be demonstrated by way of the head loss, Hv, as calculated according to the following equation. DN 200 mm pipes were selected on the basis of assumed flow velocities of v = 1 - 1.5 m/s on the suction side and v = 2 - 2.5 m/s on the discharge side. Applying these data, the equation

yields 1 m as the head loss attributable to the lift check valve. The same equation yields a head loss of just 0.08 m for a SERIE 2000 valve. Depending on the application in question, this could mean that a smaller pump could be installed.

To ensure stable, vibration-free behaviour of the closing elements, though, even dual plate check valves need a flow stabilisation section measuring about 5 x DN. This helps ensure smooth and energy-efficient pump operation under any set of load conditions.

Conclusions drawn It pays off to take a holistic view of the valve, the pump and the frequency inverter as a system.

The cost of installing a new valve redeems itself very quickly. Of course, optimal matching of pump and valve is not the only way to reduce energy expenditure. No matter which measures are taken, though, the decisive factor is to ensure that the system is designed to match the operating point.

For more information contact KSB Limited, Loughborough, Leicestershire.

Tel: 01509 231872 E-mail: sales@ksb.com

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

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

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

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

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

Meet the energy challenge NOW with Grundfos Today there is so much focus on using energy wisely that it is no surprise that, as pumps consume 10% of the world’s electrical power, focusing on optimising the amount of energy they use makes a lot of sense. This is both from an environmental perspective as well as to save energy/money.

Pumps are all around us and are vital to every aspect of our lives, as without them we would have no hot water, heating or air conditioning, nor could we access clean water or dispose of wastewater, not to mention that manufacturing and the process industries would grind to a halt.

So making sure the best pump option is selected for a specific task can mean huge 80%+ energy savings. To help simplify how savings can be achieved the Meet the energy challenge NOW portal from Grundfos Pumps has become an umbrella for a broad range of energy information that encompasses topics such as: facts on pumps; technological advances; a broadcast centre and much, much more. Find out for yourself by visiting energy.grundfos.com To us at Grundfos, pumps are not just our business but they are also our passion. Sustainability is a very important cornerstone that we have built our company on; so presenting the facts about pumping and how to improve efficiencies is not just business as usual to us, but is part of a drive to help achieve real improvements. Together, we can make a real difference.

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

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

7

THE NEW WORLD STANDARD IN BELT TENSIONING

GEMEX®

Belt Tensioning System Reduce downtime from a broken belt transmission from hours to minutes thanks to the hydraulically pre-tensioned setup of the Gemex® system. It makes replacement faster and safer and has been proven to increase belt transmission efficiency.

It’s no wonder Weir Minerals Gemex® belt tensioning system is becoming the new world standard in belt transmissions.

Excellent Minerals Solutions

For more information, please visit: www.weirminerals.com GEMEX is a registered trademark of Gema Industri AB. Weir is a registered trademark of Weir Engineering Services Ltd.

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

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

Job Title:............................................................................

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

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

Tel:.......................................Fax:........................................

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

Main Business Activity:.......................................................

Estimated No. of Employees at this address:......................

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

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

Copyright © 2013 Weir Minerals Europe Limited. All rights reserved.

Summing Up Sealless Pumps for the Oil & Gas Industry Having pioneered the magnetic drive sealless pump almost seventy years ago, Sundyne HMD Kontro has continued to develop the technology to meet the increasing demand for sealless pumps in the offshore oil and gas industry and has now produced a new brochure dedicated to this market sector.

The oil and gas industry is facing significant challenges to provide safe, sustainable and smart supplies along with continuing to explore and develop new sources. Environmental concerns from seal system complexities and their recurring mechanical seal problems are resulting in increasing demand for sealless pumps in this sector. In some cases, more stringent regulations and local agencies are mandating their use.

Sundyne HMD Kontro offers an extensive range of products and services to satisfy the pumping needs and specific requirements found within the oil and gas industry, while maintaining its flexible approach and without compromising the quality as well as the reliability of its equipment. The pumps manufactured by Sundyne HMD Kontro offer the ultimate solution to environmental concerns from; seal system complexities; recurring mechanical seal problems; maintenance and downtime reduction; health & safety worries; whilst also minimising spare parts inventory To demonstrate its experience and expertise in this market, the company has produced a dedicated brochure that supports HMD Kontro pumps for oil and gas applications including: • Process Pumps • High Capacity / High Pressure Pumps for Crude

Oil Transportation • Produced Water Start Up Pumps • Oil Start Up Pumps, Installed in the Oil Outlet Line • Glycol Dehydration Pumps • Condensate Pumps • Sampling Pumps • Closed Drains Pumps • Flare Knockout Pumps • Seawater Cooling Pumps • Booster Pump Units HMD Kontro sealless pumps are designed to comply with the requirements of API 685 specifications for magnetic drive, sealless end suction, centrifugal pumps required by the oil and gas, as well as the petroleum and heavy chemical industries. HMD Kontro has been building sealless magnetic drive pump units for the oil and gas industry since 1983.

Improved magnet drive technology has enabled more efficient and powerful pumps to be built, thus increasing the application scope for this technology.

A copy of the new brochure for the oil and gas industry can be downloaded from the Sundyne HMD Kontro website at www.sundyne.com/ hmdkontro. For further information, please telephone +44 1323 452128 or email info@hmdpumps.com

Using the right pump for your process?

Or just the ones you’ve always used?

Safeguarding your process from the unthinkable is just one part of what we do. Selecting the right pump for the job with world class equipment and applications understanding or carrying out emergency repairs, we add a whole new level of operational security to your process.

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AxFlow Ltd., Tel: 0208 579 2111, Fax: 0208 679 7326, e-mail: info@axflow.co.uk AxFlow locations; London, Aberdeen, Huddersfield, Windsor and Durham

A guide to selecting the right float switch for your application When selecting a float switch for a liquid level sensing application, a number of factors need to be considered, including float switch and gasket materials, physical arrangement, electrical ratings and cable type, says Simon Dear of Cynergy3 Components. a good indication of the suitability of the various float switch materials in a wide range of liquids. For some process liquids, it may be necessary to obtain a sample float switch in order to test the compatibility.

Electrical

horizontal/side mounting type normally has a fixed housing, which passes through the sidewall of a tank, with a hinged float attached to the fixed housing.

Vertical mounting types normally have a fixed vertical stem, which is installed through the top or bottom of a tank, along which slides a cylindrical float.

Many industrial processes require devices that are able to sense the level of liquid stored within various types of tank or chamber. The signals from these devices may be used to control the production process or to provide indication of the status.

One of the most reliable, well-proven technologies for liquid level sensing is a float switch. This type of switch comprises a magnet contained within a float, as well as a magnetic reed switch contained within a fixed housing. The movement of the float, due to the changing liquid level, will cause the reed switch to operate (i.e. close or open) at a particular level. This tried and trusted technology is based on a relatively simple design that offers long term reliability without the need for the user to calibrate the switch.

Whilst there are different methods available for selecting the right float switch for a particular application, the main factors to consider include the following:

Physical arrangement and style The choice of styles that may be suitable for an application will depend on the physical arrangement of the tank, the available mounting positions and whether access is available to the inside of the tank. The main styles are horizontal/ side mounting and vertical mounting. The

28

Another important consideration is whether a build up of deposits from the liquid on the float body is likely to occur. These deposits can, over a period of time, accumulate to such an extent that the float switch can fail to operate. Whilst particular types of float switch have been developed to limit the effects of this build up, the experience and knowledge of the switch manufacturer is also critical here.

Material selection It is critical to select a float switch that is constructed from the right materials that are compatible with the liquids and temperatures of the particular application.

Component damage as a result of incorrect materials selection can ultimately cause failure of a float switch, which may have severe consequences. Typical float switch materials include:

Nylon: suitable for many oils, diesel, organic chemicals and MEK-based printing inks.

Polypropylene (PP): suitable for many acids and alkali, detergents, inorganic and organic chemicals, oils and water.

Polyphenylene sulphide (PPS): suitable for many of the more aggressive chemicals and higher process temperatures, up to 120ºC.

It is important to fully understand the nature of the load that needs to be switched and to ensure that the float switch is capable of handling this load. The electrical ratings, which most manufacturers provide in their float switch specifications, are for purely resistive loads. Any loads that have either inductive or capacitive components should have the appropriate contact protection measure applied.

Cables In applications where aggressive liquids may spill onto external wiring, it is important to specify particular materials for the cables used to connect to the float switches. There are standard, UL-approved cable types for the various float switches, as well as high temperature, low smoke zero halogen (LSZH) and other specialised materials.

Custom engineered float switches The operating environment is critical to the choice of float switch. A water tank for an industrial process may only require a simple plastic float switch. However, if the application is in a hazardous area, for example, a petrochemical storage tank where flammable gases, vapours or dust are present, a stainless steel, explosion-proof float switch will be required.

Over the years, we have custom engineered many variants of its float switches to match particular customer requirements in a wide range if industry sectors including oil, gas & petrochemicals; food and beverage; chemicals and pharmaceuticals; water and wastewater; and process manufacturing. These include float switches for all types of environment, including industrial process control, safe areas, intrinsically safe and hazardous areas (ATEXcertified), as well as WRAS-approved switches for drinking water applications.

Buna/Nitrophyl: suitable for many oils, diesel, petrol and water (non-potable applications).

D300 foam (PVC): suitable for most hydraulic oils and many chemical solutions.

Stainless steel: suitable for most medical and food applications, chemicals, hydraulic fluids, fuel oils and applications with process temperatures up to 135ºC. Selection of the most suitable materials for both float switch and gasket can be made by referring to a ‘Chemical Compatibility’ table. These tables provide

Cynergy3 Components Ltd, Wimborne, Dorset.

Can be contacted on Tel: +44 (0) 1202 897 969 E-mail: sales@cynergy3.com Web: www.cynergy3.com

Process Industry Informer September 2013

Precise, Reliable Bulk Solids Inventory Management

CONTOUR improves bottom-line efficiency with more accurate safety stock and COGS management.

A self-cleaning feature ensures continuous performance integrity.

Low-frequency acoustic technology maintains signal strength and accuracy even during dusty filling conditions.

CONTOUR measures challenging applications that incur buildup loads or random material surface irregularities.

Multiple-point measurement precisely maps material surface variation.

CONTOUR transmits a 3D graphical display to capture powerful consumption data.

3D Visual Mapping Takes Volume Measurement to the Next Level To learn more about the bottom-line benefits of CONTOUR acoustic volume mapping for bulk solids and powders, visit: Contour.Magnetrol.com

Now, you can improve safety stock tracking and COGS (cost of goods sold) efficiencies with more precise control of your bulks solids and powders inventory. New CONTOURTM acoustic volume mapping provides more accurate, reliable measurement than traditional level instrumentation to enable you to visualize true material consumption in your bins and silos.

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

Because B ecause exida exida ® s says ays so. so.

STA Safety Trip Alarm, up to SIL 3 capable in a redundant architecture

SRM Safety Relay Module, SIL 2 capable

When you specify exida certied safety instrumentation, you know it meets the necessary IEC 61508 safety standards.

At Moore Industries, every FS series product that we manufacture is designed and built from the start in compliance with IEC 61508 specications and third party veried by exida. That means you can apply it in your safety instrumented system with condence that it will perform reliably when you need it most.

Take no chances. Select Moore Industries exida certied FS Functionally Safety Series instruments.

Watch our safety trip alarm demo, and download the free white paper. www.miinet.com/safetyseries

United States • info@miinet.com Tel: (818) 894-7111 • FAX: (818) 891-2816 Australia • sales@mooreind.com.au Tel: (02) 8536-7200 • FAX: (02) 9525-7296

Belgium • info@mooreind.be Tel: 03/448.10.18 • FAX: 03/440.17.97 The Netherlands • sales@mooreind.nl Tel: (0)344-617971 • FAX: (0)344-615920

China • sales@mooreind.sh.cn Tel: 86-21-62491499 • FAX: 86-21-62490635 United Kingdom • sales@mooreind.com Tel: 01293 514488 • FAX: 01293 536852

REACH:

By Dr. Dieter Reiml, Certified REACH-Multiplicator at TÜV SÜD Industrie Service GmbH

Time is running out The wave of registrations is now reaching small and medium-sized companies too. The EU’s REACH Regulation obliges all manufacturers and importers of chemicals above a quantity of 1 t/a to register them by June 2018 with the European Chemicals Agency (ECHA). This is a tight time frame for small and medium-sized companies because the requirements are very complex. External service providers like TÜV SÜD can relieve the pressure on companies and prevent serious errors in the registration process.

The motto of the REACH Regulation is unmistakable: “No data, no market”.

Chemicals with an annual production or an import volume of one metric ton or above must be registered by the end of May 2018.

This third registration phase now affects mainly small and medium-sized enterprises that manufacture or import chemicals. Anyone who cannot comply with this deadline will have to cease production or import and will no longer be allowed to put the substances on the market within the European Union.

Many a small or medium-sized enterprise is still shying away from getting to grips with the REACH Regulation – after all, the deadline is still five years away. This way of thinking entails risks due to underestimating the complexity of the registration process and the time and effort it requires. There are often not the staff resources and the IT infrastructure necessary for the registration process. Even when the registration dossier is submitted on time, there is still a threat that the marketing rights will be withdrawn if the data quality is poor. As delays or errors during registration can be vital to the company’s existence, the REACH experts recommend starting the necessary preparatory work right now. First and foremost, it should be borne in mind that REACH is not only about the technical implementation of legal obligations but also about economic and financial aspects.

Increased documentation effort REACH places high requirements on documentation which can involve a considerable amount of in-house effort and expenditure. The registration dossier for quantities above 10 metric tons per year must additionally contain a Chemical Safety Report (CSR). The safety-relevant information and protective measures must be listed in this dossier for all intended uses of the substance. This means that the CSR can easily grow in size to a hundred pages or more.

In this case, it is not only the manufacturers and importers but also the downstream users who are being required to comply. There are new obligations ahead of them. They must not only comply with the usage conditions specified and implement risk reduction measures but they are also required to help shape these measures by providing feedback and actively participating in discussions. For their part the users are therefore required to provide information to the manufacturers and importers and in this way to contribute to continuous adaptation of the safety data sheets. If the chemicals are exported to EU countries, the safety data sheets must additionally be translated into the relevant languages.

The exposure assessment can also cover more than a hundred pages. This must always be prepared if the substance is classified as hazardous. The document must contain answers to the questions regarding the potential risk of a chemical, how great this specific risk is and what measures will be taken to protect the environment, consumers and employees.

In this case, the substance’s entire life cycle from manufacture to disposal or recycling must be taken into account.

Cooperation in the SIEF takes the pressure off SMEs It is not always clear at present whether the registration of a chemical is appropriate from an economic point of view in view of the high expenditure. So companies should check

Process Industry Informer September 2013

first of all whether the substance will still be relevant for marketing in 2018. It should also be clarified whether the chemical will be produced or imported in the tonnage band above one metric ton per year at that time and will therefore be subject to registration. If this is the case, then even small companies should appoint a responsible person who coordinates all activities for planning and managing the REACH process on schedule.

The most important building block is active participation in what is referred to as the Substance Information Exchange Forum, SIEF for short. All manufacturers and importers of a substance that is to be registered come together in the SIEF to exchange information about substance properties, uses and hazards as well as cost sharing. The aim of this is to prevent the repetition of studies and duplications when registering. As SMEs generally function as co-registrants, this amalgamation reduces both the effort and the costs for registration. On the other hand, participation in the cost sharing process is essential.

However, the need for communication within the SIEF should not be underestimated. If a joint chemical safety report (CSR) is prepared, the co-registrant must ensure that it supplies the leading registrant with all the relevant information about the uses it has identified.

Otherwise it must either prepare its own CSR or forego the use.

The most frequent sources of error The first two phases of the REACH implementation have been completed since the end of May. During evaluation of the dossiers submitted, the European Chemicals Agency (ECHA) discovered that in some cases the data were inadequate. According to the Association of the Chemical Industry (VCI), the ECHA is considering whether the registration number for a chemical should be withdrawn in such cases. As a result, it would no longer be permissible to market the substance within the EU – with all the economic consequences for the company concerned.

REACH experts, such as those at TÜV SÜD, have identified some of the most frequent sources of error in the registration process. If communication in the SIEF is not monitored precisely, then in practice the wrong substance might be registered. The registration is therefore invalid. It is also often forgotten to list every use of a substance explicitly. Yet another stumbling block: although the ECHA’s detailed ‘guidance documents’ provide valuable aids and explanations about the REACH process, they are not legally binding in themselves. Anyone who takes only these documents into consideration when preparing the dossier is not necessarily acting within the law.

In some cases, important information provided by the ECHA has also been overlooked because this body only communicates via its own data processing system REACH-IT. In other cases, it was forgotten that the dossiers also have to be kept up-to-date after registration and to this end must be updated continuously. For example, if the substance’s use changes, this must communicated along the entire supply chain after registration. And perhaps the most serious error of all: the REACH process is simply started too late.

Medium-sized enterprises initiative is expedient The European Commission reduced the registration fees for SMEs in March. Although this takes the financial pressure off the SMEs, it makes no difference at all to the level of administrative effort and the associated demands made on staff resources. External support can resolve these bottlenecks and prevent delays and errors during the registration process. For example TÜV SÜD’s small and medium-sized enterprises initiative, as a REACH service specifically for SMEs, will ensure reasonably-priced and timely registration of chemical substances. The companies’ own employees will have no need to get to grips with either the complex REACH Regulation nor the relevant data processing systems IUCLID and REACH-IT. TÜV SÜD Industrie Service GmbH Munich,Germany Can be contacted on Tel: +49 (0)89 5791-1004 E-mail: dieter.reiml@tuev-sued.de Web: www.tuev-sued.de/is

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FLUIDS & LIQUIDS HANDLING inc. pumps & valves

FlexiDrive provides safe, remote valve operation in oil, gas and chemical processing industries STORAGE TANK VENT DRYERS Protect against water contamination



Quick and easy to install



IP65 rating



Visual colour change indication



Easy ENVIROGEL replacement



Polycarbonate or glass sight window



Floor and wall mounting



Available in mild or stainless steel





ISO9001/2008 design approved

ATEX Directive 94/9/EC approved

our or y ng f s luid nd f a l i o

Cari

Smith Flow Control’s FlexiDrive valve actuator can be applied to any conventional wheel-operated device in oil, gas or chemical processing plants to make them constantly accessible and safe. The FlexiDrive is a dependable, versatile and cost effective remote valve operator.

The FlexiDrive system allows a user to locate a point of operation in a place of safety or convenience. It is adaptable to any conventional valve with no modifications needed. A patented flexible linear drive cable effectively delivers rotary torque for distances up to 30 metres depending on the output torque required. The system can be passed through and around walls, bulkheads and floors, and is completely sealed and permanently lubricated for maintenance-free, continuous loop operation.

The FlexiDrive is suitable for underwater use and is constructed from corrosion-resistant 316 stainless steel. It is designed to withstand temperatures from -22 to 347 degrees Fahrenheit and is delivered as a complete unit.

For more information about FlexiDrive, please visit the company website at http://www.smithflowcontrol.com/flexidrive.html For more information contact Smith Flow Control Ltd, Witham, Essex Tel: +44 (0) 1376 517901 Fax: +44 (0) 1376 518720 E-mail: sales@smithflowcontrol.com Web: www.smithflowcontrol.com

Unit 2 | Abbey Road Industrial Park, | Commercial Way Park Royal | London | NW10 7XF | T: +44(0) 20 8965 9281 F: +44(0) 20 8965 3239 | info@brownell.co.uk

www.brownell.co.uk

OPERATING PANEL ALLOWS SAFE AND EFFICIENT CONTROL OF ACTUATED VALVES

AFTERMARKET PARTS that fit AIR OPERATED DIAPHRAGM PUMPS

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25%

www.thinqk.com 32

Safety engineering company Smith Flow Control has manufactured a custom-built operating panel which enables a client to control a sequence of actuated valves. The operating panel can be used in a wide variety of applications that involve the use of actuated valves, for example to launch or receive a pig.

The panel works as a communication and proofing system to improve efficiency and safety. A typical application often includes two interlocked key units to isolate power to the panel and ensure a specific sequence of operation.

Using the panel, the operator can select to close the valves. Red LED lights prove that the valves have reached their fully closed position. When all valves are closed, the operator can isolate the panel by removing the ‘A’ Key. The ‘A’ key is entered into the solenoid key unit and only when the SAS (safety and automation system) confirms all valves are closed, a permissive signal is sent to energise the solenoid and release the ‘B’ key. This allows the operator to safely continue the mechanical interlocking sequence, for example, to manually unlock a pig trap door to load or unload a pig.

The panel has been designed with the operator and environment in mind, making it easy to use and robust. It is made to support applications in the most aggressive environments, suitable for temperatures ranging between -40 to +55 degrees Celsius (-40 to +131 degrees Fahrenheit) with an antireflective coating that eliminates glare.

The panel is designed to meet strict safety guidelines and regulatory body requirements. It is made using 316 Stainless Steel and conforms to Zone 1 Ex de classification and protection class IP66. It also boasts a compact design and can be used in weight restricted and space-limited areas.

For more information about the operating panel and how it can be used, please call Smith Flow Control Ltd, Witham, Essex Tel: +44 (0)1376 517901 Fax: +44 (0)1376 519720 E-mail: sales@smithflowcontrol.com Web: www.smithflowcontrol.com

Process Industry Informer September 2013

FLUIDS & LIQUIDS HANDLING inc. pumps & valves

CSF aseptic hygienic pumps with steam protection barrier ideal for sterile products The established range of CSF hygienic centrifugal pumps includes the CSD Aseptic series which achieve the ultimate level of hygiene when transferring liquids in food, beverage, pharmaceutical, injectable/ intravenous, ultra pure and other process applications where hygiene is critical. When fitted within an Aseptic plant these pumps ensure sterility and can assist in extending shelf life by ensuring the cleanest possible process conditions.

Grundfos NB range now with extra efficiency as standard Continuing Grundfos’ ambition to deliver the most energy efficient products to the market, they have announced that their entire NB pump range is now available with high efficiency IE3 motors as standard.

This sturdy family of end-suction pumps is suitable for a wide variety of different applications that require reliable and cost-efficient operation in a range of applications including: water supply, pressure boosting, industrial liquid transfer, HVAC and irrigation.

The new NB IE3 pump range includes Grundfos MG motors, and with standard motors starting from 0.75kW and up to 200kW (2 pole), 200kW (4 pole) and 90kW (6 pole), all this means that today Grundfos offer you a virtually limitless range of close coupled NB end-suction pumps that are the perfect choice in so many applications.

And with the added benefit of now being even more energy efficient at no additional cost, they are perfectly in-line to deliver against even the highest expectations.

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

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

Trust ARI... Trust ARI... Trust ARI... Trust ARI... Trust ARI...

Available through the liquids handling specialist, PUMP ENGINEERING LTD, CSF CSD series pumps are robust and reliable. The mechanical seal is internal and balanced, fitted with EN12756/ISO3069 seats protected from contamination by a high temperature flush. Inlet and outlet ports are fitted with a steam protection barrier to ensure sterility, ensuring all points of potential microbial ingress are securely defended.

As with all CS series pumps, the CSD features an open impeller and a clamp casing, seal design and back pull out IEC standard motors, which allows for quick disassembly and inspection. These close coupled pumps are designed on a modular concept, which ensures a wide range of models and therefore an extensive performance range covering capacities from 1 to 300 m3/hour at heads up to 100 metres, with low NPSHr. CSF CSD pumps are manufactured in electropolished investment cast AISI 316L stainless steel, with stainless steel for all wetted parts. They are also available in Sanicro 28, Duplex SAF 2507 and Hastelloy C276 and with an optional 0.5 micron Ra surface finish. Elastomers are available in a choice of Viton, EPDM, or PTFE. Typical applications for CSF CSD hygienic pumps include aseptic / long life food, beverage and milk products, injectable and intravenous products, pharmaceutical/ biopharm, fine fragrances and flavourings where cross contamination and/or microbial ingress cannot be tolerated.

Further details on CSF pumps are available from: Pump Engineering Ltd, Littlehampton, West Sussex Tel: 01903 730900 Fax: 01903 730234 E-mail: sales@pumpeng.co.uk Web: www.pumpeng.co.uk ARI-205x150.indd 1

Process Industry Informer September 2013

29/08/2012 11:02

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CO2 Gas Hazards in the Brewing Industry The hazards associated with CO2 in the brewing industry are well known, yet people still die needlessly every year in tragic and completely avoidable accidents in breweries. Just last year in Germany, which has a good safety record, two workers died in separate incidents at the same brewery.

Chris Wilson, Crowcon’s Senior Support Engineer, discusses these incidents and explains how they could have been avoided by following the right CO2 gas safety procedures.

In the first incident, the owner was found dead with his head and torso in a beer mixing tank. It is thought that, after bottling and subsequent cleaning, the owner had leaned in to check the container and was overcome by CO2. 10 months later in the same brewery a worker was found dead in a pressure tank used to recirculate wheat beer. He had probably forgotten to fit a yeast plug and had leaned into the tank – which was already pressurised with CO2 – to fit one. He was found up to his hips in the container and had been poisoned – probably in seconds – due to the high concentration of CO2.

Both these accidents demonstrate the extremely hazardous nature of CO2 and how quickly one can be overcome by its deadly properties.

Properties and effects of CO2 CO2 is extremely hazardous and can kill in two ways: either by displacing O2, leading to rapid asphyxiation, or as a toxin in its own right. Exposure to as little 0.5% volume CO2 represents a toxic health hazard, while concentrations greater than 10% volume can lead to death. Because CO2 is completely odourless and colourless there is no physical indication of danger until it is usually too late.

CO2 is a by-product of the fermentation process and, because the gas is heavier than air, it collects at the bottom of containers and confined spaces such as tanks and cellars and can even spill out of fermenting tanks and sink to the brewery floor, where it forms deadly, invisible pockets. In fact, CO2 is a hazard throughout the brewing process, right through to packaging and bottling.

Safety precautions Fermentation tanks, beer mixing tanks, silos and other confined spaces in the brewing industry are easily accessible – it is rare for them to be fitted with safety interlocks.

For this very reason rigorous safety systems should be in place and always adhered to.

Employers must assess the risks these areas pose to their employees and endeavour to prevent them. In most cases, both the assessment and the safe working system will require testing of the atmosphere with gas detection equipment.

As a rule, entry should not be routine and should only be carried out if absolutely necessary. However, if entry is necessary – for example for an inspection or to ensure cleaning has been carried out correctly – suitable safety procedures must be followed.

Firstly, CO2 from the space must be completely removed. This can be done by discharging all the fermentation and pressure gasses directly into the open air using a ring main system. If this is not possible due to the layout, the CO2 must be manually extracted and safely diverted.

Prior to entering a tank or other confined space, a ‘release measurement’ of CO2 must be taken using a suitable CO2 monitor. This is the only reliable method to check whether the CO2 concentration is actually at a safe level. The measurement must be taken by a qualified person, usually by lowering the monitor into the chamber and leaving it there for several minutes. It goes without saying that any monitoring device must be durable, reliable and regularly calibrated and tested.

Protecting the worker entering a confined space Anyone entering a tank or other confined space must also be equipped with a suitable gas detector. If a certain CO2 concentration is exceeded the device will go into alarm

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mode with both audio and visual alarms.

Generally, at a CO2 volume of 0.5 % by volume, a pre-warning is set off; at 1 to 2 % by volume the main alarm is activated. With most devices other alarm thresholds can be selected with the aim of avoiding the alarm sounding too frequently and simultaneously ensuring the safety of the person working in the container.

CO2 gas detector types Both portable and fixed CO2 detectors can be used for CO2 monitoring in breweries.

Fixed systems typically comprise one or more detector “heads” connected to a separate control panel. If a detector reads a dangerous CO2 level, extractor fans are automatically triggered and sirens or visual beacons can also be activated to warn workers to vacate the area. This sort of installation is suited to larger spaces like cellars and plant rooms.

However, much confined space work in the brewing industry takes place in more restricted areas like fermentation tanks where fixed detectors cannot be installed.

This means compact portable units are required. Ease of use, with one button operation, should be the norm when it comes to portable detectors. This means minimal training is required while increased safety is ensured. Combining one or more sensors with powerful audible and visual signals to warn when pre-set gas levels are reached, compact portable detectors are easily carried in a confined space, ensuring that pockets of high CO2 concentration are not missed.

Certain features should be expected in every portable CO2 detector. Clearly, lifesaving tools for demanding environments must be as tough as possible, with reliable electronics housed in impact-resistant casings. While the need to leave gas sensors exposed to the atmosphere means that no instrument can be fully sealed, a high degree of protection against dust and water ingress is essential. Toughness notwithstanding, a well-designed detector will also be light and compact enough to wear for an entire shift.

Finally, because of the difficulties of working in a cramped space, perhaps under poor lighting, instruments should be easy to use. No matter how advanced a detector’s internal architecture or data management options, personnel in the field should be faced with nothing more daunting than a clear display, simple, one-button operation and loud/bright alarms.

Conclusion Not taking the risk of CO2 seriously has led to many unavoidable deaths. If all the safety procedures described above are observed, the risks of dealing with this colourless, odourless and tasteless gas can be significantly reduced.

Crowcon Detection Instruments Ltd, Abingdon, Oxfordshire.

Can be contacted on: Tel: +44 (0)1235 557700 Fax: +44 (0)1235 557718 E-mail: sales@crowcon.com Web: www.crowcon.com

Process Industry Informer September 2013

FLUIDS & LIQUIDS HANDLING inc. pumps & valves FLEXIBILITY AND PRECISION WITH THE ARI-STEVI® RANGE OF CONTROL VALVES ARI-Armaturen, worldwide leaders in the manufacture and supply of high quality process valves, make a wide range of STEVI control valves for variable industrial use including control, mixing/diverting and isolation.

Latest additions to the range include the STEVI®AS Y-pattern process valve which is reliable at high differential pressures and will deliver unbeatable power and tight shut-off for up to 1,000,000 strokes. The superior, self-adjusting stem sealing system, composed of a spring loaded PTFE-V-ring unit and a burnished stem with double bearing, ensures a tight seal on closing with zero leakage.

Water hammer is reduced to a minimum due to the damped closing function and the flow-optimised Y-pattern body design facilitates large strokes and excellent flow capacities, leading to energy savings of up to 31%. Also available with a Stainless Steel Actuator with an ambient temperature range from -10ºC to +60ºC, the stainless steel construction makes it ideal for a wide range of applications requiring regular hose-down.

The new STEVI®472 is another significant addition to the range. It is an extremely efficient high performance valve with flexibility and reliability up to PN160 and is suitable for a variety of process control applications including hot water and steam. As well as offering exceptional levels of leak-tightness and valve longevity in high pressure applications, the STEVI472 is extremely versatile due to its modular strength with more than ten electric or pneumatic actuator variants.

Commenting on the company’s latest product developments, Nick Davies, UK Sales Director, said, “These recent introductions to the STEVI range further extend the comprehensive range of specialist valves available from ARI-Armaturen and underpins our philosophy of providing a one-stop-shop for controls and pipeline equipment.”

For more information contact ARI Armaturen, Tewkesbury, Glos. Tel: 01684 wmb-630_Layout 1 21/03/2013 13:20 Page 1 or visit Web: www.ari-armaturen.com 275752 E-mail: inquiries@ari-armaturen.com

FLANGE PROTECTORS PREVENT HAZARDOUS PIPE CORROSION Protecting pipelines from the damaging effects of corrosion is an essential requirement for many offshore or onshore oil and gas installations, where if left unchecked can cause leakage, failure and in extreme cases, result in expensive shutdown. Kleerband Flange Protectors, recently introduced by ALLISON ENGINEERING are an innovative solution to the problem as they provide a quick and easy way to apply protection and prevent corrosion.

Kleerband Flange Protectors offer clear benefits compared to traditional corrosion protection devices such as shrink sleeves, tapes and wax fillers.

For example, they are simple to install with a wormgear connection, with no mess or special tools. They feature a positive loading relief valve vent and plug which ensures complete loading of flange cavities, whilst a transparent and flexible polyband allows for 360º uninterrupted inspection, without the need to remove the protector.

Kleerband protectors are designed to fit all DIN and ANSI flanges from 1/2” diameter up to 144” and are also available for non-standard sizes and Christmas-Tree applications off-shore. In addition to being used on oil and gas installations they are also ideal for protecting flange faces, studs, gaskets and ring joints on pipelines in chemical plants, refineries, oil fields, metering stations, water and waste water plants, pump stations and underground pipelines.

Further details are available from: Allison Engineering, Allison House, Cranes Farm Road, Basildon, Essex. Tel: 01268 526161 Fax: 01268 533144 E-mail: generalsales@allison.co.uk Web: www.allison.co.uk

Bredel pumps save water, chemical and maintenance costs • Average 71% water savings* lowers chemical costs • Glandless design, no costly valves, seals or liners to replace • Can easily handle SG 4.0 and 80% solids • Metering to ± 0.5% accuracy 50 years of innovation in pump technology

* vs centrifugal pumps

wmpg.co.uk/bredel 01326 370370 wm-630

Process Industry Informer September 2013

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FLUIDS & LIQUIDS HANDLING inc. pumps & valves

Grundfos MQ the compact pressure booster

SEAL-LESS BYPASS VALVES GIVE SMOOTH DEPENDABLE SYSTEM PROTECTION

The Grundfos MQ booster system is a fully integrated unit that delivers a complete water supply solution. These systems come complete with a pump, motor, diaphragm tank, non-return valve and pump control. With everything available as a single unit, this means the unit comes ready to install.

Once filled with water MQ units can guarantee lifting from a depth as low as 8 metres. The innovative water-cooled motors also mean silent operation and the integrated components deliver premium performance.

So whether the requirement is to pump water from a well or to increase mains pressure via a break tank or the mains depending on local water authority rules, with over 1 million MQ units in use around the world these solutions have already proved their value.

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

Wanner International has introduced a range of heavy duty, seal-less diaphragm bypass valves that are reported to provide accurate, repeatable smooth response without causing “chatter” in bypass lines.

The Hydra-Cell C62/C63/C64 Series offers accurate, repeatable, smooth operation with minimal pressure surge and “chatter-free” bypass. Available in a choice of 316 stainless steel, Hastelloy or brass body with PTFE or Viton ‘O’ rings and PTFE diaphragm these valves are ideal for use in systems pumping corrosive or dirty liquids. They can be used with any positive displacement pump with flows up to 151 lpm.

The Hydra-Cell Valve design is simple: a tapered plunger with an attached diaphragm. When excess pressure overcomes the adjustable spring pressure on the plunger, the plunger lifts off the valve seat, allowing fluid to bypass and reduce system pressure.

When a system discharge is completely closed – such as a closed spray gun, closed valve or plugged nozzle – the Hydra-Cell Valve bypasses the total system fluid flow. Thanks to their immediate response these valves also balance system pressure for multiple-gun operations.

Hydra-Cell Diaphragm Bypass Valves can be serviced in place, without removing any fittings or plumbing, simply by removing the top of the valve body and replacing any worn internal components.

For more information contact Wanner International, Fleet, Hants. Tel: 01252 816847 E-mail: NHerrington@wannerint.com Web: www.hydra-cell.eu

STAINLESS STEEL TUBES & PIPE FITTINGS

Extended range of stainless steel fittings provides more choice from one source Axium Process, specialist stainless steel fabricators, has further extended its range of stocked stainless steel tube and pipe fittings to support customer requirements in terms of material specification, consistent product quality, next day delivery and value for money across a wide range of industries including biotechnology, pharmaceutical, food, beverage, dairy, cosmetic,

chemical and textile The company’s comprehensive range of hygienic stainless steel clamp fittings now includes both forged and machined clamp ferrules and its heavy duty clamps are available in both 304 and 316 stainless steel in line with customer demand.

Stocked tube and pipe fittings include fully traceable ASME BPE, Clamp, RJT, DIN, IDF, SMS, BSP unions, bends, tees, Y pieces, concentric and eccentric reducers, hosetails, equal cross pieces, seals and 316L stainless steel hygienic tube to ASTM 270.

For customers requiring stainless steel fittings and component fabrication to site specific operating conditions and requirements, Axium Process can provide a fast track specialist stainless steel fabrication

service delivering engineering solutions and expertise based on a wealth of stainless steel experience. In-house processes include orbital, spot and manual welding, machining, fabrication, polishing, pickling and passivation as well as ferroxyl and dye penetrant testing, pressure testing to 110 Bar and certificated surface finishing to 0.2 Ra. For further information contact: Axium Process Ltd, Hendy, Swansea Tel: +44 (0) 1792 883 882 Fax: +44 (0) 1792 886 049 E-mail: info@ axiumprocess.com Web: www.axiumprocess.com

SPRAY NOZZLES COMPACT, EASY CLEAN SPRAY NOZZLE OFFERS OUTSTANDING LONG-LIFE A compact and easy-to-maintain air actuated fan nozzle which has an extremely high life cycle rating compared to other similar nozzles is the latest addition to the range offered by BETE Ltd. The Hydropulse is an innovative, low flow rate, flat fan, air actuated nozzle which has a huge life-time rating of 380 million cycles, compared to alternative nozzles which typically offer around 10 million cycles.

The Hydropulse is ideal for spraying applications which require a flat fan pattern with an intermittent spray. It is designed to recycle spray up to 3 times per second without dripping so is ideal for coating and other similar precision spraying applications in food and chemical processing, lubrication etc.

The internals of the nozzle can be removed in one simple operation and this, combined with its ability to be assembled without the need to uninstall the entire unit, facilitate easy cleaning and maintenance.

Further details on Hydropulse nozzles are available from: Ivan Zytynski, BETE Ltd, PO Box 2748, Lewes, East Sussex, BN8 4BA Tel: +44 (0) 1273 400 092 Fax: +44 (0) 1273 401 220 E-mail: Ivan@bete.co.uk Web:www.bete.co.uk

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Process Industry Informer September 2013

MATERIALS CRUSHING

From waste glass to cosmetics - the swing hammer can crush it all!

The Glen Creston Swing Hammer mill range is designed for light/medium duty crushing of a broad range of materials in batch, in-line and recycling applications. Available in cast iron/ carbon steel, with optional blower discharge, and in stainless steel, this versatile mill is a cost effective solution for process engineers.

Waste glass to cosmetic pigments, the SHM range will tackle many dry materials at rates from a few kilos to up to 1000 kg per hour, depending on material and screen aperture.

The mill features a 180º full width, dis-charge screen; easily interchangeable once the safety interlocked top half of the mill is hinged back to give unrestricted access to the crushing chamber.

This type of mill will successfully grind Chemicals, Resins, Grain, Clay, Seaweed (dried), Fruit (dried), Wheat, Barley/Oats, Domestic waste, and Glass, but could be applied in any similar situation.

For further information from Glen Creston please contact: E-mail: enquiries@glencreston.com Tel: +44 (0) 208 545 9140 Web: www.glencreston.com

Purity through innovation

Global sieving and filtration specialists

The Russell Finex Separator™ ...

• Improves product quality • Increases productivity • Reduces maintenance costs

What makes us specialists..?

Customized solutions - Applying innovation to meet your requirements Comprehensive customer service - Technical support & global stocking Specialized testing facilities - Trial your products for total peace of mind

Call us on +44 (0) 208 818 2000

filtration & separation LOMA SYSTEMS INTRODUCES ATEX21 SOLIDS IN A BAG - COMPLIANT METAL DETECTION – SIMPLE! The popular IQ3 metal detector head from Loma Systems is now available with Atex21 certification, providing in-processing metal detection in areas where a potentially explosive atmosphere exists.

Explosive hazards can be found in many areas of the food industry. Milling plants, bakeries, snack factories and powder processing units contain airborne dust from materials such as flour, cocoa, rice, and grains.

Following a painstaking development programme and a rigorous testing procedure, Loma Systems has been awarded Atex21 compliance, and is now available with the new detector head as a complete new system, or as a retrofit via the company’s network of OEM partners.

Atex21 compliance has been achieved using a combination of low temperature electronics and advanced sealing techniques. David Phillips, R&D Manager at Loma Systems commented: “We are determined to bring the highest levels of safety to the food industry, both in the products that leave the factory, and in the welfare of its employees.

This development has been driven by customers looking to increase efficiency whilst eliminating risk in the workplace, and the results reflect our absolute commitment to operator safety.”

“After a long and challenging process, we can now offer high levels of detection performance within a Zone 21 environment, ensuring product integrity across a wide range of food and pharmaceutical products”.

The IQ3 metal detector uses award-winning variable frequency technology, which allows the operator to autoselect the correct frequency, and an ‘Automatic Product Learn’ system. This enables it to calibrate and retain the characteristics and settings for up to 100 product lines.

Designed to survive, the detector head performs well in harsh operating environments where rigorous wash-down procedures are needed. It also features an on-board performance validation system which tests performance at pre-set intervals, helping to create a detailed audit trail for each production run. This enables responsible manufacturers to demonstrate the highest levels of product integrity to the most demanding retail customers. This new accreditation supports the company’s continued drive to build the toughest, most durable metal detectors on the market.

For more information contact Loma Systems, Farnborough, Hants. Tel: 01252 893300 Fax: 01252 513322 E-mail: enquiries@loma.com Web: www.loma.com

Process Industry Informer September 2013

The Sedi-filter de-watering system is a low cost, simple & highly effective passive dewatering and containment system that is also environmentally friendly.

Made from high-quality geotextiles, Sedifilter is designed to tackle the problems contractors face when excavating and storing wet slurry & sludges.

Sedi-filter removes up to 90% of water whilst retaining all dewatered solids neatly in the bag that can be left on site to biodegrade.

Manufactured in the UK to your preferred size, this versatile, efficient and easy-to-use dewatering system is used without excessive use of machinery.

Thanks to over 40 years of experience in the Filtration Industry our expert team produces high quality and reliable textile filters.

Consistent and Reliable Quality since 1970 Manufactured in the UK For more information contact DRM Industrial Fabrics Ltd. Tel: +44 161 763 1776 E-mail: info@sedi-filter.co.uk Web: www.sedi-filter.co.uk

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PREMIUM CONVEYOR LINES

piFLOW p - taking powder transport to the next dimension ®

Piab, a leading supplier of industrial vacuum technology, introduces piFLOW®p. It is the next generation of premium conveyor line from Piab. piFLOW®p meets the high demand from the food and pharmaceutical industries. With its proven design for robustness and clean ability, Piab conveyors are regarded as the leading option for vacuum conveying worldwide.

Features and Benefits • High performance COAX® patented technology • ASTM 316L – internal finish Ra<0.4 • Easy to install and use • Reduced energy consumption • ATEX Dust certified • Antistatic filter and seals available • Automatic filter cleaning • Fully compliant to FDA • CE marked • Designed according to USDA guidelines The conveyor is designed according to USDA guidelines Typical applications • Powder and granules transfer • Form-fill-seal • Big Bag loading and unloading • Drum/bag filling and emptying • Mill/Sieve/Mixer/Blender filling • Tablet/Fragile products transfer • Applications in explosive atmosphere • Hygienic applications • Compact applications For more information contact PIAB Limited, East Leake, Nottinghamshire.

Tel: 01509 857010 E-mail: info-uk@piab.com Web: www.piab.co.uk

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BULK BAG FILLERS

Spiroflow launches enhanced C1 bulk bag filler Spiroflow Ltd, world-leading manufacturer of conveying and weighing systems, has announced an upgrade to one of its most popular weigh fillers for pallet handled bags – the C1.

Ideal for low to medium volume use where bulk bags filled on pallets are moved by forklift truck, the new C1 facilitates dust-free, accurate filling of up to 20 bulk bags per hour. Its base is directly mounted on an approved load cell weigh platform and the required weight can be pre-set for automatic cut-off. The platform includes a vibration facility for an even, accurate fill and effective compaction – perfect for handling products that aerate and resulting in a stable load for both storage and transportation.

Boasting modular construction for ease of modification, the new C1 now features automatic height adjustment for different sized bags. Its inflatable neck seal ensures a dust-free environment and minimises product waste, and removing the filled bags has been made even speedier with the addition of a roller conveyor to complement the automatic bag loop release facility.

The new C1 has also retained many of the features which have helped to make it one of Spiroflow’s most popular products across multiple industry sectors, including a carbon/stainless steel filling nozzle and a dual concentric filling spout incorporating a venting system.

Rob Hudson, Managing Director at Spiroflow, explained: “Many millions of bulk bags, with a capacity from 500kg to 1500kg, are sold worldwide every year, making them one of the most convenient, cost-effective methods of packaging, storage and transport. Customers in industries ranging from food and pharmaceuticals to plastics and

building products use bulk bags, and hence require the best equipment to fill and discharge their often fragile or fineparticle products quickly and with the minimum of fuss.

“At Spiroflow our technical team is constantly innovating, developing new solutions and adaptations in our test centre to meet customer demand for the next improvement or upgrade. Our C Series of weigh fillers remain extremely popular as they’re both efficient and versatile, and we’re confident that the new C1 will prove an equally successful addition to our range.”

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

For more information contact Spiroflow Limited, Clitheroe, Lancashire.

Tel: +44 (0)1200 422525 Fax: +44 (0)1200 429165 or visit their website at www.spiroflow.com

GRINDING, CLASSIFYING & DRYING NEW 3 IN 1 DRYMEISTER-H FOR GRINDING, CLASSIFYING AND DRYING IN ONE COMPACT UNIT The new 3 in 1 Drymeister-H multiprocessing unit from Hosokawa Micron offers energy efficient and speedy grinding, classifying and drying operations in one compact unit.

The Drymeister-H combines intensive dispersion with high performance classification to deliver stable product quality, particle size and moisture content and is applicable for drying slurries, solutions, wet powder and pasty cake, giving speedy and reliable results.

Compared to traditional spray or rotary dryers, the Drymeister offers energy savings of 50-70%. A fluidised bed of product in the drying chamber in conjunction with a heated drying track ensures a low level of adhesion of undried product.

With options for ceramic faced wear parts and a specially designed screw feeder for cakey material the Drymeister-H has applications across a range of industries with typical uses in the processing of retardants, lithium cobaltite, minerals, foods, detergents, pesticides, surfactants and pigments.

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

Available on iPhone and Android devices Process Industry Informer September 2013

Keep up with ATEX and stop dust fires Most of us are aware that devastating explosions and fires can be caused by explosive gases and vapours but are perhaps not so aware that fires caused by dust can be equally as destructive. This has now been addressed by the recently defined ATEX zone 20 to 22 dust conditions. To avoid liability, companies are advised to use suppliers and repairers who correctly certify machines to comply with the new legislation, says ERIKS. The trend for many years now has been to tighten up Health & Safety in the workplace. Engineering companies have a responsibility to their employees, and engineers themselves have a responsibility for their own safety and those around them. Statistics at a recent H&S course illustrated the point that over 90% of all industrial accidents are attributed to complacency. At H&S courses, attendees are encouraged to think about what they would miss most if they lost their sight or the ability to walk, even temporarily, and suddenly the wearing of safety glasses

doesn’t seem such a chore.

Understanding and appreciating the risks to workers and establishing the most effective and efficient practices by which to minimise them can be a complex task but one that looks set to become more urgent than ever. A new Health and Safety Executive (HSE) cost recovery scheme for inspections and interventions is now in force under the Health and Safety (Fees) Regulations 2012. These Regulations put a duty on HSE to recover its costs for carrying out its regulatory functions from those found to be in material breach of health and safety law. A material breach is defined by the HSE as a contravention of health and safety law that is serious enough to require them to notify the person in material breach of that opinion in writing.

When it comes to machine safety, legislation is particularly thorough and far reaching. Since moving machinery is capable of causing fire in hazardous environments, designers and engineers have invested a lot of time and energy in trying to minimise the problem. The fact that so much is at stake as a consequence of failure has driven the development of a range of tools and practices to defend the workforce from such hazards and their consequences, and routine maintenance procedures have enabled engineers to minimise the development of faults. Indeed, components themselves are continually being refined and upgraded to prevent, or offer greater resistance to, hazardous environments. To achieve a consistent and efficient management of plant safety, an awareness of ATEX-approved components is vital and, in many process and manufacturing applications, plays a major part in enabling operators and maintenance engineers to ensure that plant is observing all current legislation.

Compliance with ATEX has always been a challenging, step-by-step process. Even in traditional ATEX industries, such as petrochemical processing facilities, there have been some challenges that have proved particularly hard to surmount, such as providing sensors that can perform reliably in the presence of the high pressures found within applications such as wellhead automation, gas distribution and gas compressors. In these applications, safety is critical and component failure could result in a serious accident. These hazardous conditions present complications to engineers, not only in ensuring safety but also in carrying out installation and replacement of components, which can be extremely difficult. However, solutions have been developed and engineers in these applications are now well used to conformity. Now maintenance operatives in a much wider section of industry need to make sure that repairs and maintenance meet the latest ATEX dust regulations.

Newly defined regulations determine the need to select suppliers more carefully…

The recently defined ATEX zone 20 to 22 dust conditions present a new challenge and companies are advised to use suppliers and repairers who correctly certify machines, if they are to avoid liability. Most of us are aware that devastating explosions and fires can be caused by explosive gases and vapours but are perhaps not so aware that fires caused by dust can be equally as destructive, and this is reflected by the new legislation. The regulations have

Process Industry Informer September 2013

been influenced by the fact that there have been several large explosions investigated in recent years, in areas such as crop storage, food processing, coal processing and plastics that have been attributed to dust, either atmospheric or settled. So, with both these dust conditions covered by the regulations, and with the dangerous substances and explosive atmospheres regulations (DSEAR) 2002 also requiring employers to control the risks from fire and explosions, it is time for engineers to be sure that they understand what constitutes a risk to safety and consider carefully how to address it.

Key to achieving conformity is to consult a leading supplier with expertise in a wide range of parts and components such as motors, belt drives and couplings – all of which are included in the regulations. Any party with responsibility for certification of supplied equipment, including product manufacturers, can be held legally responsible for accidents due to non-conformity with the new directives. The newly defined zones will affect many new operations, so if you are in any doubt about your responsibilities, conformity or the best way to achieve it, you should talk to a supplier who understands your industry, the legislation, and the machinery to which it applies.

ATEX compliance – indeed, plant safety at large – has thankfully become an established part of the business processes for most industrial and manufacturing companies. It has moved beyond a simple assessment of risk to comply with and exceed the requirements of legislation and the welcome growth of this more responsible culture will make it easier for most firms to adjust. Indeed, the more enlightened companies are already recognising that by getting in line with legislation as early as possible, they can both comply with legislation and improve their productivity and profitability, while also presenting an impressive set of credentials to their customers.

Don’t take chances…

Understanding and appreciating the risks to workers and establishing the most effective and efficient practices by which to minimise them can be a complex task. So, it may be advisable to work with a partner such as ERIKS that can help you to cost-effectively and efficiently review and renew your plant to comply with the regulations. Take, for example, the requirements for motors that operate in hazardous areas.

The ATEX labelling scheme provides a vital indication of the level of protection offered and the zones in which the motor is suitable for use but the judgement as to whether a repaired motor remains ATEX-compliant is more complex and may require help from a specialist.

To maintain safety, operators must be sure that a repaired motor is as safe as a new one, so it is important to enlist the help of a partner that offers an accredited repair service.

The recently defined ATEX zone 20 to 22 dust conditions present a new challenge but also an opportunity to maximise safety and minimise plant shutdown, which will benefit people as well as profitability.

ERIKS UK, Halesowen, West Midlands Can be contacted on: Tel: 0121 508 6000 Fax: 0121 508 6255 E-mail: marketing@eriks.co.uk Web: www.eriks.co.uk

39

instrumentation

ELECTRONIC RELATIVE HUMIDITY (RH) INDICATOR Brownell has introduced an Electronic Relative Humidity Indicator as an alternative to paper and chemical colour based indicators.

The new Electronic Humidity uses a polymer humidity sensor combined with a thermocouple to provide a digital display reading of relative humidity, ambient temperature and dewpoint. The operating range of the electronic relative humidity indicator is 5 to 80%RH, -20oC to +15oC dewpoint and -20oC to 60oC temperature.

The electronic RH indicator removes the uncertainty associated

with temperature by converting the readings to dewpoint.

Dewpoint is an absolute measure and is not influenced by temperature.

Dewpoint indicates the temperature to which the system or instrument can be cooled before condensation (or frost) will occur.

This qualifies dewpoint as a quality control standard for specify an operating performance for systems and instruments.

The Electronic Indicator is mounted in a robust IP67 enclosure with a membrane press switch to activate the three readings in sequence.

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

The operational battery life is typically 10 years.

For more information contact Brownell Limited, Park Royal, London Tel: 020 8965 9281 Fax: 020 8965 3239 E-mail: marketing@brownell.co.uk Web: www.brownell.co.uk

control & power distribution Are you prepared for

iec61439?

Rittal offer a total solution that meets the new standards that will impact all control and power distribution panels from November 2014.

To satisfy the requirements of their customers Rittal have invested considerable resources to ensure they can offer a total solution to the panel builder and OEM. Rittal also offer customers a software package that will reduce engineering time and confirm panels produced will meet the IEC61439 standard.

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

For further details please contact Rittal Ltd, Rotherham, South Yorks.

Tel: 01709 704000 E-mail: information@rittal.co.uk Web: www.rittal.co.uk

Innovation – Experience – Excellence

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

40

Process Industry Informer September 2013

MULTI PIN CONNECTORS

enclosures

New crimped RITTAL TOPTHERM INVERTER contact design CHILLER – IMPROVED launched for PRECISION AND EFFICIENCY Marechal’s multipin connectors MARECHAL has further enhanced its range of multi-pin connectors by offering the user a new design of crimped contact. Quick and easy to use, these connectors are designed for the transmission of power, signal and data in one connector thus providing greater operational flexibility whilst reducing the bench time required to make them off.

Comprehensive multipin range The new crimped contact design is available with up to 37 contacts in both the IP66/67 DSN and DXN ATEX types as well as the industrial IP54 DS versions. The more compact industrial PN12C and ATEX PXN12C versions offer 12 contacts. They are all rated to 10A at a maximum of 415V (PN12C, 500V). Each socket and plug is supplied with the requisite number of contacts in multiples of 13. Socket and plug contacts can be removed from the housing using the tool supplied, crimped and then re-inserted into the socket/plug using the same tool.

Patented safety technology MARECHAL’s DECONTACTOR™ offers a patented design including the plug release latch on the socket.

When pressed the plug is ejected from the socket to a parked position, off load and providing visible isolation of the equipment in use. Contacts are silver-nickel tipped and spring loaded for better electrical performance.

Whilst being crimpable the new contact design can also be soldered if preferred. The DECONTACTOR™ offers MARECHAL’s on load make and break capability for additional user safety.

Reducing maintenance costs Replacing hard-wired connections in junction boxes with a quick release DECONTACTOR™ reduces plant downtime or conversely, speeds up maintenance time by being able to isolate equipment in seconds. Whether washing down, re-arranging machine locations or making repairs, downtime is substantially reduced without compromising user safety.

Long-term reliability Contacts are housed in a choice of robust casings – polyester or metal - with suitable accessories available for each type. Both casings resist corrosion and vibration whilst offering over 2000 mating cycles.

Shock resistance is IK08 for poly and IK09 for metal housings with both rated to IP66/67 for water and dust ingress. The ingress seal is achieved automatically as the plug is inserted into the socket or socket lid closed.

The all-round quality of the DECONTACTOR™ multipin range is the reason it is installed in so many diverse industries including food & beverage, shipping, chemical, waste water and oil & gas. For durable, space-saving and simply assembled multipin connectors take a closer look at the MARECHAL range.

For more information contact MARECHAL ELECTRIC Tel: 01244 851926 E-mail: contact@marechal.com Web: www.marechal.com/en

With the focus on flexibility, operation an security Rittal’s complete range of Top Therm chillers now has a reduced depth of 605mm, increasing the number of enclosures to which it may be bayed.

The condenser fan, relocated to the roof of the unit, provides an optimised thermodynamic performance and an incorporated condenser protection grill minimisies the risk of damage during transit and installation.

The temperature of the chilled water supplied for enclosure cooling is not as critical as that used in process cooling. Spindle cooling demands the cooling medium is supplied within a tolerance of ± 0.5 K, to guarantee the necessary accuracy in processing, otherwise the thermal expansion of the components will cause inaccuracies in the machined workpiece.

Chillers are generally governed by a two-point control system, i.e. turning the compressor on and off as the temperature of the cooling water either rises above or falls below the maximum and minimum permissible limits. However, it is not possible to control within the small hysteresis required for machine cooling using this method as the frequent switching would adversely affect component life.

Rittal’s new TopTherm Inverter Chiller incorporates a variable speed compressor powered by a brushless DC motor, the speed of which is controlled by an inverter, to deliver the cooling medium at a temperature with the required accuracy.

This technology, in conjunction with other optimised components in the refrigerant circuit, an electronically controlled expansion valve and energy efficient electronically commutated (EC) fans, has culminated in a range of chillers with a capacity range of 2-19.5 kW, a chilled water temperature tolerance as low as ± 0.2 K and an impressively high energy efficiency ratio (EER) of up to 3.3.

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

RiPOWER FORM 4 DISTRIBUTION SYSTEMS Rittal Ri4Power Form 4 distribution systems achieve internal compartmentalisation by utilising metal shielding that segregates the busbar systems, functional units and terminals.

To increase flexibility several new wiring systems are available as an option.

The new wiring systems facilitate vertical and horizontal cable routing whilst ensuring internal Form 2-4.

Vertical cable routing and pre-punched cut-outs are provided in the mounting brackets for compartment dividers, which can easily be knocked out and used to install a vertical wiring channel.

Horizontal cable routing occurs behind the front trim panels. This entails fitting a wiring trim panel suitable to accommodate a wiring channel which, at the same time, conceals the busbar system.

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

SET POINT GENERATORS

IS loop powered 4/20mA set point station reduces cost BEKA associates have introduced a new intrinsically safe panel mounting loop-powered 4/20mA Set Point Station [set point generator], which is ATEX and IECEx certified for use in all gas and dust hazardous areas.

Enabling manual set point adjustment from within a hazardous process area, it incorporates a bold five digit display which may be calibrated to show the engineering variable represented by the 4/20mA current, plus a thirty one segment bargraph showing the output current.

The new BA427E generator which is backwards compatible with the earlier BA405C, has additional features including five pre-set outputs, an extended temperature range, an easy to change scale card and a lower list price than its predecessor.

For general purpose applications, the new BA627E offers the same additional features.

Both models have a 96 x 48mm DIN enclosure with an IP66 front panel and are available with a factory fitted green backlight which may be loop or separately powered.

For further information including datasheets, certificates and instruction manuals please visit http://www.beka.co.uk/setpoint or phone the BEKA sales office on 01462 438301

Process Industry Informer September 2013

41

air powered equipment

SHIPYARD HANDLING SOLUTIONS FROM J D NEUHAUS With nearly 270 years of hoisting technology experience, the J D Neuhaus company have pioneered many substantial innovations in the field of air powered handling equipment and are now acknowledged as global market leaders utilising this technology.

Their impressive range of hoists, covering lift capacities from 250kg up to a full 100 tonnes, are used worldwide within many heavyindustry applications including shipbuilding and offshore, covering newbuild, refits and repair as well as dismantling. Typical shipyard external applications include the installation and disassembly of rudder blades, shafts and propellers, while internal work includes

heavy components for the engine room drive equipment as well as drive shafts and other general fitting out or installation work.

Compared with electrically operated hoists, the JDN air powered equipment offers a wider range of operations that can be safely undertaken in outdoor damp, dirty or even hazardous area locations as well as indoor operation in dusty or potentially explosive atmospheres. Typical performance advantages include easy installation with robust, low-maintenance compact designs combining reduced weights and easy handling with 100% duty rating toughness.

Operating air pressures range from 4 to 6

bar with lube-free performance ensuring non-pollution of the environment as exhaust air is oil-free. A range of optional pendant controllers are available to provide sensitive, infinitely variable speed controls for the safe and precise positioning of suspended loads.

General insensitivity to dust, humidity and temperatures ranging from -20°C to +70°C helps to ensure an unlimited duty-cycle performance capacity.

For more information contact J D Neuhaus, Dyce, Aberdeen, AB21 0BF Tel: 01224 722751 Fax: 01224 729895 E-mail: info@jdneuhaus.co.uk Web: www.jdngroup.com

range of transmitters

BUDENBERG LAUNCHES TRANSMITTER RANGE INTO THE UK/EUROPEAN MARKET Budenberg is pleased to announce the launch of their new transmitter range into the UK and European market.

The transmitter range includes Pressure, Absolute Pressure, Vacuum, Differential Pressure, Temperature and Level and it forms a natural progression for Budenberg as they continue to expand into new markets with product development at the forefront.

Calling for your Nominations The BPMA is delighted to announce that the call for nominations for the 2014 Pump Industry Awards is now open! The awards programme recognises individuals and companies who make exceptional contributions to the Pump Industry so if you or your company, or another that you know of or work with, is worthy of recognition for a ‘job well done’ why not put forward an entry?

Sponsored by some of the leading brands in the pumps sector and with ITV & BBC Radio Five Live Presenter Helen Fospero hosting and entertainment by ex England Rugby Player Martin Bayfield, this year's ceremony is set to be a very special night.

Budenberg transmitters have unique features to provide the edge when installing instruments to meet the needs of the process control in the 21st Century.

These include: • Stand-alone monitoring and/or closed loop control applications • Two wire loop powered 4 – 20mA current outputs with HART communications as standard (Foundation Fieldbus optional) for seamless integration with a host DCS, PLC, SCADA, AMS PDM and/or hand held communicator.

• High accuracy and excellent stability (as you would expect from a Budenberg product) • Automatic temperature compensation integrated into advanced signal processing for stability during changes in ambient temperature • High reference accuracy: 0.075% of calibrated span.

• Advanced self-diagnostic functions • Localised operation – eliminates the need for a hand-held communicator In addition to transmitters, Budenberg is able to supply a complete range of instrument valves and manifolds as well as standard pressure and temperature instrumentation to offer package pricing, reducing overall costs.

Budenberg Gauge Company started manufacturing pressure and temperature gauges in the UK from 1850 with their first factory in Whitworth Street Manchester before moving to Woodfield Road, Altrincham. They now operate from Gilchrist Road, Irlam, Manchester where the tradition for quality and reliability has been maintained.

For more information contact Budenberg Gauge Company Ltd, Irlam, Manchester Tel: 0161 777 7300 E-mail: sales@budenberg.co.uk Web: www.budenberg.co.uk

SUBMIT YOUR ENTRY

www.pumpindustryawards.com hannah@touchwavemedia.co.uk

42

Available on iPhone and Android devices Process Industry Informer September 2013

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To advertise here or within our editorial pages or on our website please call Peter or Guy on 01428 751188

Speed

You’re invited to the

Process Automation World Tour Driven by progress What challenges do you face on a daily basis?

• How do you maximize your productivity through greater plant transparency?

• How to manage the risks associated with aging process plants?

• How to protect your investment throughout the life of your asset ?

Siemens is a key partner to the process industries and this has given us a unique insight into overcoming these challenges.

At the Process Automation World Tour, we will demonstrate how we can impact on the three key issues in the Process Industry: Productivity, Migration and Lifecycle Cost.

Productivity Smooth plant operation is the fundamental requirement for increasing productivity. Discover how the use of technology has optimised production processes.

Migration Hear from our team of experts how to manage the risks of migration.

Through practical case studies we will demonstrate strategies undertaken to ensure minimal to your business.

Lifecycle Learn how adopting the lifecycle management approach can support whole lifecycle costs of your process automation platform.

In addition our Microfair will showcase the latest trends in technology, including Alarm Management and Human Factors, Process Safety, Industrial IT Security and Diagnostics. Siemens experts will be on hand to share their knowledge and discuss your requirements.

Places are limited so don’t delay and register today!

For more information and to register online please click on the link below:

www.siemens.co.uk/automation-events Alternatively you can call 08457 70 50 70 to register your place.

15th October Museum of Science and Industry, Manchester 17th October Marcliffe at Pitfodels Hotel, Aberdeen 29th October RBS Williams F1 Conference Centre, Oxford 31st October Handpicked Crathorne Hall Hotel, Yarm We look forward to welcoming you to one of our events.

Yours sincerely

Steve Leech Product Manager - Process Automation

w w w. s i e m e n s . c o . u k / a u t o m a t i o n - e v e n t s