Process Industry Informer July 2014

5/20/2018 Process Industry Informer July 2014

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PROCESSINDUSTRY INFORMER.THE UKS LEADING PUBLICATION SERVING THE PROCESS INDUSTRIES

JUN/JUL 2014

Volume 10 No. 4

In this issue... 12 Generic Editorial Articles

News & Events

Case Studies

Product Introductions

Solids Handling & ProcessingSupplement/SHAPA News

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

Subjects cover - controlling heat transfer costs to

multi-touch systems, plant efficiency & safety, smart

solutions for integrated industry & continuous integrity

monitoring. In the supplement - check your flow properties,

why dust is an issue, weigh the benefits of scale systems,valves for solids processing and efficiency for conveyors.

Find out about them on the back cover


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The Emerson logo is a trademark and a service mark of EmersonElectric Co. The ASCO logo is a registered trademark of ASCOValve Inc. 2014 ASCO. All rights reserved.


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CONTENTSMulti-touch Technology:

Intuitive Functionality

Advances Automation 10/11

Keep heat transfer costs

under control 12

Smart solutions for

integrated industry 16/17

Optimising Plant Efficiency 20/21

Continuous integrity monitoring 22

Reliability: The Safe Option 24

SHAPA NEWS- SOLIDSHANDLING &PROCESSINGSUPPLEMENTStarts on page 31 (1 SP)

SHAPA Update 1 SP

Know your flow properties 4 SP

Dust why its an issue and what the

processing industries should be doing

about it 6 SP

Weighing up the benefits of an

electronic scale system 10 SP

Spherical Disc Valves For Solids

Processing Applications 12 SP 13 SP

Enhancing efficiency

in conveyors 18 SP

EDITORIALFEATURES

News & Events

4-5

Applications

6-9

Overlay Welding Alternative

13

Heat Transfer & Energy

13

Industrial Amplifiers

14

Temperature Humidity Chambers

14

Analysers15

Instrumentation

18

Health & Safety

19

Dust Prevention for Interlocks

19

Fluids & Liquids Handling

inc. Pumps & Valves23-28

Infrared Thermometers

14-15

Compressors & Compressed Air

30

SHAPA News - Solids Handling &Processing Supplement31-51 (1 SP-17 SP)

Maintenance

29

Wastewater Systems

30


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4 PROCESS INDUSTRY INFORMERJune-July 2014

Sponsored by

At their Users Conference held in Berlin over 3 5th July Yokogawa Electric

Corporation announced the signing of an agreement with Norway based GasSecure

AS on the distribution of GasSecures ISA100 Wireless* based gas detectors

through Yokogawas global sales network. With this agreement, Yokogawa gains

access to GasSecures wireless gas detectors and thereby strengthens its lineup

of plant field wireless solutions and enhances its support of health, safety,

security, and environment (HSSE) management applications. This agreement

will also allow GasSecure to gain access to Yokogawas global sales and service

network and thereby boost the sales of its wireless gas detectors.

OverviewWith a field wireless system, the field devices at a plant are able to communicate

wirelessly with host systems that perform functions such as monitoring and control.

Wireless communications offer many advantages, including the ability to install field

devices in difficult-to-wire locations and reduced cabling costs.

Yokogawa has been developing a wide variety of ISA100 Wireless compliant

technologies and devices such as wireless adapters that allow conventional wired

devices to access wireless networks. GasSecure specializes in the development,

manufacture, and sale of low power, high reliability wireless gas detectors that are

used to monitor for hydrocarbon leaks at offshore platforms, tank farms, industrial

plants, and the like. GasSecures clients include major oil companies and their

products are in wide use around the globe.

Under this agreement, Yokogawa will distribute GasSecures ISA100 Wireless

gas detectors through its global sales and service network. The growing need to

improve plant safety by installing more gas detectors and replacing out of date

detection systems is driving the demand for wireless gas detectors, which have the

added advantage of eliminating the need for wiring and thus are easier to install

and cost less. As such, Yokogawa will be better able to satisfy its customers needs

by incorporating wireless gas detectors in its field wireless system solutions. At the

same time, GasSecure will be able to utilize Yokogawas global sales and service

network to expand its wireless gas detector business.

Also, under the terms of a separate sales agreement that was reached in February

of this year, GasSecure will sell Yokogawas field wireless system devices together

with its own gas detection systems.

Features of GasSecures Wireless Gas DetectorsGasSecures wireless gas detectors detect leaks of hydrocarbon gas that can cause

explosions. Utilizing ultra-low power infrared sensors, they perform measurements

and send that information wirelessly to the host monitoring system. The key

features of these detectors are as follows:

1. High reliability

As gas leaks are a frequent cause of major plant accidents, it is very important to

have a highly reliable gas detection system that keeps plant personnel constantly

up to date on any changes in gas concentration levels. With a five-second responsetime, GasSecures wireless gas detectors are able to perform highly specific and

reliable infrared measurements of gas concentrations and wirelessly update a host

monitoring system. With their ISA100 Wireless mesh network capability and their

reliance on dual redundant communication paths between the detector and the

host monitoring system, they are at least the equivalent of

any wired alternative with respect to reliability.

2. High availability

With heated optical surfaces for removing condensation,

GasSecures wireless gas detectors are suitable for

use in highly humid environments and have excellent

availability under a wide range of conditions, from

tropical to arctic. The GasSecure detectors also utilize

a stable triple wavelength infrared technology that

eliminates the need for calibration for the entire

lifetime of the product, something that is not

possible with conventional instruments.

3. Low power consumption

The power consumed by these gas detectors averages just

5 mW thanks to the use of micro-electro-mechanical system (MEMS) technology.

Compared to other battery-powered gas detectors, GasSecures products have a

much longer battery life, and are also more reliable.

Major Target Markets - The oil & gas,

petrochemical, and chemical industriesCommenting on this agreement,

Masatoshi Nakahara, director and

senior vice president of Yokogawas

Industrial Automation Platform

Business Headquarters, said, We

selected GasSecure, a leading supplier

of gas detectors, and believe that their

best-in-class ISA100 Wireless solution

will allow us to broaden the use of our

field wireless systems.

GasSecures CEO, Knut Sandven, also

commented, GasSecure selected

Yokogawa for their reliable and high-

quality wireless infrastructure. We are

very excited about entering into this

agreement as it will give us access to

Yokogawas extensive global sales and

service network.

* ISA100 Wireless, or ISA100.11a,

is an industrial wireless networking

technology standard developed by the International Society of Automation

(ISA). ISA100 Wireless features high reliability, diverse applications, network

extendibility, and high compatibility with wired communications standards

such as FOUNDATION fieldbus, HART, and PROFIBUS. This standard is

currently being discussed as IEC62734 by the International Electrotechnical

Commission (IEC).

The names of the companies, organizations, and brands in this text are the

trademarks or registered trademarks of the respective companies and organizations.

For more information contact GasSecures website: www.gassecure.com

For further information please contact: European Industrial

Automation,Yokogawa Europe BV, Amersfoort, The Netherlands

Tel: +31 88 464 1191 Fax: +31 88 464 1107

E-mail: [email protected] Web: www.yokogawa.com

Yokogawa Reaches Agreement with GasSecure on

Distribution of GasSecures Wireless Gas Detectors

through Yokogawas Global Sales Network-A wider field wireless product lineup for improved safety management-

Shaking hands on the Yokogawa/GasSecure

agreement are (left) Masatoshi Nakahara,

director and senior vice president of

Yokogawas Industrial Automation Platform

Business Headquarters, and (right) Knut

Sandven, CEO of GasSecure


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5PROCESS INDUSTRY INFORMERJune-July 2014

TEL: 01903 730900 [email protected]

www.pumpeng.co.uk

Pick the perfect pump from Pump Engineering

CSF centrifugal pumps are quick-strip, easy-clean

and reliableperfect for food, brewing, pharmaceutical

and other sensitive applications.

Can handle capacities from 1 to 550 m3/hour at headsup to 155 metres

AISI 316L stainless steel for all wetted parts

Quick strip, easy-to-clean and designed for CIP(clean-in-place)

AB13-613

Sponsored by

RECOVINYLCONTINUES TOINCREASE PVCRECYCLINGACROSS EUROPEPVC recycling continues to grow across Europe, with the UK

contributing more than 20% - or 88,648 tonnes to the

total recycled through Recovinyl, the PVC industrys recycling

scheme, in 2013. A total of 435,083 tonnes of waste PVC was

recycled through Recovinyl last year across its 16 European

member countries. To date, the Recovinyl recycling network

comprises 141 companies.

Recovinyl is the operational arm of VinylPlus, the ten-year

Voluntary Commitment of the European PVC industry, which

is tackling the sustainability challenges for PVC and delivery of

current recycling targets to 2020.

Waste PVC-U profiles comprised 50,421 tonnes of the UKs recycling effort in 2013, with pipes, rigid

and flexible PVC films and cables making up the rest.

This profile fraction is equivalent to the replacement of 3 million individual frames, or more than

300,000 homes based on an average of ten windows per house. The assumption is based on the

weight of an average PVC-U window frame.

These latest figures show that PVC recycling is maintaining its upward trend, with demandcontinuing to grow for good quality recycled material that can be reused in a variety of new products,

from windows to flooring and advertising banners, comments Project Manager Jane Gardner of

Axion Consulting, Recovinyls UK agents.

Once again, the UK has made a significant contribution to the success of PVC recycling, thanks

to ongoing commitment from the sector and sustained investment in recycling infrastructure across

the country, continues Jane

For further information, contact Axion Consulting, Bramhall, SK7 2DG Tel: 0161 426 7731

E-mail: [email protected] or visit: www.axionconsulting.co.uk and www.recovinyl.com.

WWEM 2014Conference Programme

announced

The organisers of WWEM 2014,

the international Water, Wastewater

and Environmental Monitoring

conference and exhibition, have

announced the details of the

Conferences that will take place

at the Telford International Centre

in the UK, 5-6th November. The

first days Conference will focus on

the monitoring aspects of industrial

and municipal monitoring, whereas the second day will address some

of the key issues relating to sampling and laboratory analysis.

WWEM 2014 (www.wwem.uk.com), the 6th in a series of highly

successful environmental monitoring events, will provide delegates

with the latest information on the techniques, technologies, methods,

standards and regulatory requirements that relate to the monitoringwhich takes place both on-site and in the laboratory, covering sampling,

field analysis, gas detection and continuous water and wastewater

monitoring applications.

The first day of the Conference will include presentations by

senior individuals from the Environment Agency, CSA-Sira, WRc and

Siris Environmental, addressing key environmental monitoring issues

such as Operator Monitoring Assessment (OMA), CEN standards for

water quality and flow monitoring equipment, MCERTS, independent

instrument approval, and examples will be given of the good, the bad

and the ugly of flow monitoring.

Addressing a laboratory analysis theme, Day 2 of the Conference

has been organised by British Measurement and Testing Association.

The speakers represent the national accreditation body, UKAS, large

water companies and commercial laboratory-based organisations,

presentations addressing issues such as proficiency testing, the UKAS

document TPS 47, the lowering of detection limits, good sampling

protocols, mobile data capture and Laboratory Information ManagementSystems (LIMS). Intriguingly, Professor Clive Thompson from ALcontrol

will deliver a presentation entitled:Sampling and analysis in relation

to Priority Substances Directive 2012/39/EU for which he says he will

provide a devils advocate response.

In addition to the main Conferences, delegates will also be provided

with access to over 80 Workshops, a Flow Demonstration area, Forums

on Flow and SMART Water, and an exhibition featuring over 130 stands

representing more than 250 of the worlds leading providers of test and

monitoring equipment and related services.

CPD points will be awarded to Conference delegates and the cost to

attend will be 55 per day. However, registration for the event is free of

charge and pre-registered visitors are provided with free access to the

exhibition and to the workshops, in addition to free on-site parking, and

complimentary lunch and refreshments.

For more information please visit www.wwem.uk.com

Exhibition Opening Hours

9.30am 5.00pm Wednesday 5th November 2014

9.30am 4.30pm Thursday 6th November 2014


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MEASURINGSUCCESS FOR

HOSOKAWAMICRON LTD

& XOPTIX LTDHaving recently reached a milestone of over 100

operational in-process measuring units, manufacturer

Xoptix Ltd is celebrating the difference that in-process

monitoring technology is now making outside the

laboratory and in everyday operations. Differences

that deliver material quality consistency, energy

efficiency, reduced waste and higher profitability.

With a range of applications typically in the production

of calcium carbonate, powder coatings and

petrochemical catalysts, these in-process measuring

units are being used extensively by powder processing

experts Hosokawa Micron Ltd, in partnership withXoptix Ltd. Unusual power processing applications also

include toner and fire retardant manufacturing, and

this technology can even be used in the production

of gold.

Utilising laser diffraction technology, the Xoptix

in-process measuring units offer a cost effective

measuring option that is robust enough for use in

even the most arduous powder processing fields.

This means they are ideal for many of our customers

seeking real time sampling and measurement of

materials in production. Presenting fast, reliable and

easy to understand particle size distribution data

that is automatically fed to the plant control system,

these flexible units are a key part of delivering

optimised processes for a number of our customers,

explains Iain Crosley, MD, Hosokawa Micron Ltdwho

applauded Xoptix Ltds 100+ achievement.

Stuart Barton, MD, Xoptix says, Customers receive

a superior product for less money, compared to

older established in-process measuring technologies.

And with the automated cell clean function there is

no need to strip the unit down to clean it can just

keep running 24/7 with no deterioration in readings,

efficiency, operational capability which is essential

in many of the critical processes with which we and

Hosokawa Micron are involved. Our initial design

objectives were to build an in process particle size

measurement unit with usability, flexibility, reliability

and functionality, and customers agree that the system

delivers on all points.

For more information about Xoptix particle sizer

technology and Hosokawa Micron, contact Xoptix

Ltd, Malvern. Worcs

Tel: +44 1684 899345

E-mail: [email protected] Web: www.Xoptix.co.uk

Riley helpsCanadianmanufacturer with

its expansion intoproduct finishing

Riley Surface World has recently enabled the sale

and shipment of a complete Delta Industrietechnik

copper/acid electroplating line for Billdidit, a

specialist manufacturing organisation based in Nova

Scotia, Canada.

The redundant Delta electroplating line was acquired,

with the help of Rileys, from the site of a former costume

jewellery manufacturer in Ireland. It will be used for

chrome and zinc plating by volume and for silver and gold

plating in smaller quantities.

The system comprises three sizes of tanks: 600, 1200

and 2400 litres.The 600 litre tanks are predominantly

used for the non-electrolytic processes, dragout and rinsestations. The larger tanks are used for the electrolytic

stations, with either 3 or

6 flight bars in operation

at any one time.

A technical support

team from Riley Surface

World is set to install and

re-commission the plant

at the companys Nova

Scotia headquarters dur-

ing summer 2014.

Commenting on the

project, John Aylward,

Billdidit Vice President

of Operations said:

Whilst price was obv-

iously an importantfactor in the purchase

of the electroplating

plant, we also made our

decision based on the

professionalism, technical expertise and flexibility that we

experienced from Michael Riley and his support team.

Not only have we made a very worthwhile investment in

plant and machinery, we also believe we have found a

partner who will help us to realise our expansion plans

in the metal finishing sector, both in North America

and worldwide.

For further information, visit: httpwww.billdidit.ca

www.sabian.com

For more information contact Riley Surface World,

Aldridge, West Midlands Tel: +44 (0) 1922 45 8000

Fax: +44 (0) 1922 45 8001E-mail: [email protected]

Web: www.rileysurfaceoworld.co.uk

Water Treatment PlantReplaces DiaphragmMetering Pump withPeristaltic Pump

The ChallengeA water treatment plant in the US state of Georgia uses

several wells to provide its residents and industries with

fresh water. Each well site had to be equipped with theappropriate treatment equipment to ensure that the

water meets and exceeds regulatory requirements.

One such well site used a diaphragm-style reciprocating

metering pump to pump lime slurry directly into the

well output. The well runs about 12 hours per day and

discharges either to the system or to the tower for storage.

Lime slurry demand is up to 11.4 litres per minute (3

gallons per minute) and must be pumped at pressures

exceeding 4 bar (60 psi).

Traditional diaphragm-style metering pumps use check

valves which wear out and cause eff iciency loss. Because

this well site is unmanned, water plant supervisor Mr.

Gibson or his associates had to make daily trips to the

site in order to check the pumps efficiency. This took

up a lot of time and was becoming a major headache for

the department.

SolutionVerders local representative, GPM Environmental,

introduced the plant to the Verderflex Dura, a peristaltic

metering pump that does not suffer from abrasive

wear and does not lose efficiency over time. Mr Gibson

purchased one unit and was immediately pleased with

how smoothly and quietly the unit ran compared to the old

diaphragm pump. After the initial two month installation

period, Mr Gibson quoted that: The old pump lost flow

and we had to constantly check on it. The new pump is

very consistent; we never have to adjust it.

For more information please contact Verderflex,

Verder Ltd, Castleford, West Yorkshire.

Tel: +44 (0) 1924 221020E-mail: [email protected] or visit verderflex.com

Available

oniPhone

andAndroid devices


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Spirax SarcoandDallol Energys

partnership helpIgnis Wickto heat

Scottish homes withrenewable energy

Spirax Sarco and Dallol Energy combined to

provide the boiler controls and steam system for an

innovative energy scheme that uses a wet biomass

boiler system to heat around 200 Scottish homes

via a district heating system and to deliver steam

to a neighbouring distillery.

The plant is owned and operated by Ignis Wick,

which took over the district heating scheme in Wick,

Caithness, in 2012. The company engaged biomass

steam specialist

Dallol Energy to

deliver a 3.5 MW

boiler and plantsteam distribution

system that would

use locally sourced

clean woodchips

as the fuel.

For this project

we needed a rep-

utable partner that

could help us design, commission and install a

whole new boiler house and steam distribution

system, says Victor Buchanan, Director at Dallol

Energy. We knew we could trust Spirax Sarcos

knowledge and proven technology and they were

happy to trust our biomass expertise.

Spirax Sarco provided all the steam distribution

equipment, including the heat exchanger skids and

the boiler house controls on the project, as wellas the boiler hot well and steam accumulator.The

boiler house is equipped with the latest supervisory

control and monitoring system and level controls, as

well as automated heat recovery blowdown systems

to minimise energy losses.

For more information on boiler house design

or steam distribution systems please email

[email protected] or visit

www.spiraxsarco.com/uk

EDF FENICE/AVTOVAZ: A NEWENERGY EFFICIENCY

CONTRACT FOR THECOMPETITIVENESSOF INDUSTRYEDF Fenice, expert in energy and environmental efficiency

solutions of the EDF Group, and AVTOVAZ, first Russian

car manufacturer, signed a series of agreements within

the framework of a global energy efficiency project

for the setting-

up of power factor

correctors on more

than 1200 electric

motors operating in

Togliatti site (Russia).

This initiative led to a

significant decreasein the energy losses

allowing AVTOVAZ to

save more than 15

GWh/year of active

energy through the resulting 7% decrease in the energy

con-sumptions of the electric motors.

Initiated in 2009, the global optimization plan of AVTOVAZ

energy consumption has been developed through a

series of targeted interventions dedicated to different

facilities of the site: compressed air production system,

lighting system and currently the reactive energy factor of

the internal distribution grid.

To date all these energy efficiency interventions led by

EDF Fenice allow the Russian car manufacturer to save

about 117GWh/year thus decreasing the production

costs, so as to develop its own competitiveness on

national and international markets and to reduce the CO2emissions by 40.000 tons.

The energy performance completed thanks to the EDF

Fenice-AVTOVAZ collaboration clearly shows it is possible

to combine profitability and sustainable development, in

the service of a modern, clean and efficient industry.

For more information contact EDF Fenice Corporate

Communication, Via Acqui 86, 10098 Rivoli (TO)

Italy. Tel: +39 011951 3852 Fax: +39 011951 3665

E-mail: [email protected]

Web: www.edf-fenice.com/en/

Micro-etchedcomponents forsurveillance UAV

An innovative miniature

surveillance helicopter is

benefitting from the high

precision manufacturing

capabilities of Precision

Micro, Europes leading

photo chemical etching

specialist.

The miniature unmanned

aerial vehicle (UAV), features an array of small, lightweight

and extremely precise components manufactured by the

UK based company, a division of global engineering

group, Meggitt PLC.

The UAV engine operates using miniature motor

laminations, etched to tight tolerances. The laminations

utilise Precision Micros R bond technique, which uses

the photo resist protecting the material surface during

chemical etching as the bonding agent.

This novel approach offers improved performance versus

conventional punched, riveted or welded laminations.

For the helicopter to effectively navigate obstacles

and identify hidden dangers and enemy positions, the

composition of the base metal must not be compromised

during manufacture.

Communication integrity to the ground elements

is maintained by the miniature shielding cans also

manufactured by Precision Micro, protecting the sensitive

electronics from EMI and RFI interference.

With low set-up costs, the customer was able to try

multiple components without incurring excessive charges

and have them in hand in a matter of days.

This innovative UAV has fast become a key component

in intelligence, surveillance and reconnaissance activities

and Precision Micro is proud to be playing a part in

its success.

For more information please contact Precision Micro

Ltd, Erdington, Birmingham, West Midlands.

Tel: +44 (0) 121 380 0100

Fax: +44 (0) 121 749 419 4157


Web: www.precisionmicro.co.uk

Spirax Sarcoshows

commitment toquality in 1.5mboiler house projectSpirax Sarco has completed the handover of a 1.5

million turnkey boiler house project as part of an

innovative 4.3 million waste-to-energy plant at Davyhulme in Manchester. Owned by

United Utilities, the plant uses sewage to supply gas for a combined heat and power

plant. It recycles the waste heat from electricity generation to produce steam in the

boiler house that can then be used in the process.

The scope of the contract included three boilers, two boiler feedtanks and a

comprehensive water treatment system. It also included all the associated controls

to enable the boiler house to run unmanned and maximise energy efficiency, such as

automatic TDS and bottom blowdown systems. The main design and build contractorfor the overall Davyhulme project was Black & Veatch.

In 2013, the Davyhulme plant won the Energy Award at the IChemE awards, with United

Utilities and Black & Veatch named as joint winners.

For more information visit www.spiraxsarco.com/uk

or e-mail [email protected]

SECOND SIPOS

INSTALLATIONAT KHOMS

POWER STATIONFollowing the successful installation of SIPOS 5 actuators as part of a modernisation

programme at unit 4 of the Khoms Power Station in Libya in 2007, the company has

received an order for an additional 284 valve control devices.

The latest contract has been placed by Babcock Power Systems for the supply of new

actuators at the Khoms plant to units one and two. SIPOS advanced actuators will

replace Siemens legacy products which were installed in the 1970s.As part of the

plant upgrade, Siemens will supply a new DCS control system.

GECOL, the owner of the station, is the state-owned power utility responsible for

generation, transmission and distribution of electric power throughout Libya.

On-site support and service will be provided by SIPOS local agent.SIPOS Aktorik the manufacturer and global supplier of specialist and standard

electric actuators.

For more information contact SIPOS Aktorik GmbH, Im Erlet 2, D-90518 Altdorf,

Germany Tel: +49 (0) 9187 / 9227- 0 Fax: +49 (0) 9187 / 9227-5111

E-mail: [email protected] Web: www.sipos.de


8/52


THE SPIRIT OFWASTEWATER

TREATMENTVeolia Water Technologies has been awarded a prestigious contract to providewastewater treatment plant to the Macallan Distillery in Craigellachie, Moray.

The Macallan single malt whisky is currently the worlds second highest selling

brand and owners, Edrington Group, are investing over 100m in a new

distillery to meet the growing demand.

Wastewaters/washwaters from the new distillery will be t reated on site to meet the

SEPA consent for discharge to the environmentally sensitive River Spey. Prior to

commencing on the design, Veolia carried out a wastewater characterisation

study and also helped the distillery to optimise operation of the existing

wastewater treatment plant. The experience gained by working closely with The

Macallan allowed Veolias engineers to design the new plant with a high degree

of confidence.

The Veolia treatment process is based on IdraflotTMdissolved air flotation (DAF)

unit followed by a BiosepTMmembrane bioreactor (MBR), and there is a long-

term goal to treat the BiosepTMMBR permeate by reverse osmosis for re-use in

the distillery as boiler make-up.

Ian Hart, Veolias Business Development Director, said We are delighted to

be working with The Macallan distillery on this project and helping to assure

the continued success of this great brand. The 2.5m contract is due for

completion in summer 2015.

For more information contact Veolia Water Technologies, Birmingham

E-mail: [email protected] Web: www.veoliawaterst.co.uk

Kliklok International:Keeping food on the tablewith Testothermal imaging

Keeping the food on our table by keeping the production line moving

Bristol based Kliklok International

supplies food packaging equipment to

household names around the world.

Their machines box, wrap or bag the

food we see in our kitchen cupboards,

fridges and freezers.

We take packaging for granted, but

there are serious consequences should

the machinery used go wrong. Wear in

moving parts is normal for any equipment

and not least in bearings, rotational parts

and chain rails of a food packaging line.

The demand in the food industry means

these machines are often working 24/7

and so the consequence of a component failure bringing the production line to a halt is

a headache that any line manager would rather not have.The ideal solution would be to predict likely component failure, so those parts could be

replaced during routine maintenance before it fails and seriously impacts production.

Additionally, complex equipment can hide worn machine parts and so a solution

to pin point the component would be beneficial. The answer came in the form of

thermal imaging.

Finding faultThermal imaging isnt new. Seeing how it fits in with your business, however, may not be

obvious. In 2009 Kliklok used a thermal imaging camera for the first time to identify a

worn component. Using a borrowed camera it became obvious where the fault was and

it underlined how effective thermography could be. All moving parts create heat, but a

worn component generates more. The component that had been troublesome to locate

was found almost immediately by its heat signature saving time and money.

It wasnt long before Kliklok started evaluating thermal imaging cameras on the market

as an indispensable tool for themselves. They needed something that could easily be

transported by an engineer, show images clearly and with an ability to send these back

electronically to headquarters if required.Advances in the technology and production have also brought the price point down to

a level that any company can easily afford the cost savings made using it means it is

also a piece of equipment these companies cannot afford to be without.

After a full evaluation of other thermal imaging cameras available, Kliklok chose the

testo 875-2. Roger Mason, Service & Installation Manager at Kliklok explains, The

testo 875-2 was able to demonstrate all the features that assist us in fault finding when

servicing our customers equipment and all at a price that was well within budget.

Its about having the right specification at the right price, something which the testo

875-2 offered over other suppliers. The camera has a good list of optional extras, but the

standard equipment includes digital camera, USB connection and SD memory cards

that permit the capture and transmission of images.

Incorporating an integrated digital camera, the testo 875-2 can take a true optical digital

image that can be compared to a captured thermal image, very useful if used remotely

to identify the part or area where a fault may be located.

So now Kliklok have a tool that can identify and overcome a mechanical problem before

a costly breakdown. The good news didnt stop there, as scanning electrical installations

clearly show unusually heavy loads, bad connections and arcing. Great news for the

food industry and great news for the Kliklok service department, as they can offer (and

honour) quality maintenance and service agreements.

Saving reputationPreventative maintenance on-site may be the key advantage to Kliklok in using thermal

imagery, but to reinforce its effectiveness it is used routinely to build a thermal image or

heat signature record for all new equipment being supplied.

On average 20 images are taken, but on larger or more complex machines Kliklok

can take up to 50 reference images of the various parts and components. This record

can also be supplied as part of the documentation shipped to the customer, with

Kliklok holding a master copy on file. This fingerprinting allows the flexibility of

either the customers own or a Kliklok engineer identifying a possible problem. The

heat signature reference library held by Kliklok or the customer can be used for a

comparison. If the customer has similar thermal imaging equipment they could capture

a thermal image and send this image electronically back to Kliklok for comparison,

in effect providing a remote diagnosis. With customers throughout the world, remote

diagnosis ensures parts can be supplied and be on hand locally when they are needed.The Testo 875-2 has proved to be an extremely cost effective piece of kit for Kliklok. An

affordable solution that protects Klikloks reputation in providing a quality product and

ensures their customers keep the production lines running.

For more information please contact Testo Limited, Alton, Hampshire Tel: 01420

544 433 E-mail: [email protected] or visit Web: www.testolimited.com/thermal

HRS HEAT EXCHANGERS

EXPANDS FURTHER INTOTHE SOUTH AMERICANFRUIT JUICE MARKET

A complete skid mounted fruit juice thermal processing system

HRS Heat Exchangers Limited, a leading heat transfer specialist for the process

industry, has recently supplied San Clemente Foods of Chile a packaged, skid

mounted fruit juice processing system.

San Clemente Foods originally came to HRS with an enquiry based on HRS MI

food grade corrugated tube heat exchangers, however after lengthy discussions

HRS collaborated with the customer and designed a complete and bespoke skid

mounted system.

The system supplied includedHeating, Holding

and Cooling sections all based on food grade MI

corrugated tube heat exchangers, the systemsupplied is self contained and also includes a hot

water loop, CIP tanks and pumps, Valves and a

control cabinet.

The HRS MI system was installed to sterilise

Apple and various fruit juices concentrate prior an

existing aseptic filler system. The new HRS system

has a flow rate of 4000 L/Hour and sterlises up to

temperatures of


9/52


GRUNDFOS S-TUBEREVOLUTIONISES

WASTEWATER

PUMPING STATIONThe wastewater industry traditionally had to choose

between selecting a pump that delivered energy

efficient performance or free passage. Today the

Grundfos S-tube with its unique impeller has alleviated that situation as with it there

are no dead zones and no cutting or moving parts that can get worn out over time.

Just such a scenario faced a water utility company in the south west at a WwPS where

they were suffering high operating costs and many disruptions. This situation had

resulted in call outs which needed to be followed up by vacuum tinkering and resulted

in 15 blockages over a 3 month period necessitating vacuum tanker cleaning events to

remove rags and clean the pump chamber.

Grundfos were asked to look at the pump station and selected the SL1.80.80 Atex

rated S-tube wet well submersible pump to improve the performance of the pump

station. This pump had a solids handling capacity of 80mm whilst maintaining an

efficiency of 63% therefore there was no compromise between pump efficiency and

solids handling capacity a key feature of the S-tube impeller.

The introduction of the Grundfos S-tube impeller pump brought about majorreduction in operating costs and disruption as blockages were reduced from 15 over

three months to zero; there was no further need to use the vacuum tanker to empty

and clean the chamber; reactive call outs were reduced from 31 to 8 over the period

of the trial.

This, now permanent, solution has also brought about operational savings of 5000+ in

the initial 3 month period of the trial. A true win/win situation.

For more information or Literature request please contact Grundfos Pumps Ltd,

Leighton Buzzard, Bedfordshire. Tel: 01525 850000

E-mail: [email protected] Web: www.grundfos.co.uk

Promet moisture analyzer

from Michell Instrumentsplays a key role in Germanyssustainable energy planA key energy company in Germany has

chosen Michell Instruments Promet I.S.

process moisture analyzer to monitor

moisture levels in bio-methane before it

is injected into the grid to ensure that it

meets the correct quality standards.

Biogas is saturated with moisture

immediately after production, as well as

having other undesirable components such as CO2. Before

it can be used as a fuel away from the production site, it needs

to be scrubbed of the contaminants and dried. When it is destined

to be upgraded to bio-methane and injected into the grid with natural gas, precise

measurements of moisture are vital as it will need to meet tight quality standards. For

transmission into the local distribution network in Germany, the bio-methane needs to

meet the moisture levels permitted by the DVGW G260 Code of Practice. For distribution

networks, this is 200mg/m3at less than 10barg pressure (267 ppmV).

The Promet I.S. was selected for this task because it has a proven track record

of monitoring moisture during the processing of natural gas, as well as for quality

checks of gas in the network and transmission pipeline. It has an accuracy of 1C

dew point, and measures reliably in pressures up to 450 barg. The unit is certified for

hazardous areas around the world, including ATEX, FM, CSA, IECEx as well as GOST.

Michell design and supply sampling systems fully equipped with filtration and sample

conditioning to ensure reliable measurements and prolong the life of the sensor.

The Promet uses Michells ceramic moisture sensor which is highly resistant to

contamination and provides long term stability in process applications. The sensor

is part of Michells sensor exchange programme, which greatly reduces the cost of

ownership. With the exchange programme, a freshly calibrated sensor is sent out and

swapped for the old sensor that is due to for recalibration, which keeps process down-time to a minimum. Where traceability is needed, Michell provide a fast and efficient

calibration service, with traceability to national standards.

For more information please contact: Michell Instruments, Ely, Cambridgeshire

Tel: +44(0)1353 658 000 Fax: +44(0)1353 658 199

E-mail: [email protected] Web: http://www.michell.com/uk


10/52

Most industrial automation and other manufacturing

personnel are very familiar with multi-touch

technology from their smartphones and tablets.

Many work for companies that allow employees to

use their personal mobile devices for work purposes,

from checking emails to accessing corporate data.

Now, multi-touch technology is making its way to

the automation world through multi-touch Human

Machine Interface (HMI) applications.

When used in industrial settings, many of the benefits of

this technology are similar to those encountered in the

commercial sector: relatively low cost hardware, the ability

to access and work with data quickly and easily, and near

universal familiarity with the technology. However, when

multi-touch technology is used with HMI systems, it offers

unique advantages in addition to those mentioned above.

Using multi-touch devices such as smartphones and tablets

to access and interact with data when in remote areas or

simply away from the control room is fast becoming the

de facto standard for manufacturers. A significant leap was

ushered in with the introduction of browsers, apps and

virtual private networks to access HMI systems through

hand-held devices. Multi-touch offers the next step: the

ability to quickly and intuitively view and analyze data fromvirtually any location.

Beyond Touchscreen

At first glance, its easy to confuse multi-touch applications

with traditional touchscreen designs. A traditional

touchscreen application simply uses single touches to

access different screens, basically replacing a keyboard and

a pointing device such as a mouse. But multi-touch offers

a number of advantages over touchscreens, keyboards and

pointing devices (Table 1).

Multi-touch systems recognize the position of several

touches and finger movements, which are referred to as

gestures. As with touchscreens, multi-touch technology

enables users to operate an entire system without the

need for a keyboard or pointing device. However, it goes

further in that it enables intuitive gestures that facilitate theexecution of commands up to three times faster than those

performed on traditional touchscreens.

Gestures used with multi-touch screens provide the ability

to move through many screens by swiping. Zooming

by pinching enables users to quickly zero in on areas of

interest, and rotation and other manipulation of screen

objects is greatly simplified and expedited. A good example

of how these gestures improve operations is enabling users

to swipe through pages quickly to find the data they need.

This is a great improvement over touchscreen buttons,

mouse movements and keyboard commands that require

the user to slowly drill down page by page.

Low Implementation Costs

There are many new technologies being introduced that

started in consumer electronics. Some of these are moreeasily adaptable for the industrial market than others. In the

worst case, some require a paradigm shift or investment

that outweighs the benefits of the new technology. Multi-

touch for HMI is clearly different in that it offers many

real advantages without significant required investment or

changes in work practices.

The arrival of the Windows 7 operating system and its built-

in multi-touch programming capabilities has made it much

easier and cheaper to implement multi-touch on tablets

and smartphones. Windows 7 has also created a platform

that greatly eases development of HMI software for multi-

touch applications. In response, certain providers of HMI

software are including multi-touch development tools with

their traditional PC-based HMI packages; and these tools

typically encompass PCs, tablets and smartphones.

Therefore, a company can invest in the same HMI software

package to develop multi-touch screens for the PCs in the

control room, and then use the same development tools

to provide multi-touch enabled access for smartphones and

tablets used in the field (Figure 1).

Figure 1. Multi-touch for HMI will greatly enhance the ease

and mobility by which remote workers can access systems and

perform command through a variety of handheld devices.

In addition, multi-touch for HMI doesnt require an

expensive investment in new hardware. Workers can

use their company-provided smartphones and tablets, as

these devices have multi-touch functionality built-in. Many

companies are going a step further by allowing for workers

to use their own handheld devices on the job, a trend

known as BYOD, or bring your own device.

Job satisfaction is increased when workers use their owndevices, and companies often provide a monthly allowance

to workers using their own devices, as the cost is typically

lower than making a large capital expenditure to provide

each worker throughout the company with handheld device.

Inherently Suited forIndustrial Conditions

The design of multi-touch screens, with their lack of

moving parts, is inherently better suited than keyboards

and pointing devices for industrial areas subjected to

contamination from dust and water. No moving parts are

exposed, which extends the equipments lifespan. This

design enables some off-the-shelf devices to be used in

the field without any additional protective measures, while

others require only minimal modifications as compared to

keyboards and pointing devices.

However, just as industrial PCs are made for the rigors

of the automation world, panel developers have also

introduced multi-touch screens that are reinforced for use

in hazardous and other extreme environments. Its possible

to protect keyboards and pointing devices in hazardous

By Richard Clark,

Product Manager, InduSoft

Mr. Clark started with InduSoft in

2012 and prior to that he spentalmost 15 years at Wonderware.

He has extensive technical

expertise encompassing IT and

control systems engineering,

administration, and security.

Mr. Clark combines 20 years

experience in all industrial

sectors of automation with

technical training in electronics

from California State

Polytechnic University.

Multi-touch Tech

Functionality AdvMulti-touch HMI takes HMI visualization to the next lev



11/52

areas such as Zone 1 or 2, but very expensive. Multi-touch

HMI screens provided with a protective overlay of glass or

polycarbonate to safeguard them from splashes, dirt and

extreme temperatures are often a better, less expensive

alternative for these and other demanding areas.

Lowering Training Time and Costs

As mature operators and technicians retire at greater

rates, younger workers will have to be trained to replace

them, and companies naturally want to minimize training

time and cost. Since the majority of these younger workers

will have years of experience using smartphones and

tablets, using multi-touch gestures for HMI systems will be

intuitive and quickly learned.

In addition, interface to the process or operation will

be similar whether the device is a PC, a tablet or a

smartphoneas all will utilize multi-touch technology.

This obviously is much simpler than learning a different

method of interface for each device. With less time

required to learn how to use HMI system interface devices,

more training time can be spent on learning about the

manufacturing processes and operations.

On the flip side, in the not-so-distant future a generation

of workers will be very unskilled at performing keyboardcommands and using pointing devices, so companies that

continue to rely on these older technologies will have to

spend more time and money training new workers.

Protecting Workers and Machines

The ability to improve safety with multi-touch HMI

probably isnt as immediately apparent as the economic

benefits and convenience of this technology. However,

multi-touch technology used to access HMI systems

does enable the implementation of significantly enhanced

safety features.

In order to ensure worker safety and reduce the possibility

of an accidental command, the HMI system screens can

be programmed to require users make certain gestures

unique to a specific operation. For example, the ability to

start or stop a machine can be designed so a checkmark

across the screen must be performed as a final step before

the machine executes the command.

Operations for machines can also require users to

have both hands on the screen at the same time in

order to execute the command, thus protecting hands

from accidentally becoming injured, and ensuring that

critical operations are not performed with casual or

accidental touches.

Some multi-touch applications even enable actions to

be performed with gloved hands, an operation that is

extremely difficult with keyboards. This frees workers

from removing and putting gloves back on, saving time and

making it easier to maintain personal protection.

Easier Diagnosis of Possible Problems

Perhaps the most unique functionality multi-touch

technology offers is the ability to visualize machines and

processes, and then access the right screen to diagnose

a problem. One of the difficulties in viewing complicated

machines and processes is that numerous layers of screens

must be created to capture an entire view (Figure 2).

Figure 2. Multi-touch for HMI enables users to quickly access

data and execute commands by using familiar gestures, such as

pinch and swipe.

Traditional HMI applications use multiple screen frames,

and more frames mean greater memory requirements for

the PC or other display device. A multi-touch application,

on the other hand, requires far fewer screen layers to

show a complete system overview. Smartphones and

tablets have less memory than PCs and were once

prohibitively slow when trying to move through multiple

screens, but now users can access data very quickly andeasily via multi-touch gestures.

Users can tap options on the screen to shrink and enlarge

as needed, getting rid of the constraints of screen frame to

enter a new era of visualized control. Perhaps, this ability

to drill through screens in an instant or enlarge areas with a

simple gesture is the new functionality, the killer app, which

will hasten the adoption of multi-touch technology in the

industrial workplace.

The Next Step in Visualization

HMI applications at the core have always been about

providing visualization for machines and processes,

rendering these operations and systems in a way that

humans can easily understand. HMI systems are also

designed with the purpose of viewing and controlling

remote locations, and multi-touch HMI is the latest step in

the evolution of visualization and remote access.

In addition to improved visualization capabilities, multi-

touch technologies simplify how users physically interact

with systems each time they touch a screen to expand

or contract a view, or drag an item. Making it easier and

Indusoft, Austin, Texas, USACan be contacted via:

Tel: 001 512 349 0334E-mail: [email protected]: www.indusoft .com

more intuitive for humans to interact with machines and

processes improves performance and reduces errors.

This lets operators spend more time on analyzing and

improving systems and processes instead of on access

and visualization.

In the near future, operators in a control room will most

likely continue to use PCs as their workstations. However,

it isnt difficult to envision those same operators taking

their smartphones and tablets to locations outside the

control room to access HMI systems and troubleshoot

problems. Furthermore, combining reduced headcounts

and smaller budgets with improved remote technology

means the workplace of the coming years must and can be

far more mobile than in the past.

The advantages that multi-touch for HMI bring in terms

of improved performance, faster and more accurate

command execution, and enhanced safety mean it will

become more prevalent in the industrial world. Seeing

technicians in areas outside the control room, both in plant

and remotely, using multi-touch smartphones and tablets

to access HMI systems will probably become the norm

rather than the exception over the next few years.

Table 1:

Benefits of Multi-touch for HMI

1. Three times faster than

traditional touchscreens

2. Reduces training time and cost

3. Improves remote access and functionality

via smartphones and tablets

4. Similar operation to smartphones

and tablets

5. Better suited for harsh and

hazardous environments

6. Provides enhanced protection for worker

and machines7. Delivers superior visualization, the next

step in HMI evolution

ology: Intuitive

nces Automationl to improve performance, enhance safety and cut costs



12/52

Transferring heat efficiently from one place or process to another is the basis of a wide

range of industrial processes, as well as being fundamental in building services for

space heating and hot water. Most energy transfer applications in industry are based

on the heat exchanger.

Steam is the most efficient and flexible energy transfer medium and there is a range of

heat exchanger technologies available that can provide reliable service across a wide

variety of applications.

Essentially heat transfer is concerned with two things: temperature and the flow of

thermal energy from a heat source to a heat sink. To be practical, any heat transfer

technology must also be efficient and controllable.

Energy efficiency determines what proportion of the energy entering the process ends

up where its needed, while effective control enables the thermal energy transferred to

match the demands of the process. Not only does this link closely with energy efficiency,

but it can also influence production efficiency by affecting parameters such as product

quality and waste.

For any steam user, it is important to have a sound grasp of the basics of energy transfer

and steam plant operation in order to specify systems correctly and prevent problems

cropping up later. They also need to understand the differences between the types of

heat exchangers currently available (see below). In the case of users for whom steam

lies outside the scope of their core activities, bringing in expertise from external steam

specialists can help to ensure that their heat transfer installations provide optimised,

reliable service for years to come.

Heatexchangers at a glance

Of the three methods of transferring thermal energy, conduction is the most

widespread and versatile approach and can be applied by several different heat

exchanger technologies.

Shell and tube- Shell and tube heat exchangers are based on a pressure vessel (the

shell), containing a bundle of tubes. One fluid flows through the shell and the other

through the tubes. Each fluid enters the exchanger at a different temperature and heat

passes between them through the tube walls as they flow through the exchanger.

Plate heat exchangers Standard plate heat exchangers (PHEs) are increasingly

popular in applications that transfer heat between medium- and low-pressure fluids.

In place of tubes passing through a shell, standard PHEs are built from a series of

corrugated metal plates held together to form channels through which the two heat

transfer fluids flow in alternating layers of the sandwich. The plates produce an

extremely large surface area relative to physical size, which promotes very effective

heat transfer.

This design also offers the additional benefit of having a low pressure/volume

relationship minimising the level of routine inspection requirements.

Plate and shell heat exchangers- The plate and shell combination offers high heat

transfer, compact size, low fouling and a close approach temperature, which is the

temperature difference between the leaving process fluid and the entering service fluid.

It is also able to cope with a high pressure/temperature envelope.

Corrugated tube heat exchangers - A variation on traditional shell and tube

exchangers. They have corrugated tubes to create greater turbulence, achieving much

greater heat transfer compared to smooth tube heat exchangers, allowing them to be

more compact.

Shell and coil heat exchangers- Built from circular layers of helically corrugated tubes

inside a compact shell. The large number of closely packed tubes creates a significant

heat transfer surface, while the alternate layers create a swift uniform heating of fluids

and increase the total heat transfer coefficient.

Heat pipe heat exchangers - Vacuum tubes with one end in the hot stream and

other in the cold stream. They contain a working fluid, and its the constant cycle of

evaporation and condensation as the working fluid moves around the sealed tube that

transfers thermal energy from one stream to the other. The big advantage of heat pipes

is their great efficiency in transferring heat. For example, a heat pipe can transfer up to

1,000 times more thermal energy than copper, the best known conductor.

Controlling steam heatexchangers

Apart from heat pipes, all the different types of exchanger are generally controlled in a

similar way, by sensing the temperature of the secondary fluid (often water) emerging

from the unit and using a valve to modulate the primary fluid (the incoming flow of

steam) to the exchanger.

An alternative control method to modulating the steam flow into the heat exchanger

is condensate control, which keeps the input steam pressure constant and instead

adjusts the flow of condensate coming out of the exchanger. This varies the amount of

condensate inside the exchanger to control its heat transfer area and hence its heat

transfer rate.

Condensate control allows the condensate to be maintained at a sub-cooled temperature

to extract the maximum amount of useful heat from the steam and avoids any potential

flash steam plumes.

Heat exchangers of any type can stall when the condensate is not removed effectivelyand builds up internally. Typical symptoms of heat exchanger flooding include

banging and crashing noises coming from shell and tube heat exchangers caused

by waterhammer.

Stalling happens when the pressure in the heat exchanger is less than or equal to

the back pressure on the steam trap, often occurring when demand from the heating

process falls due to a change of flow rate. Stalling is also dependent on the rate of

change of flow. When this happens, the control valve reduces the steam pressure

accordingly and this may reach a level thats too low for the steam trap to clear the

condensate effectively.

The best protection against stalling heat exchangers is prevention by good system

design and by fitting measures to solve the problem. One solution is to fit an

automatic pump trap to ensure condensate is always cleared under even the most

demanding conditions.

What is clear is that efficient and controllable heat exchange is essential for thermal

processes and should be considered crucial for any steam-using operation. As well as

providing the heat transfer needed to enable the process to operate correctly and at

the right rate, it also keeps energy costs down and reduces the production of carbon.

Spirax Sarco Limited, Cheltenham, Gloucestershire

Can be contacted via: Tel: 01242 521361


Web: www.spiraxsarco.com/uk/

Keep heattransfercosts under control

Heat transfer is an important aspect of many commercial and industrial processes, so making it as efficient as

possible is vital. Graham Dear, Marketing Product Manager Heat Transfer at Spirax Sarco highlights some of the

advanced techniques available for improving heat transfer efficiency, such as sub-cooling condensate, and the

best ways to ensure reliable operation by tackling stalling in the heat exchanger.

The latest heat exchanger packages feature intelligent monitoring systems to

deliver meaningful energy management and system performance data for the user



13/52


For welding in aggressive environments, the

conventional approach is to use nickel-based materials,

work with clad bonding methods, or use UNS S31803

or S32750/S32760 plate materials. A safe and cost-

effective alternative for overlay welding is Sandvik

25.10.4.L, a super-duplex strip electrode with

composition complying with EQ2594. An innovative

grade unique to Sandvik, this electrode is used with

Sandvik 47S flux.

High resistance to corrosion

Sandvik 25.10.4.L gives weldments with high corrosion

resistance. In some applications the level of corrosion

resistance achieved matches that of nickel-based alloys,

such as alloy 625. Yet the grade is less expensive and

the price is more stable due to the lower nickel content.

Super-duplex, a safe choice for aggressive environments

Super-duplex stainless steels can withstand aggressive

service environments such as warm chlorinated

seawater and acidic water, chloride-containing media

up to temperatures of 300C (600F), hydrochloric acid,

formic acid, acetic acid, sulfuric acid of high or low

concentration, and caustic soda.

Advantages over austenitic materials

Duplex material is highly suitable for overlay welding. In

contrast to austenitic stainless steels, there is only a small

difference in thermal expansion between low alloyed

steels and duplex stainless steels. Super-duplex also

has higher erosion resistance, significantly higher stress

corrosion cracking resistance, and is less sensitive to

microfissuring cracks compared to austenitic materials.

Sandvik 25.10.4.L is a safe choice

Cladding with EQ2209, achieving UNS S32750/S32760 by

alloying through flux, can

be unreliable in terms

of quality. With Sandvik25.10.4.L strip, neutral

non-alloying flux is used

with a genuine weld

composition solid filler.

In terms of weldment

homogeneity, quality and

durability, this is a safer alternative.

For more information: contact

Sandvik Materials Technology, Box 502, 734 27

Hallstahammar, Sweden Tel: + 41 41 368 30 38

Web: www.smt.sandvik.com

Sandvik25.10.4.L super-duplex strip foroverlay welding in aggressive environments

SPLs process offers more effective protectionagainst contamination and corrosion andoffers reduced downtime compared to jettingcleaning methodsA new immersive chemical cleaning process that can maintain the efficiency and extend the

working life of heat exchangers is now available from Surface Processing Ltd (SPL).

Heat exchangers are prone to fouling, namely, the accumulation

of organic and/or non-organic material deposits within heat

transfer equipment (commonly on the cooling water side), inside

tubes and on external surfaces. This causes blockages, corrosion

or leaks, which affects flow and pressure levels and ultimately

impairs heat transfer.

Unlike traditional jetting methods, SPLs immersive process

offers consistent cleaning power on both inner and outer

surfaces. SPL can treat small heat exchangers at its Dudley facility or equipment too large to

be moved or dipped in tanks can be treated on-site who can achieve effective results through

immersion by pumping SPLs cleaning products through the entire system.

Using the latter method, the company has successfully cleaned a 13-metre long heat exchanger

weighing 34 tonnes.

For more information contact Surface Processing Ltd, Dudley, West Midlands Tel: 01384

242010 E-mail: [email protected] Web: www.surfaceprocessing.co.uk

IMPROVED HEATEXCHANGER

PERFORMANCETHROUGH SPRAYINGSpraying coils with water can significantly improve the performance offinned heat exchangers. Especially in refrigerating plants implementing

free-cooling (e.g. for the cooling of server racks) considerable energysavings can be realised. The COP can be improved by up to 40 %through using a spraying system in high ambient temperatures to lower

the condensing temperature.These advantages may be fully exploited and maximized by using theappropriate fan and spray control system.

With the new, internally developed HydroSpray System, Gntner offers a

spraying system with numerous application advantages. For perfect control

of this unique spraying system, Gntner Controls developed the Gntner

Hydro Management the controller GHM spray.

The controller GHM spray controls the water spraying depending on the

demand from the heat exchanger and the measured temperature and

pressure. Two systems are available, the Gntner Motor Management

(GMM) with GHM spray basic and the GMM with GHM spray professional.

GHM spray basicThe basic variant is a single-stage system

that activates spraying at a defined

switching point and sprays all the fan

chambers up to 300 h/a.

Depending on different parameters, e.g.

pressure or temperature, the controllermanages an even spraying of the heat

exchanger to attain an increase in capacity

in the peak load range. All GHM controllers

are parameterized in accordance with

the GPC calculation for the units, so the

operating parameters are already adjusted

to the geographical location of the units.

GHM spray professional

The GHM spray professional controller ensures that a maximum increase

in performance is achieved over a spraying time of up to 1,000 h/a. The

water consumed is 50% of conventional systems in the market. Another

feature is the automatic vacuum drainage which ensures that spraying is

always carried out with fresh water and that no water is left standing in the

unit in the winter.

The highlight of the GHM spray professional, however, is the so-called

Section Cycling, which is able to control up to 9 heat exchanger sections

individually. This means that the heat exchanger is sprayed in sections,

thus reducing water consumption. Moreover, the heat exchangersperformance is thus adjusted in very small steps, maximizing the life of

the heat exchanger.

For more informatgion contact H Guntner (UK) Ltd, Camberley, SurreyTel: 0844 22 50 600 E-mail: [email protected]

Web: www.guntner.co.uk

Winn & Coales Coating ProtectsPower Station Header BoxesUniversal Heat Transfer Ltd (UHT) of Atherston, Warwicks, are heat

exchange and transfer specialists in supplying equipment and services to

industry. One of their latest projects involved the manufacture of header

boxes and channel heads for the refurbishment of four hydrogen coolers

for a power station generator cooling system.

UHTs customer specified Winn & Coales (Denso) Ltds Archco-Rigidon

403D to give fit and forget corrosion protection of the carbon steel

substrate from the coolant inside the header boxes for a minimum of ten

years. Winn & Coales checked the specification for both suitability of

Archco-Rigidon 403D and also for the method of application, given that

the coating had to be applied in normal engineering workshop conditions.

UHT say that the coating arrived in a timely manner, which was appreciated

due to the tight deadlines they had to meet.

The glass flake vinyl ester Archco-Rigidon coating was inspected by UHTscustomers Quality Assurance consultants and found to be more than

adequate in terms of finish and film thickness, including Holiday detection

readings, to provide the required protection.

For more information contact Winn & Coales (Denso) Ltd, Chapel Road, London.

Tel: 020 8670 7511 Fax: 020 8761 2456 E-mail: [email protected] Web: www.denso.net

UHT manufactured

header boxes coated

with Archco-Rigidon

403D for powergenerator heat

exchangers


14/52

HBM RELEASESUPGRADED DIGITALCHARGE AMPLIFIER

HBM has released an improved

version of its CMD600-P

digital charge amplifier thatnow features IP65 degree

of protection facilitating its

use in challenging industrial

environments as well as in

laboratory applications.

The CMD600-P digital charge

amplifier also features an

extremely compact design, high function density and

can be positioned directly at the measuring point to

measure forces or torques in extremely tough and often

dirty environments.

The latest design incorporatessecure sealing of unused

connections with protective caps so that external

influences are reduced to a minimum. The digital inputs/

outputs and fast Ethernet interface enables users to easily

parameterize the device and monitor it during operation.

The CMD600-P also features integrated peak value

detection and limit value monitoring functions enabling

control functions to be distributed across decentralized

devices relieving pressure on the central control unit.

It is also possible for the system to continue operating,

monitoring and even remote maintenance while

parameter changes, such as changes in measuring

range or limit value monitoring, are being implemented.

For more information contact HBM Ltd, North Harrow,

Middlesex Tel: 020 8515 6000

E-mail: [email protected] Web: www.hbm.com

Latestindustrial

amplifier preciselymeasures torqueand angle of rotationHBM has launched its PX460 plug-in measuring card

enabling torque transducers to be fully integrated in its

PMX industrial measuring amplifier by giving dynamic

and precise measurements of frequency, pulse, speed,

angle of rotation and torque.

The PX460 amplifier plug-in card can acquire up to four

torque transducers simultaneously with a measuring

bandwidth of up to 6 kHz.In addition to torque, encoder

signals of up to 2 MHz can be acquired with absolute

precision in challenging industrial environments. Real

time Ethernet fieldbuses such as Profinet, Ethercat or

Industrial Ethernet ensure reliable integration of machineand plant control systems.

The PMX measuring amplifier featuresAdvanced Plug

& Measure technology and TEDS that automatically

recognises connected transducers. This removes the need

to manually enter complex

settings minimising delays

in actually undertaking

measurement tasks. The

card helps users reduce

time delays while giving

greater system stability and

avoiding unnecessary errors.

HBM developed the PMX

measuring amplifier system

to ensure quality assurance and system integration in

industrial production and in end-of-line test benches.

All production data can be accessed via a password-protected web browser interface using an Internet-

capable end device.

For more information contact HBM Ltd, North Harrow,

Middlesex Tel: 020 8515 6000

E-mail: [email protected] Web: www.hbm.com

Unitemp have introduced a new range

of cost effective compact combined

temperature / humidity chambers and

temperature chambers manufactured

by Japan based E.S.P.E.C. This high

quality range has been designed

for the testing and monitoring of

electronic / electrical components,

semiconductors, small assemblies

and selected chemicals. Improved

fast temperature and humidity cycling with increased

ramping provides the capability to validate quality and

reliability for the item under test.

The range consists basically of 10 models with half of

them designated the SH having a temperature range

of -20,-40,-60 to 150 / 180 degrees C combined

with a humidity range of 30 / 95% RH. The other 5

models are designated SU and have a temperature

ranges of -20,-40,-60 to 150 / 180 degrees C. The interior

is constructed from high quality stainless steel, thechambers have internal measurements of between W300

x H300 X D250 mm and W400 X H400 X D400mm.

Ideal for situations where space is at a premium

the models are stackable. Capacity is 22.5 or 64 L

dependant on the model and the weight is between 78

and 130 kg. An easy to use 4.3 inch

colour LCD touch panel controller is

integrated as standard making it easyto set various patterns of constant,

program remote operation to meet

various testing conditions. Incorporated

is a unique web application (Ethernet

connection) which allows the operator

to monitor the chamber operation from

a P.C. Without any software the chambers can be

accessed and controlled via a web browser on the

P.C, Smartphone and IPADS. Wireless connection and

multiple units connection are also possible.

Options include viewing window door and roof

top viewing, port arrangements, and various

stand combinations with castors for ease of movement.

These new chambers complement Unitemps extensive

ranges of chambers, and the company has the expertise

to build special chambers to order.

For further information please contact Unitemp Ltd,

High Wycombe, Bucks.

Tel: 01628 850611

or E-mail: [email protected]

New range of compact benchtoptemperature and humidity chambers

AMETEK Land, a leader in non-contact temperature

measurement, combustion efficiency and environmental

emissions monitoring, has launched the latest update

to its Cyclops family of portable, high-precision, non-

contact thermometers the Cyclops L.

With its internal data logging capabilities, configurable

route modes and dedicated software, the Cyclops L further

establishes AMETEK Land as the industry leader in high-

quality, portable non-contact temperature measurement.

Four New Models

There are four new models in the new Cyclops L

family, measuring across the range 200C/392F to3000C/5432 F. They are aimed at a wide range of

applications including liquid metal, steel and glass

production, furnaces, plus many others.

Route Manager Function

The Cyclops L family features the new Route Manager

function, which enables users to configure a path/route

around a plant by identifying the location with description,

an emissivity value, a window correction factor (if

applicable), and a unique identifier (a description).

This Route Management mode allows for complete

repeatability of readings, making the thermometer the

ideal tool for multiple locations requiring regular and

reliable monitoring.

High Capacity Internal Data Logging

The Cyclops L thermometer stores up to 9,999

temperature measurements, which can be downloaded

to optional logger software for further analysisand comparison.

New Dedicated Data Logging Software

- on a mobile device

The Land Cyclops Logger Software allows users to

connect a Land Cyclops portable thermometer to a

personal computer or mobile device to view, analyze

and record live temperature readings.

Connections between the Cyclops

L model thermometers and a

mobile device /computer can be

either wireless (via Bluetooth) or via a

USB cable.

Models Available for a wide range of applications

These reliable, high-accuracy battery-powered

thermometers have application in a wide range of

industries, including metal foundries, steel making, glass

refractories, petrochemical processing, and laboratory/research & development. They have precise, narrow

field of view continuously focusable optics with through-

the-lens sighting for accurate sample point selection.

Long-term, drift-free measurement assures confidence

in the readings.

Outstanding Damage Protection

The new Cyclops thermometers benefit from a new

industrial rubber casing cover, for increased protection

from accidental damage. Plus a new lens hood that adds

further protection.

Full UKAS Calibration Available

Cyclops L thermometers can be certified by US and

UK ISO 17025 accredited laboratories to recognized

international standards, in both the UK and USA.

For more information contact AMETEK Land (Land

Instruments International), Dronfield, Derbyshire,

S18 1DJ Tel: 01246 417691

Contact: Stuart Harris: 01246 581588


Web: http://www.landinst.com

AMETEK Land introduces

NEW Cyclops L - portablenon-contact thermometers



15/52

www.HARTING.com

HARTING Ha-VIS

eCon switches with PoE+

Data and power

perfectly combined.

Flexible power supply directly over Ethernet connections.

Ha-VIS eCon switches are now even more powerful: In addition to data transfer, the IEEE PoE+ standard allows simultaneous

energy transfer over an Ethernet cable. Up to four remote devices can each be supplied with 34.2 watts from IP telephones to

camera systems to WLAN access points or RFID readers. Switch models with integrated voltage converter can be supplied

directly with 24 V instead of the usual 54 V. And, thanks to intelligent energy management, Ha-VIS eCon switches with PoE+

reduce wiring effort, while cutting energy costs at the same time.

For more information, phone +44 (0) 1604 827500 or send an e-mail to [email protected]

Findall product informationhere

www.eCatalogue.HARTING.co.uk

Fluke has introduced the new Fluke VT04A

Visual Infrared Thermometer - a lower-

priced version of the Fluke VT04 with a

manufacturers recommended price of

495. While including all the features of the

high-end VT04, it is powered by AA batteries

offering flexibility to technicians who may wish

to replace batteries in the field.

The Fluke VT04A is a troubleshooting tool with an infrared

heat map which offers high resolution as well as temperature alarms and time-lapse

features. The VT04A comes with updated firmware that extends battery life by offering three

screen brightness levels, automatic screen dimming after a set period with instantaneous

override, a configurable automatic time-off capability, and the ability to save images in .bmp

format. It also comes in a more compact, soft carry-case.

The Fluke VT02 / VT04 / VT04A Visual IR Thermometers instantly detect problems using

blended thermal and digital imagery. They will display and save images as full visual, full

infrared, or in three blended modes. Markers pinpoint hot and cold spots indicating the

hottest temperature with a red box and the coldest with a blue box. A temperature reading

is provided at the centre point.

For more information contact Fluke (U.K.) Ltd, Norwich, Norfolk

Tel: 0207 942 0700 Fax: 01603 256 606

E-mail: [email protected] Web: www.fluke.co.uk

NEW LOWER-PRICE FLUKEHIGH RESOLUTION VISUALINFRARED THERMOMETER

WITH AA BATTERY FLEXIBILITY

COMPLIMENTARYe-BOOKLETON

TDL GAS ANALYSERAPPLICATIONS

GPro 500 TDL analysers are designed for ease of installation and

low maintenance operation in a wide variety of process applications

in refining, petrochemical and associated industries. With a range of

innovative process interface adaptions, they provide a flexible and cost

effective measurement solution.

This applications eBooklet is a

convenient reference to a selection

of the most common GPro 500

applications.

It provides a brief overview of the

application, a process diagram

highlighting the installation location

and the rationale behind themeasurement.

Additional information, including

typical gas stream parameters and

tips on probe selection, will assist in achieving the most suitable

configuration to meet your measurement requirements.

To download this best practice guide visit: www.mt.com/uk-gas-eBook

For more information www.mt.com/o2-gas

Tel: 0116 234 5095




16/52

Modular production

Customer-tailored manufacturing requires a high

degree of flexibility in production. In smart factories,

modular production units are connected toge

Documents

Process Industry Informer July 2014