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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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ASCO Numatics. Experts providingengineered actuator control systems
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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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Editor
Phil Black
Publisher/Advertising Manager
Peter Ullmann
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Guy Ullmann
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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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6 PROCESS INDUSTRY INFORMERJune-July 2014
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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7PROCESS INDUSTRY INFORMERJune-July 2014
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
E-mail: [email protected]
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
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8 PROCESS INDUSTRY INFORMERJune-July 2014
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
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9PROCESS INDUSTRY INFORMERJune-July 2014
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
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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
10 PROCESS INDUSTRY INFORMERJune-July 2014
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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
11PROCESS INDUSTRY INFORMERJune-July 2014
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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
E-mail: [email protected]
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
12 PROCESS INDUSTRY INFORMERJune-July 2014
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13PROCESS INDUSTRY INFORMERJune-July 2014
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
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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
E-mail: [email protected]
Web: http://www.landinst.com
AMETEK Land introduces
NEW Cyclops L - portablenon-contact thermometers
14 PROCESS INDUSTRY INFORMERJune-July 2014
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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
E-mail: [email protected]
15PROCESS INDUSTRY INFORMERJune-July 2014
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Modular production
Customer-tailored manufacturing requires a high
degree of flexibility in production. In smart factories,
modular production units are connected toge