PECM

www.pecm.co.uk PECM Global Success Through Innovation Process Engineering Control & Manufacturing Issue 15 £3.95 practical advice & solutions on the technical and management challenges faced by engineers and managers in the process engineering & manufacturing industries. Control & 40 AutomationAir, Gas & 26 Electrical & 54Odour Control ElectronicsFacilities 64 Health & Machining &Management Safety 78 Machinery 88Measurement Process 109 Storage, Handling& Monitoring 95 Technologies & Equipment 117 industry news & events || boilers & maintenance || fluid handling || manufacturing || software & systems || water & effluent treatment

Man and Machine Training Academy Man and Machine offer an extensive range of Autodesk  training coursesMan and Machine specialise in Autodesk training forManufacturers, Engineers, Architects & Product Designers.All courses are taught with the official Autodesk coursewareand includes one month’s free post training support.Autodesk AutoCAD courses include:  AutoCAD Essentials  AutoCAD Electrical Fundamentals  AutoCAD Advanced  AutoCAD 3D Drawing & Modelling  AutoCAD Mechanical EssentialsE: [email protected] Connect with usW: www.manandmachine.co.uk T: 01844 263 700

Global Success PECM Through Innovation Process Engineering Control & Manufacturing Issue 15 ContentsEditor: Tel: 01227 392575 Email: [email protected] Editors Choice 6Elizabeth Hutton Tel: 01227 392575 Email: [email protected] Air, Gas & Odour Control 26Assistant Editor: Tel: 01227 392529 Email: [email protected] Boilers & Maintenance 29Justine Sanders Tel: 01227 392517 Email: [email protected] Cables 30Sales Director: Tel: 01227 392571 Email: [email protected] Calibration Solutions 32Benjamin Dubois Tel: 01843 830249 Email: [email protected] Cleaning 38Sales Manager: Control & Automation 40Sophie Plowman Drives, Gears & Motors 50Digital Manager: Electrical & Electronics 54Jamie Bullock Facilities Management 64Publishing Director: Fasteners & Fixings 66Martin Holmes Flow Measurement & Control 68 Fluid Handling 72 M H Media Global Ltd. Health & Safety 78St Augustine’s Business Centre, 125 Canterbury Road, Westgate On Sea, Kent, CT8 8NL Hydraulics & Pneumatics 82 Lubricants 84 Tel 01843 830249 Fax: 08721 152240 www.pecm.co.uk Machining & Machinery 88 Measurement & Monitoring 95 All web addresses are inter-active, simply click the web address of your choice to view News & Events 107 the company website. There is also a useful tool bar where you can search for a specific Process Technologies 109 Product News 114 product, or simply view the index on page 3 and then type in the page number of the Software & Systems 115 section that you wish to view. Storage, Handling & Distribution 117 Tools 122 Please mention Process Engineering Control & Manufacturing Valves & Flow Control 124 when responding to items in this issue. Waste Management 128 Water & Effluent Treatment 129 Every effort is made to ensure the accuracy and reliability of material published inProcess Engineering, Control & Manufacturing however, the publishers accept no responsibility for the claims or opinions made by the contributors, manufacturers or advertisers. No part of the publication may be reproduced or transmitted in any form or by any means, mechanical, electronic (including printing), recording or stored in any information retrieval system without the prior written consent of the publisher.DELYIOVUERRIPNRGOSJTERCTAIWNEITRHSO&UTFIDLTEELRASYTO Y-type strainers 3 asket strainers 3 Duplex strainers 3 T-type strainers 3 Radial fin cartridge filters (to 1 micron) Filter separators and demister pads 3 Quick release closuresMaterials available include: Carbon Steel & LTCS 3 Stainless Steel 304/316 3 Duplex and Super Duplex Stainless Steel 6Mo 3 Monel 3 Aluminium ,*)2e 3 Cunifer 3 Hastelloy 3 Incoloy 625 & 825 3 Titanium 3 Norsok MDSBased in the UK, Barton Firtop manufacture and stock hold an extensive range of ASME/CE Marked Y-type, Basket and Duplex strainers.Contact: [email protected] or visit our website: www.bartonfirtop.co.uk Issue 15 PECM 3

Introduction toElectrical PrinciplesThis course will give you a basic working knowledge of the principles ofelectrical engineering and will also cover safe working practices. -See more at www.peta.co.ukCourse Details ĖĺLocation: Havant ĖĺDuration: 4 Days ĖĺMember: £629 ĖĺNon-Member: £740All fees subject to VATObjectivesOn completion of this course, delegates will be able to; understandthe basic electrical principles and how they apply in electricalcircuits additionally, delegates will be shown how to work safely andcompetently with electrical equipment, including operating techniquesand the various symbols and icons which are important to understand.Course OverviewPractical application - wire an intermediate lighting circuit, a ring maincircuit, a motor control circuit and wiring of junction boxes and terminalsElectricity at Work Regulations 1989 Introduction to 17th EditionElectrical safety, safe system of work and permit to work Ohms law,relationship between voltage, current and resistance and basic electricalcalculations AC Generation and Transformer Principles AC Starters -theory of operation Protection devices including fuses, MCBs, RCDs andRCCBs Understanding simple electrical drawings and simple circuitdiagrams Identification and use of a range of electrical cables Electricalsystems testing – continuity, polarity, insulation resistance Measurementof voltage, current and resistance Basic electrical fault diagnosisEarthing, bonding, insulation of electrical circuits.Group Discounts5% off for 2-3 people8% off for 4-5 people12% off for 6 or more people For more information please see www.peta.co.uk4 PECM ssue 15

Introduction toTurningLathes are highly technical and require specialist training. This courseis extremely safety-focused and will enable you to operate to a highstandard of safety. Attending this course will enable you to operate themachinery effectively and safely. See more at www.peta.co.ukCourse Details ĖĺLocation: Havant ĖĺDuration: 5 Days ĖĺMember: £799 ĖĺNon-Member: £940All fees subject to VATObjectivesOn completion of this course, delegates will be able to; use digitalreadouts and dials calculate speeds and feeds use of automatic feedsunderstand machine axis use tailstock and compound slide useattachments and precision techniques.Course OverviewMachine safety and guarding How to read and use measuring tools Howto use feeds and speeds Tail-stock and running centre drilling, reaming& threading Precision techniques of turning diameters and boring holesUnderstanding drawings Facing/Parting off Machining shoulders andchamfers Basic cutting tool identification and setting Machining anglesusing compound slide Understanding and using digital readouts (DROs)Course DataDue to the nature of this course, dates are available upon request.Company Sponsored OptionThis course is also available as a company sponsored option which isfor your delegates only, this is a flexible solution and can be tailored toreflect your business needs, delivered on a date, time and place to suityou. For more information please see www.peta.co.uk Issue 15 PECM 5

Full Thrust: Innovationfor Maintenance of High Performance Industrial Gas TurbinesRepair process based on EOS technology opens new opportunities for industrial gas turbine maintenance cost reduction I n 1852 James Prescott converted into mechanical energy. This the machine’s interior, which had to Joule described for the first mechanical energy is used to turn the be enlarged to accommodate the 800 time the physical principle gas turbine compressor and generator millimetre burner. The manufacturer of the gas turbine – the (to generate electricity) or other driven also amended further hardwarethermodynamic cycle, also known as equipment (e.g. compressor to pump components such as a camera systemthe Joule Process. The initial ideas and the gas /oil through the pipe lines). and an optical measuring system andconcepts behind this invention date During operations, the components in made corresponding adjustments toback as early as 1791. the engine’s hot gas path are exposed the software. EOS carried out the to high temperatures, at times in extensive re-working of the EOSINTThe Swedish-based company excess of 1,000 degrees Celsius (e.g. system in less than a year.Siemens Industrial Turbomachinery blades and vanes). This, in turn, leadsAB (SIT) manufactures gas turbines to a high level of wear of the hot gas From the outset it wasfor power generation in industrial path components. clear that the approachand oil and gas applications. The would be reapingperformance spectrum of Siemens’ This is also true for the burner tip – benefitsindustrial turbines ranges from 15 to the point at which the ignition of the60 megawatts. Besides construction, fuel-air mixture takes place. Here, the From the outset it was clear that thethe Siemens subsidiary also provides effects of wear and tear can be clearly approach would be reaping benefits.long-term service and maintenance seen and measured. The manufacturer Rather than replacing a large portionfor these engineering masterpieces. In undertook rigorous testing to establish of the burner tip, Siemens beganan effort to help reduce maintenance a prescribed operating period after by removing the damaged materialcosts, Siemens is currently working on which the burners typically need to be only. Moreover, during repair,the development and implementation repaired. former versions of the burnersof Additive Manufacturing technology, in the fleet could be re-built toutilising EOS technology and Conventional repair procedure required the latest design. So, thesesequipment. prefabrication of a big portion of the former versions of the burners burner tip. This prefabricated burner in the fleet could be not onlyChallenge tip is used for replacement of the repaired, but also improved –The gas turbine consists of air inlet, burner tip after a specified operation thus bringing new meaningcompressor, combustor, turbine time (cut old and weld prefabricated to the term Additiveand hot gas outlet. The compressor one). Conventional repair procedure Manufacturing.compresses the air going through the can be time-consuming with aengine. In the combustion chamber, significant number of sub-processes Resultscompressed air is mixed with fuel and and examinations. To help simplify Figures, data and facts and speed up the repair procedure clearly detail the successDuring operations, Additive Manufacturing technology was of the new repair process.the components in implemented at Siemens. Siemens Industrialthe engine’s hot gas Turbomachinery AB will bepath are exposed to Solution able to make a significanthigh temperatures Such an undertaking requires an impact on the central innovative partner. Siemens found concern – the reduction of theburned in order to increase the kinetic just that in EOS: In addition to having repair time: For the operator,energy of the flow. In the turbine, the right Additive Manufacturing what is equally important isthe kinetic energy of the flow is technology, EOS was also able, that the turbines are quickly within a short time frame, to ready to return to service. This individually adapt one of its in-house provides additional opportunities machines – an EOSINT M 280 – for this processing. The alterations concerned, in particular, the scale of6 PECM ssue 15

for potential cost reduction ofthe repair process – resultingin overall maintenance costreduction.Alongside the benefits to its Repair technologyown repair process, Siemens in use: Dr. Vladimircan now offer its customers Navrotsky, Head ofstrategic advantages:Through the new process, Technology andthe experts are able to make Innovation at Siemensimprovements to the turbinetechnology relating to the Energy Service O&G,component by building them holding a burner tipinto the repair process. In this which was repairedway, operators could have within a short timeaccess to the latest technology,even if their turbines have seen frame by means ofyears of service. Additive Manufacturing (Source: Siemens).Dr. Vladimir Navrotsky, Head of EOSINT M 280 Custom:Technology and Innovation at The system wasSiemens Energy Service, Oil &Gas and Industrial Applications, individually adaptedsummarizes: “With this new to the purposes ofrepair technology we arelooking to carry out these high Siemens and helps toprecision jobs much more simplify and speed upquickly.” the repair procedure ofIt’s not only the SwedishSiemens’ subsidiary that burners for industrialviews the project as a gas turbines (Source:significant achievement.“We have successfully Siemens).pushed our technology intothe repair arena. We have Factsshown that we are capable ofmodifying our system quickly Short Profileto meet customer-specificrequirements. In this case, the Siemens Industrial Turbomachinery AB manufactures, installs,modifications to both hardware commissions and services industrial gas turbines with a power range ofand software were significant.Everyone involved can look 15 to 60 megawatts.back with satisfaction, not onlyat the end result but also the Addressroute to achieving it,” saysStefan Oswald from EOS. Siemens Industrial Turbomachinery AB SE-612 83 Finspong“Additive Manufacturing opensup new dimensions for us in the Swedenuse of integrated design andproduction. This technology Challengeenables us to manufactureand repair components for our Customising an EOS solution for the precise, cost-effective, andindustrial gas turbines far faster repair of gas turbine components exposed to extremequicker than before. At thesame time, the functionality temperatures.and performance of the part isincreased.” SolutionDr. Vladimir Navrotsky, Head ofTechnology and Innovation at Enlargement of the construction capacity to accommodate individualSiemens Energy Service O&G customised repairs through the reapplication of material to the worn burner tip of the gas turbine. Results - Fast: time required for the repair process of burner tips has fallen by more than 90% - Innovative: old versions of the burners can quickly be brought up to the latest standards of technology - Cost-effective: potential cost reductions already seen at an early stage Issue 15 PECM 7

I nnovation underpins the both the business and the wider The UK’s strong position needs to be continued success of economy. constantly reinforced through ever global-leading multinational smarter investment in priority themes Procter & Gamble (P&G). By Since 2006, P&G’s Strategic and research tools to partner withstrengthening its portfolio of consumer Partnership with Engineering & business, as other regions learn fromproducts and the processes behind Physical Sciences Research Council and try to emulate UK success.them, scientific breakthroughs sharpen (EPSRC) has helped it to access crucialthe company’s competitive edge, expertise in academia and catalysed • P&G has 16 sites across the UKcreate jobs and ultimately drive growth new upstream work dovetailing with and Irelandand market share. But they simply its own nearer-market research. Withcould not be achieved without a solid Innovate UK helping innovations • P&G serves approximately 4.8platform of world-class research. P&G negotiate the ‘valley of death’ between billion people around the worldcommits R&D resources in the UK that the laboratory and the marketplace, with its brands including Always,are at levels significantly higher than real- world solutions to tough industrial Ariel, Ambi Pur, Braun, Duracell,the UK’s proportion of P&G’s global problems and outstanding career Fairy, Febreze, Gillette, Head &business, reflecting what it sees as the opportunities for some of the UK’s Shoulders, Iams, Lenor, Olay,UK’s unique research climate where brightest scientists are the welcome Oral-B, Pampers, Pantene, SK-IIpioneering projects and high-calibre result. and Wellaexpertise generate insights that benefit

EPSRC invests around £800 million a year in a broad range of subjects – from mathematics to materials science, and from information technology to structural engineering UK ResearchOpens the Road to GrowthLetting good ideas flow an Innovate UK-funded project aiming Cold water cleaning is also a focus‘Caking’ of powdered materials to reduce the energy costs of spray- of CEMENT (Centre of Excellence inis a common problem for many drying techniques used in powder Methods and New Technologies forindustries including detergents, bulk production by 10 per cent. In addition, Surface Modification and Cleaning),chemicals, food and pharmaceuticals. he is fostering tomorrow’s research a £14 million Regional Growth FundP&G Engineer Graham Calvert’s leaders, overseeing multiple research initiative involving P&G, Durhamwork on a rig allowing caking of projects at Leeds University receiving University, Peerless Systems andpowdered materials to be studied substantial P&G investment on top of the Centre for Process Innovationin unprecedented detail builds on EPSRC/Innovate UK support. (part of Innovate UK’s High Valueknowledge developed during his partly Manufacturing Catapult). CreatingEPSRC-funded PhD, his post-doctoral Cold water comes clean a ‘hotspot’ of academic/privateplacement at P&G and his Innovate Effective low-temperature detergents expertise, it will also harness theUK/EPSRC-funded Knowledge Transfer offer huge benefits for the consumer skills of EPSRC-funded students thatPartnership (KTP). and the environment. Funded through it is inspiring in North-East England – an EPSRC/P&G collaboration, research binding research and innovation in aMeanwhile, Senior Engineer Hossein led by Warwick University has shown lasting partnership.Ahmadian – also harnessing insights that nano-scale carbon pieces helpfrom his partly EPSRC-funded PhD and loosen fat from fabrics without hotInnovate UK-backed KTP – is leading washing.

Editors ChoiceE-TECK: experts HRH The Duke of Yorkin advanced visits BSRIA Instrumentadhesives Solutions as a part of 60 year celebrationsE-Teck Ltd provides industrialusers with advanced adhesives As a part of their 60 year celebrations BSRIA were visited by HRH Thetogether with ancillary products for the engineering, marine and Duke of York, KG on April 13th. The Duke visited BSRIA’s Bracknellautomotive sectors. Our products cover both generalist and specialist Headquarters where he met with Senior Staff before touring the BSRIAapplications and are compatible with a wide range of substances including test laboratories and meeting the test engineers. The Duke follows in hiscomposites, plastics, metals, glass, wood and concrete. father’s footsteps as His Royal Highness The Duke of Edinburgh visitedOur current products utilise the latest chemical technology while our BSRIA in 1962. During the visit The Duke toured the BSRIA Instrumentexcellent laboratory facilities in Europe and the USA ensure our customers Solutions calibration test labs where he saw a number of instrumentsbenefit from continued product development. With over 20 years’ being calibrated including BSRIA’s new infrared test rig. His Royal Highnessexperience in the adhesives industry, we supply customers all over the then watched a demonstration of one of BSRIA Instrument Solutions mostworld. Exceptional customer service remains our priority. popular thermal imaging cameras before progressing on to view the wind tunnel that caught The Duke’s eye during the tour.Email: [email protected] www.e-teck.com Tel: 01344 465677 www.bsria.co.ukHBM go above and HBM waves tobeyond the standard success with tidalwith load cell range power plantFollowing recent changes to the European HBM – a market leader in the field ofATEX Directive 94/9/EC, HBM – a market test and measurement – has beenleader in the field of test and measurement successfully awarded the contract to– is pleased to announce that nearly all standard load cells are now available for install strain gauges inside Deep Green, the latest tidal power plant fromvarious zone areas. Minesto, which is the largest marine energy company in the Nordics.The ATEX Directive 94/9/EC outlines the requirements suppliers must meet to As part of the rigorous development work undertaken by Minesto, HBM wasachieve compliance for their equipment and protective systems for use in hazardous able to play a key role in verifying how the plant behaved in the water andareas. It applies to both electrical and mechanical equipment and covers potentially how it measured the forces to which it was exposed.explosive areas below ground, on the surface and on offshore fixed facilities. Underthe ATEX regulations, hazardous areas are now divided into ‘zones’ relating to the Although relatively protected inside the power plant, the most importantlikelihood of an explosive atmosphere existing. Almost all standard load cells from issue was to ensure that the moist environment in no way compromised theHBM cover device groups I (for mining) and II (non mining) and are suitable for use measurement result but thanks to HBM’s installation and sizing technologyin categories 1, 2 and 3, corresponding to zones 0, 1, 2 ,20, 21 and 22. for offshore environments, this was successfully achieved.Tel: 0208 515 6000 Email: [email protected] Tel: 0208 515 6000 Email: [email protected] www.hbm.com Seton UK wins ECMOD awardAndrews celebrates 50 years as hire specialist Top players in the UK multi-channel retail sector gathered at the exclusiveAndrews Sykes this year celebrates 50 years in sector that has seen them grow Hurlingham Club in London earlier thisto become a dominant player in the hire of industrial equipment such as air-con, month for the eagerly anticipated Europeandehumidifiers, boilers and chillers, heaters and ventilation equipment. Catalogue & Mail Order Direct Commerce (ECMOD) Awards. Presented by Sky News anchor Dermot Murnaghan, the“Now firmly established as one of the UK’s leading specialist hire firms, we have much event recognised the hard work, flair and commitment of businesses in theto celebrate as we look back on five decades of sustained growth,” says Paul Wood – catalogue and multichannel retail sector. Seton UK, a leading manufacturer andManaging Director. “What started off as a humble heater and steam cleaner supplier distributor of health and safety and facilities management solutions, is proud toin Wolverhampton and developed into a multi-million pound, multi-national corporation have won the prestigious Outstanding Customer Service Award against toughthat has only been made possible by the dedicated endeavours of our staff.” Originally a competition.one-man operation that started in the mid 1960’s, the Andrews specialist hire businessnow has over 600 employees with depots in Western Europe and the Middle East. Excellent customer service has always been the corner stone of the Seton business, giving customers the positive buying experience they expect andEmail: [email protected] www.andrews-sykes.com deserve. Winning this award is a fantastic endorsement of Seton’s exceptional service and ongoing commitment to customers. www.seton.co.uk Improving Health and Safety VisionScope Technologies in the Workplace Ltd for all your Industrial InspectionMarken offer a range of solvent cleaning wipes standard and specials(made to order). The bespoke service was introduced to help improve As from the 1st July 2015, VisionScopeHealth and Safety standards for applications where loose solvent of Technologies and INSPECTION OPTICS LTD willcustomer choice can be substituted by using our pre-saturated wipes. A be merging together to provide multiple brandsgood range of wiper fabric, size and packaging is available. and own make Industrial Imaging devices. Endoscopes, Camera systems, Light Sources, Pipe Camera and MachinePopular choices; IPA, Acetone, MEK, Low Odour Solvents. Vision components.Our wipes are the solution to solvent storage issues, effective in reducing Combined we are agents for Heine Technoscopes GmbH, HIPP Endoskopiesolvent emissions for wiping applications, improving operator safety and GmbH, Wohler GmbH, IT Concepts, Endoscan Ltd, MC Medical Ltd andquality of finished product. Moritex. Additionally we offer second user equipment and provide service support for Medical Devices.Tel: 0114 2697107 Email: [email protected] Our main website is www.vst.org.uk and email [email protected] Additional websites: www.heinetechnoscopes.co.uk and www.hipp-borescopes.co.uk Telephone : 01223 440239 or 01935 88141410 PECM Issue 15

Instant datamanagement enablessmart grids to maximisepower distributionefficiencyRaimadelivers high-performance,always on databasetechnology for both in-memory database usageand persistent storagedevicesT here are multiple pressures make better use of available power. database technologies need to be on the power supply Smart grids are also attractive in married with automated metering and network. More people relation to renewable power sources, other supporting technologies. which are variable in output and are using it, established tend to lead to a complex network A state-of-the-art high-performance architecture, based on many small-to- database management system, suchcustomers are consuming ever medium power sources, rather than a as the Raima Database Manager few large power stations. (RDM), can be configured to preciselymore electricity, and the pressure to match the needs of any grid. Multiple A smart grid uses data collection databases can be embedded into thereduce carbon emissions from power and computer technologies to gather grid to provide local real-time control. information about consumption bygeneration is increasing. Part of the individual consumers, interpret it and RDM is an ACID-(atomicity, optimise operations to match the ever- consistency, isolation and durability)solution to this dilemma will lie in changing patterns of demand. compliant database management Electric utilities are transforming their system (DBMS). Its multi-coredeveloping smart grids that provide grids by improving and renewing processors can be distributed about the infrastructure, while simultaneously grid, yet work together to maximisebetter husbanding of the available adding the intelligent digital the use of available memory capacity. technology, which includes automatic Its speed of processing is almostpower – metering it more precisely, meter reading. instantaneous, because it uses on-chip data storage; however, it also instantlyreducing transmission losses and For instance, smart meters use transfers data to disk for secure long- continuous communications to provide term storage.encouraging more sustainable practices real-time monitoring, so that they can determine how demand from If smart grids are to achieve theirby consumers. A key characteristic of individual users varies over time – and full potential, efficient data handling predict future needs. Often the data is is a prerequisite. Raima’s RDM dataa smart grid is the efficient and timely transmitted as broadband over power management technology is proven in lines (BPL), although other systems many demanding fields, such as theuse of operational data to constantly use wireless technologies, such as control of nuclear facilities, subsea mesh networking. oil well management and worldwidematch supply to demand. telecommunications networks, and is The amount of data that needs to fast proving its worth in smart gridIn recent decades developing countries be collected is enormous and it has applications.have wanted to extend their electrical to be analysed instantly as well asdistribution networks to new population being stored for reference and reuse. www.raima.comcentres and industrial bases. In many Quite simply, this could not be donecases they have not been in a position manually, so high-performanceto increase their generating capacityquickly enough, so have looked todevelop ‘smart grids’, which make bestuse of the power available.The developed nations are also lookingto smart grids, although it is to meetgrowing demand from existing users.(The alternative is to add generatorsto the network, but capital outlayand increased emissions are hard tojustify.)Further, there is increasing concernabout global warming, and smart grids Issue 15 PECM 11

Editors ChoiceNew TC Model Electrical Ranget
500 - 2000kg/hr t
Compactt
Touch control screen t
8 - 160kg/hr Steam outputt
Full modulation feature 50-100% firing t
Modulating ouputt
Natural Gas, Light Oil, LPG and Bio Fuel t
Skid mountablet
Automatic facility option t
Steam in 3 minutest
>98% Efficiency * t
Automatic facility optiont
Steam in 3 minutest
Compact construction CVE Package Plantt
Lightweight, suitable for mezzanine floors t
compactt
Factory tested prior to dispatch to site t
Pre-pied, Pre-Wiredt
Dual fuel option t
Skid mounted t
Fully factory testedJunior & Universal Range t
Lightweightt
80 - 2000kg/hr t
Easily maintainedt
Natural Gas, Light Oil, LPG and Bio Fuelt
Automatic facility optiont
>98% Efficiency *t
Steam in 3 minutest
Compact constructiont
Lightweight, suitable for mezzanine floorst
Factory tested prior to dispatch to siteCERTUSS (UK) Limited Tel: 0121 327 5362Unit 45 Gravelly Industrial Park Fax: 0121 328 2934Tyburn Road [email protected] www.certuss.co.ukB24 8TG £3.5 Million Amazon order is largest Smallest cable gland meets ever for Stertil Dock products constantly changing market needsStertil Dock Products has won its largest ever order to supply Combilok Specialist German component supplier, Walter Logan, now offers thevehicle restraint systems for 14 Amazon sites throughout Europe. industry’s smallest cable gland, the PFLITSCH UNI Dicht cable gland system from PFLITSCH, the German industrial cable gland and cable routeingBefore securing the contract, Stertil Dock Products was asked to participate manufacturer.in exhaustive trials, in competition with other manufacturers, at Amazonsites in the UK, France and Germany. The trials were highly successful in Responding to demands for smallerproving the performance and reliability of the Combilok across a whole cable glands, the PFLITSCH UNIrange of lorries and vans including double deck trailers. Consequently, Dicht M4 cable gland has a mountingAmazon placed an order, with a contract value of £3.5 million, covering height of just 8.8mm (max) with athe supply and installation of more than 500 Combilok systems. connection thread length of 2.7mm.The Combilok was developed to reduce the risk of unintentional vehicle The PFLITSCH UNI Dicht cablemovement on loading bays and offers a ‘safety net’ by holding vehicles in gland is particularly suitable for use inone place until loading or unloading is completed. Also, the Stertil Combilok cable and pipeline routeing for sensorvehicle restraint system helps to ensure the safe loading and unloading systems and in projects where spaceof vehicles by eliminating the common problem of poor communication is a premium. It offers a compact construction with maximum sealing range,between drivers and distribution personnel in loading bays. from 0.9 to 1.6mm, ensuring it can be used with a wide variety of cable types. Offering protection against dust ingress the PFLITSCH UNI Dicht M4 cable gland is certified to IP68 and up to 10 bar / one hour. Additionally, an O-ring in the gland provides a seal to the enclosure wall. A wide operating temperature of -40 to +130C̊ makes the cable gland suitable for use in harsh and extreme environments. This latest cable gland is offered with brass nickel plating, and a stainless steel version is available on request. Please contact: Tel: 0044 (0)208 446 0161 Fax:0044 (0)208 445 5137 Email: [email protected] www.walterlogan.co.uk Stertil Dock Products Tel: 0870 770 0471 www.stertil.co.uk12 PECM Issue 15

DJJ Precision Engineering Ltd Specialists in Stainless Steel ProductionSpecialist in Stainless Steel, Nimonics, Brass, Duplex, Aluminium, Exotics, Super Alloys, Titanium, Inconel, Copper, Hastelloy, Bronze, Advanced Engineering Plastics, most Ferrous and None Ferrous materials and many more... 14 Pontyfelin Ave Ind Estate Pontypool, South Wales, NP4 0DQ, UK 0044 (0)1495 760561 [email protected] www.djjengineering.com

Tsubakimoto delivers power & performance to the paper industry As one of the world’s premier manufacturers of power transmission products, Tsubakimoto has developed a wide range of reliable products, specifically designed to meet the tough working environment of the paper and pulp industry.Tsubaki invests A s one of the The operating environment can be matched with aheavily in R&D world’s premier within a typical paper drive chain sprocket thatand offers a manufacturers manufacturing facility has a deep hardened layerwide range is often laden with dust over the entire componentof products of power that can stick to drive that provides excellentwhich have been chains and block the wear resistance for a longdesigned for transmission products, conventional lubrication service life.all types of path. This can causeindustries and Tsubakimoto has increased levels of wear Derek Mack, Sales Directorenvironments. in the drive chains, which for Tsubaki UK, concludes:This means developed a wide range will need more frequent “Tsubaki invests heavilythat for most maintenance, increasing in R&D and offers a wideapplications, of reliable products, costs and possibly reducing range of products whicheven traditional productivity and efficiency. have been designed forhard wearing specifically designed to all types of industries andones, we are The operating environments. This meansable to specify a meet the tough working environment within that for most applications,solution which a typical paper even traditional hardwill last many environment of the paper manufacturing facility wearing ones, we are abletimes longer is often laden with to specify a solution whichthan a basic and pulp industry. To help dust that can stick will last many times longerchain. to drive chains and than a basic chain. We will those involved in operating block the conduct a site visit prior conventional to specification to make and maintaining the lubrication path sure that we understand the unique requirements of many processes of paper Tsubaki has developed every job and can offer an a range of products, accurate estimate for our manufacture achieve their such as Lambda chain, chain’s TCO.” which is a lube-free chain performance and efficiency with oil impregnated The latest Paper Industry sintered bushes that brochure is available goals, Tsubaki has retain lubricant, thereby from the Tsubaki website, negating the need for http://goo.gl/WuxUM4 released a comprehensive external lubrication and or to find out more about extends the wear-life of Tsubaki chain, contact the product brochure, which is chain dramatically. This Tsubaki Europe Sales team either by phone available on its website. +31 (0)78 6204000. From beginning to end, the paper manufacturing process involves the continuous movement of materials from the original woodchip to the finished paper roll and each process can benefit from the expertise of Tsubaki’s design engineers. From drive chain and sprockets to couplings and reduction gearboxes, Tsubaki can deliver a wide range of products that will reduce the total cost of ownership (TCO) and improve productivity and profitability.

Editors Choice QUOTE PECMJL15 FOR A 10% DISCOUNTDerbyshire and Sons are a family run, precision Ecotile interlocking PVC floorengineering company known nationally for tiles are a heavy-duty flooringquality service at competitive prices. Trading solution with a proven trackfor over 35 years, Our commitment to premium record in many of the UK’squality & service is demonstrated by our full premier manufacturingISO9001 accreditation. companies.In addition to general precision machining, our • Fast installation: minimalareas of expertise include the production of downtimeflanges, screwed stainless steel pipe fittings,block tees for the Petrochemical / Turbine & • Durable and easy to maintainAutomobile Industries as well as one off bespoke – 10 year guaranteework to your own requirements. • Made in the UKOur services are extensive and include:- • Copes easily with forkliftTurning – Conventional methods and also trafficCNC Turning up to 6ft in Diameter. • Oil and chemical resistantAdvanced CNC turning - 5 Axis includingpower tooling; specialising in exotics metals. • Anti-slip and anti-fatigueBoring, Milling & Drilling – Conventional and • Full quality ratings including:CNC. Boring up to 1 Ton. ISO9001 / 14001, CE Mark, BFI S1 Fire Rating and the R10Tel:- 0151 423 1478 Or email anti-slip [email protected] formore information. Or why not visit our website:- Telephone 01582 788 232www.derbyshiresengineering.co.uk or email enquiries@ecotileflooring.comFree Light in a Pipe Quality products and excellent service,100,000 of our LED lights are installed in factories, Strong performance.warehouses, train stations, car parks and 12 ofthe UK’s busiest shopping centres with £2 million We provide a full range of rugged & reliable measurement sensors,annual electric and 30% carbon savings earning instrumentation, pumps, drive couplings and hydraulic components tous a Lux Award. suit the needs of even the most demanding of industrial applications.Sky Tunnel® daylight technology helps SaveCash & Carbon® plus natural light has proven q
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Process Measurement Sensors• Emergency lighting Specialist suppliers UK Flowtechnik to Large Industry• Advanced lighting and building controls Contact us today on 0800 433 4770 orThe A+ Group offers power, lighting, water, waste and ecobuild products. Email: sales@ukflowtechnik.com Discover more at www.ukflowtechnik.comCall 01202 470133, email [email protected] or look atwww.the-agroup.co.uk.DP Seals success withpatentPoole based seal and moulding specialist, DPSeals, have now been granted a UK patent fortheir unique tooling and moulding system.Originally developed by the company’sfounder, David Piper, almost 40 years ago, the basic concept was for a mouldingtool incorporating locating plates that not only allowed free and easy movementduring assembly and disassembly, but could also be locked into position to ensurethe closed cavities remained closed and so drastically reduced any potential forflashing.The combination of practicality and ingenuity immediately gave DP Seals anadvantage over their competitors and enabled it to produce small, close tolerance,flashless mouldings that no-one else could match.The system has been an integral part of its production process ever since and nowthe ownership of the idea has been signed, sealed and delivered with the grantingof UK patent GB 2 513 012.Tel: 01202 674671 Email: [email protected] Issue 15 PECM 15

The Utility Forum is an energy conservation consultancy based on the Fylde coast thatlooks in to ways to not only reduce the costs to your energy but also how you use it.A family run business that has a combined experience of over 80 years in the energy industry.Our MD, Chris Holdsworth was one of the few volunteers to take part in the Consultation process withthe DECC and the Energy Institute for ESOS (Energy Savings Opportunity Scheme), the UK Governmentsresponse to the EU Energy Efficiency Directive. Chris was one of the first Lead Assessors for thisprogramme.The Utility Forum has done over 300 Carbon Trust Energy Audits which were mainly carried out by the MD,personally.The Utility Forum has been working with M.A.S (The Manufacturing Advisory Service) for over 250 clientsand has pre-agreed funding to help with the consultancy costs involved to help with the impact ofanything relating to energy usages in manufacturing and Engineering.The Utility Forum can help any business of any size deal with their energy requirements and specialises inhelping larger organisations reduce both their costs and usages.Services we offer – of the larger clients in the UK, Redrow Homes, fees. Bibby Distribution allows for us to secure very At Mandate Utilities we have over 20 yearst
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Vodafone, 02, Orange and T-Mobile.you in areas unknown to yourself. Help you to understand how the current rangeNo hidden/additional fees – what we offer is Mandate Utilities is the first telecoms for of applications can enhance your business.what you pay. business provider to literally charge you for Arrange number porting for administrationSignificant buying power – working with some what you use instead of adding all the hidden ease.www.theutilityforum.co.uk

Call 01253 851 818 Email [email protected] or visit our websiteWe are registered members of – From right to left - From right to left -EMA – Energy Managers Association Gavin Hall - Head of Sales/ Business Tanya Hyde Gm -North East Initiative Development Chris Holdsworth MDAnd our MD, Chris Holdsworth BSc is a Sarah Walton - Principal Analyst Sarah Walton - Principal Analystmember of - Chris HoldsworthInstitute of Directors Lynette Toon - DataAdministration OfficerFellow of the Energy InstituteCarbon Trust AccreditedA Chartered EngineerRegistered Lead Assessor for ESOSMember of CIBSERPEC – Register of Professional EnergyConsultantThe Team –Chris Holdsworth – MD/OwnerTanya Hyde – General ManagerSarah Walton – Principal AnalystGavin Hall – Head of Sales/BusinessDevelopmentLynette Toon – Analyst(&.4

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it has turned out to be?!Recently the EU decided to enforce one ofits main directives across the entire grid,from Spain through to the UK. Article 8 of theEU Energy Efficiency Directive states thatindividual member states across the domainare required to enforce movements towardsreducing their impact on the environment, lookin to ways they can reduce their impact on itand investigate modern technologies to see ifthey can also reduce what they use.Modern organisations have been mainly experts and gain a clearer knowledge of your seamlessly helps you monitor ALL your energyfocused on how to reduce their costs instead own energy usages, in ways you have more usages, including fuel, for ESOS compliance. Itof looking at reducing what they use and as than likely looked at but never engaged. has been designed to fit in to any organisationmost reduction applications have taken too Companies have been making vast savings with minimal effort and comes with a fulllong to gain the benefits outlined from surveys, on their energy usages by using state of the back-up/support service. It has some of thethey have often been shelved in many cases. art technologies like converting to LED or highest encryption security protection to make updating their EMS (Energy Management sure your information is safe and secure and isThe Energy Saving Opportunity Scheme System) to a more modern version. continually updated with “opportunities” that(ESOS) has been translated the wrong way, it can help your company reduce both its costsshould be taken that you have an opportunity With this in mind The Utility Forum haveto look at energy through the eyes of industry developed a software called GEMS, that and usages from the ground up.www.theutilityforum.co.uk

Rugged Touch Screen Steatite’sComputer Reduces Cost specialised systemsThrough Modular Design are equipped to tackle the most critical tasks and roles in some of the world’s toughest working environmentsH uman Machine Interfaces pause in operational use. The rugged systems are equipped to tackle the (HMI) play a vital role and reliable structure allows users most critical tasks and roles in some within the production and to complete tasks manually with the of the world’s toughest working optional transferrable PC module environments through functional manufacturing sectors, through a plug-in design; creating a designs, responsive software and constantly running schedule. superior performance.these factory control applications are Through our expertise To learn more about how Steatiteoften installed on outdated hardware we custom build can assist you with your production industrial computer and manufacturing needs contact ourthat can be bulky and lacking the systems from the technical team on +44 (0)1527 512400 initial concept design or visit www.steatite.co.uk/pecmopportunity to upgrade or expand with through to the final product. This two part design helpstechnological advances - which can to simplify servicing and Through our expertise we custom buildlead to an expensive investment for industrial computer systems from the maintenance, meaning these initial concept design through to the tasks can now be carriedsuch demanding industry sectors. final product. Steatite’s specialised out without the need forSteatite are exclusively offering the specialist training or a pauseCincoze panel PC, which employs in operational use.a modular design that helps tominimise the total cost of ownershipwithin the control and interactivesystem technology. Through a unique‘configure by design’ build, thecomputing hardware or touch screencomponents can be upgraded andexpanded separately as your needsand requirements change. This twopart design helps to simplify servicingand maintenance, meaning thesetasks can now be carried out withoutthe need for specialist training or a STEATITE Limited Ravensbank Business Park, Acanthus Road, Redditch, Worcestershire B98 9EXTelephone: +44 (0)1527 512400 • Email: [email protected] • Web: www.steatite.co.uk/pecm18 PECM ssue 15



I nstitute of Solar Technology (IST) is an academic and research- oriented & Entrepreneurship Development institute underGATE Trust that has worked in partnershipwith companies, organizations, communitydevelopment associations and sociologicalresearch institutes. We offer professionalsolar training with a real time practicelaboratory and hands-on training on solarPV technologies. We have experiencedinstructors trained. Our professional solarPV training is tailored for your needs, mayit be for solar technicians, solar engineers,senior solar plant architects, solar sales orbusiness managers.Institute of Solar TechnologyAn established brand name in industrythrough quality and efficient trainingand education services Variety of solartraining under one roof has taken the leadto contribute to a strong and sustainablethrust for solar training.IST offer solar training course – • Hands-on Diploma in Photovoltaic System Design and Installation • Advance Certificate in Photovoltaic System Installation • Advance Certificate in Photovoltaic Business Management • Advance Certificate in Solar Rooftop Installer • Advance Certificate in Solar Street Light Installer • Advanced Certificate in Solar Water Pump Installer • Certificate in Basic of PV Solar System • Workshop On Solar Power Technology • Vocational Training Program on PV Solar Technology for B.E/B.Tech studentsAnd moreFor admission and New Branch Affiliation:Visit us: www.istindia.orgEmail us: [email protected] PECM ssue 15



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The Brand Of ChoiceFor Vibration ControlManufacturing expertise for over 60 yearsThe History….For over 60 years, TICO has been the brand of choice for vibration control. From our Manufacturing site inCornwall, we have been supplying elastomeric Vibration attenuation solutions across the world. With anon-site laboratory, technical unit and research team, we have been offering unparalleled service and tailoredengineered solutions to all aspects of industry.TICO is the generic brand name for a range ofproducts that are used for a variety ofpurposes including: Machinery Mounting,Vibration Attenuation, Plant Levelling, PipeSupports, Movement Joints, Low FrictionSupports and Impact Absorption. With a widerange of off-the-shelf and bespokemanufactured solutions, all backed withtechnical excellence and an assurance ofquality, we are able to make recommendationson all vibration and related problems.The Science ….TICO is a rubber bonded cork compound that is vulcanised to create three dimensional bonds. Thisprocedure delivers greater strength + toughness, compared to glued rubber crumb products or air filledelastomers and also gives a higher resistance to break up during the life of the products.The rubber bonded cork compound has a key benefit, our pure elastomers having a high compression setthat occurs within its own volume. This means the product under compression maintains its foot print anddoes not creep or bulge outside of the load area.TICO is only manufactured in the UK at the Tiflex facility,where it has a quality controlled production process and endof line testing. This testing verifies performance againstproduct data sheets, giving confidence of product reliabilityand consistency. Over 60 years of reliability in many diverseapplications, validates the TICO brand name, heritage andrecognition all over the world.TICO products are designed to operate in harsh environmentswith its closed cell structure, providing resistance toabsorption of oils & water. The product maintains it’s originalperformance structure through a wide temperature range,beyond that of many competitive materials.With a wide range of off-the-shelfand bespoke manufactured solutionsFor more information pleasecontact Tiflex LimitedEmail: tico@tiflex.co.ukTel: +44 (0) 1579 320808Web: www.tiflex.co.uk/tico/ Issue 15 PECM 23

Challenging thinkingThe independent design and engineering groupArup sees benefit in backing research that challengesconventional thinking and achieves broad impactacross society.Arup’s global business is in three main Arup organises its research activities The ‘different thinking’ approachareas – infrastructure, building and through a directorate called the Arup by Professor Miles, one of theconsulting – and it sees research as University, Professor Watson said. joint research chairs, has led thean essential ingredient of business “We have a group that looks over the company to collaborate with a largedevelopment in all three. “But unlike horizon at the emerging challenges: Japanese partner and become jointother organisations in these areas, climate change was one, but we see it owners of electric buses and theirwe don’t have any physical research as a current challenge now. There is a associated wireless battery charginglaboratories ourselves,” said Professor requirement to introduce new research infrastructure. This novel businessJeremy Watson CBE FREng – Director programmes and to work effectively approach has addressed the commonof Global Research, Arup Group Ltd. with research councils and universities. problem of how to deliver promising“We have always worked closely with Also, there is a requirement to and unconventional solutions inthe Academy through long- term maintain ‘skills networks’ that convert a real commercial environment.partnerships, and have strategic research outcomes into guidance Professor Watson said “We think ofmemoranda of understanding with notes or engagement with real client it as a demonstrator and it’s veryuniversities around the world. The projects.” exciting. The business opportunity isbenefit from the university connection, in designing the infrastructure systemshe said, is easy access to talent and The research chairs that Arup funds for this type of installation and this isskills. The academics also value us in jointly with the Royal Academy of also a practical way to test the conceptintroducing research projects with real Engineering are ’the jewels in the crown‘ to justify the research”.impact.” in a research network that includes up to 150 research projects. “You can place Measuring the impactThe impact of research our research activities in the category Professor John Miles, whose ResearchThe engineering design consultancy of ‘serendipitous research’. This is not Chair at Cambridge University is jointlybehind some of the world’s most blue skies but is driven by academics’ funded by the Academy and Arup’sstriking structures, including the own agendas, where we’d be looking engineering design group, said thatSydney Opera House and the ‘Birds’ for emerging technologies that might the ties between himself, Arup andNest’ Beijing Olympic Stadium, Arup be applicable to our own business. The other Academy Chairs are strong, andhas built its reputation by challenging other side is trying to shift their focus the business ventures that are takingconvention. This applies to its portfolio on some real problems that need to be on some of his work have significantof research funding as much as to its answered. Arup’s joint appointments with Arup involvement. More widely, theremanagement of engineering projects. the Academy operate on both aspects, are constant interchanges of humanArup’s co-sponsorship of Royal but the questions they are answering resources between Arup and all itsAcademy of Engineering’s research are perhaps more fundamental, and academic partners.chairs indicates the breadth of the have wider society benefits. That’s angroup’s interests and its willingness to important aspect for Arup”, Professor Professor Watson said that thedo things differently. Watson said. company’s structure is based on24 PECM ssue 15

Arup, The Ove Arup Foundation and the RoyalAcademy of Engineering’s jointly funded researchposts are, in different areas, challengingconventions (Past and present):Professor John Miles, Professor of Transitional EnergyStrategies at University of Cambridge, aims to plot apathway towards sustainable transport – a real lifeexample being the trial of electric buses in Milton KeynesProfessor Luke Bisby, currently a Research Chairat Edinburgh University, is conducting fundamentalresearch that challenges long-held views of how firesand extremely high temperatures impact on structures ofall kindsDr Graham Spinardi, Senior Research Fellow atEdinburgh University is researching ways to integratetechnical and social aspects of fire safety engineeringand expertiseemployee ownership rather than and this is kind of impact that Arup managed by the Academy, that hasexternal shareholders. Therefore, it wants. “We want to be engaged with supported 6 Visiting Professors inenables the company to take a broader policy makers in work that’s relevant Building Engineering Physics. Arupview of the research investments to the UK’s position globally and our has also been serving on national andwhich extend into other areas too. “For economic strength and the well-being international research councils. “We’veexample, the HS1 Channel Tunnel Rail of the population,” Professor Watson been involved with the Academy sinceLink was an eight-year commitment said. It is not entirely altruistic: its inception. It’s a highly regardedand I don’t think we saw any fees for “Areas such as assisted living research organisation and it’s helpful to us asat least half that time. The aim of the motivate us. There isn’t a business a company to be seen to be workingwork that the company does, is not there yet, but we think there will be closely with it”, Professor Watson said.just focussed on the time immediately and we’re willing to put in work tobefore delivery; it’s also about what develop a position and gain some “Royal Academy ofyou need to know to satisfactorily research-based information.” Engineering’s researchdeliver the project“. schemes are encouraging the “The challenging and issue-driven research community to doThis approach is not entirely due to research done by the Royal Academy high quality research, whichArup’s unique corporate structure: of Engineering research chairs isthe group has done an analysis with something that Arup wants to benefits usImperial College and found that those pursue more”, said Professor directly through tangiblewhich take a longer view have greatest Watson . “We’d expect to doimpact in terms of revenues. “Business more of it in a targeted way with outcomes”quite reasonably thinks it wants a the universities that we havesolution tomorrow and wants it to be memoranda of understanding Professor Jeremy Watsoninnovative, but actually there’s only with. We should work withincremental work you can do that way,” key universities, placing staffsaid Professor Watson. “It’s important members into the universitiesto build this into relationships and and then placing them back intoresearch structures so that even in our business.”hard times we don’t stop doing theright things.” Arup is involved in many aspects of the Academy’s work: The Ove ArupThe ‘right things’ are not limited Foundation has supported 10 Visitingto direct benefit to Arup. Research Teaching Fellows who focussed oncollaborations with the Academy, tackle issues around the Built Environmentbroad economic and societal issues and were the initiators of a consortium, Issue 15 PECM 25

Air, Gas & Odour ControlACE presents Wireless gas detectionNEWTONLINE - a brand solutions: OLDHAMnew family of industrial gas launches the MX 40springs controllerMotion control products manufacturer, ACE Controls After introducing the wireless BM 25 work siteInternational has introduced a brand new family of gas system, Oldham is expanding its product rangesprings that will now become their standard product range and today introduces the new MX 40 gas detectionsolution for customers. controller.Called NEWTONLINE, ACE has managed to integrate several The MX 40 controller was designed to centralize thenotable innovations in this new generation of industrial gas springs information transmitted by the BM 25 over a wirelessto give customers a higher quality product offering improved network and can display up to 32 measurements in real time. When a BM 25performance and lifespan. signals an alarm, the MX 40 also goes into alarm mode and can, for example, control internal relays and order other monitors to transmit the alarm as well.NEWTONLINE gas springs are available in cylinder sizes from 15 to 40 mmwith strokes from 20 to 1000 mm and force ranges from 40 to 5000 N. The MX 40 can connect to up to 16 BM 25 units on the same wireless network and up to 16 different networks can be used independently.Email: [email protected] www.ace-controls.co.uk For more information on the BM 25 Wireless, please visit the pages MX 40 & BM 25 on our web site www.oldhamgas.com.New BOGE guide explains Airdri Quest™ and Quazar™how to keep compressed - inclusive washroomair supply clean and pure provision for process plantsBOGE Compressors has released a new guide that The Airdri Quest™ and Quazar™ are the latestexplains how to ensure compressed air supply is models in Airdri’s Q range of hand dryers. Thesekept clean, pure and free of contaminants. With so models uphold the inclusive qualities identifiablemany potential contaminants placing the purity of with all Airdri products – reliability, lifespan, designcompressed air and quality of manufactured products at risk, this new guide is innovation, energy efficiency and low noise output -an essential tool for compressed air system operators. ensuring that Airdri can provide a hand dryer to meet the needs of busy process plants.The free guide outlines in depth the variety of threats that impact on compressedair systems. These threats include airborne particles such as dust and pollen, Designed to comply with the standards set out by both the Quiet Markwater vapour, which naturally occurs in air, and compressor oil that is emitted and the American Disability Act, the Airdri Quazar™ is an ultra-slim dryeras an oil vapour. It also discusses the consequences of ignoring or failing to deal with a stunning design. The stylish, wall-mounted hand dryer comes in awith potential contaminants, such as the contamination of end products. This variety of cover finishes – black, white, chrome or brushed stainless steel.creates health risks and can result in reduced productivity and profitability when Its contemporary design will suit any modern washroom environment,product batches must be discarded and is especially true in the highly regulated whilst being perfect for facilities limited in space.and competitive food and beverage industry. Email: [email protected] www.airdri.comGet the free white paper today by visiting www.boge.co.uk26 PECM Issue 15

Maintenance is virtuallyeliminated due to thedual-wall, high-densityplastic body. Tough Fans from VAF Air controlling odours and dust in confined work spacesW hen working in confined are still the biggest cause of lost man They simply last longer and offer space it is imperative work days. greater value for money and because that the air is changed to of that come with an industry beating provide a safe working Maintenance is virtually eliminated due 10 year warranty on the body.environment. Miniveyor Air VAF series to the dual-wall, high-density plasticportable fans can move contaminated body. The polythene casing is resistant The VAF series range has recentlyair out of a building or work area. They to the normal knocks and bangs of been extended with the introductioneffectively exhaust fumes, dust and everyday use that can stop a sheet of the VAF-200C Canister blower. Thesmells, ventilate confined spaces, and metal fan as metal fans often dent compact VAF-200C is ideal for confinedincrease the flow of fresh air. which can obstruct the fan blade. space ventilation and fume extraction and benefits from a, simple to attach,Weighing up to 40% less than The Miniveyor Air units easily withstand Duct Canister that neatly clips ontoconventional metal skinned fans of blows without denting, giving less the fan body and houses 7.5 metres ofcomparable size, in terms of movement downtime and greater productivity. The flexible duct. It is great for contractorsfrom site to site and indeed on site, casing is corrosion free and unlike its that have limited storage space inthis is a huge advantage. Especially metal counterparts will not rust when service vehicles and can be carried towhen you consider that back problems they are dented, chipped or scratched. the job site with ease. Visit us online at www.vaf-air.com Issue 15 PECM 27

Loss Prevention Bulletin sleaTaferhnteyt lfweraoiatdmhninyaabgccoccsdeoidsyuesrcnctootesna.ocAfe4rcn0naeiysnedevasawrtluuiatadrhcbiehslesaivfireenetsoypo.fruolerccsesesosfnosr Companywide licences available tothis valuable resource www.icheme.org/lpb ADVANCING [email protected] CHEMICAL ENGINEERING 0951_14 WORLDWIDEIChemE safetypublicationsT he Institution of Chemical organisation to have access to this vital Engineers (IChemE) offers a resource. Visit www.icheme.org/lpb range of safety publications for more information. relevant to the engineering Safety books We offer a wealthand process industries. of safety books. We have just launchedLoss Prevention Bulletin (LPB) a new edition of to help the reader understand safe Our Loss Prevention one of our best operating practices and procedures Bulletin is the selling books, within processing plants. Now available leading source of HAZOP Guide to electronically, the series comprises case studies in Best Practice, titles such as Hazards of Water, Hazards process safety in Third edition. of Electricity, Confined Space Entry, the industry and The new edition Safe Furnace and Boiler Firing, and has an archive brings additional many more. For the full list visit our spanning over 40 experience to online shop. The series is available to years of lessons buy individually, as a full set, or as a learnt from help you deliver optimum safety and company-wide annual licence. accidents. efficiency of performance. www.icheme.org/hazopguide For the full collection of our safety booksIt was first published in response to the visit www.icheme.org/shopdisastrous explosion at Flixborough in We also market the BP Process Safety For enquiries contact [email protected] when a need was established for Series which is a collection of 17 booksthe process industries to be able to share produced by us, in collaboration withinformation on accidents in the hope that BP. It demonstrates both organisations’a lesson shared is a lesson learnt. ongoing commitment to process safety and best practice through theLPB is offered on an individual dissemination of lessons learnt fromsubscription basis, or as a site recurring accidents. It is intendedlicence allowing multiple users at one28 PECM Issue 15

Boilers & Maintenance Gas Process BurnersFD-C high turndown oven/ FD-E low cost high turndown Lanemark gas burner systems offer users reliable, high efficiency, process heating solutions.dryer air heating burners. oven/dryer air heating burners. FD Series Packaged Oven/Dryer Burners FD-C (GA) modulating gas + DSpecifically designed for process air heating applications in convection ovens and dryers air process air heating burners. DHigh turndown/short flame lengths providing accurate processMidco HMA high efficiency, TX high efficiency small diameter temperature controlhigh turndown, air replacement immersion tube tank heating DHigh efficiency gas + air modulation, gas only modulation and simpleor “make-up” air heating burners. systems. high/low control options Lanemark Combustion Engineering Limited D
Heat Input Range: 9 kW – 880 kWLanemark House, Whitacre Road, Nuneaton, Warwickshire CV11 6BW United Kingdom TX/TRX Series Gas Fired Process Tank Heating Systems Tel: +44 (0) 24 7635 2000 Fax: +44 (0) 24 7634 1166 E-mail: [email protected] www.lanemark.com DHigh efficiency (80%+) heating of all types of spray and dip process tanks DCompact high efficiency small diameter immersion tube heat exchangers occupying minimum tank space DAccurate performance modelling using Lanemark TxCalc design software DHeat Input Range: 15 kW (1½\") – 730 kW (6\") Midco DB Series Air Replacement or “Make-Up” Air Heating Burners DDirect fired, high efficiency burner systems, for high volume air heating applications such as paint spray booths, ovens and dryers. DSupplied either as Midco burner heads for OEM system integration or as complete packaged systems including modulating gas valve trains and controls DWide range of firing rates to suit alternative temperature rise and air velocity system requirements DDbCalc system design software COMBUSTION ENGINEERING Large Scale Rotational Moulding New pressurised Installation benefits from Lanemark deaerator system cuts boilerhouse Process Heating Technology energy and operating costsThe heating efficiency of process gas burnersystems from Lanemark Combustion Engineering, Spirax Sarco has launched a pressurised deaerator system that reducesand the company’s ability to work closely with the dissolved oxygen content of boiler feedwater to virtually nil withoutcustomers to meet specific applications needs, chemical treatment. This enables steam plant operators to reduce energyhave been clearly demonstrated through a consumption, save water treatment costs, increase productivity and meetmajor project undertaken by rotational moulding BG01 “Guidance on Safe Operation of Boilers”.specialists, Rotomech Engineering. BG01 gives guidance on complying with the recommended guideline BSLanemark FD (forced draught) burners have EN 12953 Part 10 which deals with water quality and defines maximumbeen specified as a key element in a large-scale ‘rock-and-roll’ system levels of impurities including dissolved oxygen. A pressurised deaerator is– the latest facility to become operational at Etills, who produce a wide one way to meet the requirements of BS EN 12953 Part 10.range of water storage tanks, vessels and containers for both public andtrade markets across Europe and are well known for the ‘Ecosure’ brand. www.spiraxsarco.comEmail: [email protected] www.lanemark.comWTS Benefits from Fulton electric boiler provides aEconomic Upturn cure for Prysmian GroupWellman Thermal Services, are benefiting from the Bristol-based heat transfer specialist Fulton hasproductivity increase in the manufacturing sector supplied Prysmian Group’s Bishopstoke facilityparticularly in the Aerospace, Automotive and Steel a skid-mounted electric boiler and ancillaries,industries. Although the economy would seem to have steam from which is being used to cure theturned a corner and is now heading in the right direction, it insulation applied to the company’s electrichas not yet demonstrated sufficient growth or stability for cables.manufacturers to invest in new capital plant. Therefore theadditional production demands must be met by existing Commenting on the process, Prysmian’s Nicolas Chevaux explains thatplant. curing is used to strengthen and increase the heat resistance of the insulation. “Without the process, the insulation would have a lowerRunning and maintaining industrial heating plant, in some cases as much as temperature resistance and hence the cable would have a lower currentsixty years old, requires a lot of time and effort especially given new demands rating.”for increased production, reduced energy consumption, etc. With a pedigreestretching back 110 years and incorporating some of the UK’s best known furnace Following manufacture, batches of up to 16 drums are placed into abuilders, together with an extensive archive and spares inventory, Wellman’s container where steam from Fulton’s EP100 Electropack boiler system isFurnace Team are perfectly placed to meet the needs of manufacturing industry injected to start a curing process that can take up to twelve hours at 80°C.in keeping its furnace equipment, regardless of manufacturer, operating at peakperformance. Email: uk.sales.offi[email protected] www.fulton.co.ukTel: 0121 543 0000 www.wellman-group.com Issue 15 PECM 29

Cables Statoil’s Gullfaks subsea compression station powered by Nexans umbilicals Nexans’ power umbilicals will power two subsea compressors at the Gullfaks field off the coast of Norway. The Statoil operated Gullfaks gas field in the Norwegian Sea will rely on Nexans’ innovative power umbilicals combining power, fiber-optic and hydraulic lines in a single cross section. The cables were successfully handed over to Statoil this month. The subsea gas compression station will be installed on the seafloor at the Gullfaks Sør satellite field, 15 km from the Gullfaks C platform. It will increase total gas extraction by 22 million barrels. The cables will power two five- megawatt gas compressors at a depth of 135 metres. The 650 tonne station will be housed in a 420 tonne protective structure, managing a flow rate of 10 million cubic metres per day. Subsea compression is used when reservoir pressure falls below a critical level, reducing gas production. By compressing the gas on the seafloor, pressure in the pipelines is increased. Gas flows faster and allowing more to be extracted from the field. Subsea compression increases production, as well as the lifetime of the field. The Gullfaks compression station will be in operation later this year. Email: [email protected] www.nexans.co.ukFischer Connectorssponsors young sportstalentFischer Connectors is proud to continue itssponsorship of the young Swiss GP3 racing driver,Mathéo Tuscher.F ischer Connectors, a The company confirms its continued facilities in St-Prex. Fischer Connectors worldwide leader in high sponsorship of the young Swiss GP3 has a long history of encouraging performance circular racing driver, Mathéo Tuscher, who innovation and sponsoring young talent ranked seventh in the GP3 Series World in many fields, including car racing connectors, shares Championships in 2014, was runner and sailing. Its connectors and cable up in the FIA Formula 2 Championship, assembly solutions are known for theira passion for sport, particularly and won the prestigious AutoSport precision, ruggedness and reliability in Rookie of the Year Award in 2012. The harsh environments.motorsports where performance really talented 18 year old will race in the GP3 Series World Championship in For more information:matters. Barcelona, Spain from 8-10 May. This www.fischerconnectors.com/ event will attract young talent and automotive dedicated audiences from around the world. Fischer Connectors is keen to www.matheo-tuscher.ch continue helping young people reach high levels of achievement. www.gp3series.com Mathéo hails from Noville, near Lake Geneva in Switzerland, close to Fischer Connectors’ global headquarters and primary design and manufacturing30 PECM Issue 15



Calibration SolutionsIsotech’s New 4000 Range All-new 20-channel temperature loggerThe company has updated nine of its most popularcalibrators to bring new styling and updated features. DATAPAQ TP3 for heat treatment, paint-curing, and ceramicsEach model is available in three different versions processes.from a cost effective heat source to fully featureddevices which include a three channel temperature The new DATAPAQ TP3 data logger provides more measurementindicator, temperature logging and Ethernet interface. channels, connectivity options, and ease of use for profiling and surveying in high-temperature heat treatment applications. With a ±0.3 °C (0.5 °F)This new “4000 Range” spans -45 to 1200°C with accuracy, the all-new logger surpasses the most stringent requirements.models that can be used as Dry Blocks or Stirred Liquid Baths with options for “We have worked towards this exciting launch for two years,” states Elie Elinfrared thermometers, surface sensors and even to operate ITS-90 Fixed Point Choueiry, Furnace and Kiln Product Manager at Datapaq Ltd., Cambridge,Cells. UK. “Compared to our previous, successful heat treatment solution TPAQ21, the new DATAPAQ TP3 provides even more detailed insight into“Our customers, who range from the worlds’ leading National Laboratories to high-temperature processes. It is more resilient and includes numeroussite engineers have long valued the accuracy and quality of our equipment. new features, such as full connectivity including Bluetooth, fully certifiedThis new range is a response from customers demanding modern styling and TUS capability for AMS 2750E and CQI-9, integrated correction andmore features such as more input channels, advanced logging and an Ethernet calibration functions, and flexible charging with multiple battery options.”interface. We are proud to meet this demand in a new lighter and strongerrugged case.” The new series comprises 20- and 10-channel loggersEmail: [email protected] www.isotech.co.uk that store up to 3.6 million data points. One loggerIntertek, leading quality solutions provider to industries worldwide, has can perform up to tenlaunched a hi-tech tank calibration service in the UK offering highly measurement runs beforeaccurate calibration data to customers across Europe, complementing the data download. Thermalcompany’s existing services for the oil and gas industry. and ingress protectionThis new service combines years of tank calibration experience with the have been enhanced tolatest available software to enable Intertek to provide highly accurate ensure optimal performancetank and sphere calibrations, using the latest laser theodolites and laser in extreme applications,scanners. The new system also makes available tank settlement, tilt check such as vacuum brazing,and tank shell out-of-roundness surveys. These hi-tech surveys produce aluminum solution reheat, and water or gas quench. The DATAPAQ TP3highly accurate data which is important to identify the common ‘tank shell logger is being released along with new, durable thermal barriers for useout of roundness’ problem which can affect floating roofs, by impeding with the industry-specific temperature profiling systems from Datapaq:their vertical motion. Furnace Tracker® for metal-working, Kiln Tracker® for ceramics, and Oven Tracker® AutoPaq® for premium paint cure processes in the automotive www.intertek.com/uk OEM assembly market. Each profiling solution includes Insight™ analysis software and thermocouples tailored to the application. Email: stephan.wilke@fluke.com www.datapaq.comRaimo Ahola, Beamex Group’slong-standing CEO, will retireon the 31st of July 2015T he Board of Directors smooth transfer of CEO’s duties to the KWH Group. “Beamex’s Board of of Beamex announced a successor. Even if Raimo leaves Directors is very pleased that Jan- today that Raimo Ahola, Beamex and steps down from Henrik accepted the offer to become operative business management the new CEO of Beamex. Jan-Henrik Beamex Group’s long- positions, he plans to remain active in already has a strong track record with business in other roles elsewhere, such Beamex and his work history priorstanding CEO, will retire on the as an advisor or a board member. to joining Beamex is very valuable in this new role. I am very confident that31st of July 2015. Jan-Henrik The new CEO of the Beamex Group he will take the company to the next will be Jan-Henrik Svensson, BSc level”, says Wikström.Svensson, Vice President, Sales (Eng), starting August 1st, 2015. For the last nine years Jan-Henrik has For further information, please contact:& Marketing, at Beamex Group, been the Vice President of Beamex Raimo Ahola, Tel: +358 40 516 3888 Group. Before joining Beamex, Jan- Jan-Henrik Svensson, Tel: +358 40will be appointed as the new CEO Henrik worked in various international 506 6063 management positions within ABB andstarting from August 1, 2015. also as a Business Unit Manager withinRaimo Ahola has been the CEO ofBeamex Group for seventeen years,and his retirement in the end of Julythis year is part of a long-term planagreed with Beamex’s Chairman ofthe Board to ensure a controlled and32 PECM Issue 15

providing NEWportable temperature calibratorswith greater accuracy and additional featuresNew 4000 Range covering -45°C to 1200°CPortable Dry Blocks, Liquid Baths and Multifunction Heat SourcesThree versions from a Basic Heat Source to an ADVANCED Model with inbuilt threechannel thermometer, data logging and automatic temperature cyclingNew Rugged Lightweight Outer CasesCall now to request a FREE www.isotech.co.ukon-site demonstration - 01704 543830 Isothermal Technology Limited Pine Grove, Southport, Merseyside PR9 9AG England Telephone: +44 (0)1704 543830 Fax: +44 (0)1704 544799 Email: [email protected]

Conveniently Calibrate Plant Vacuum GaugesWhy do vacuum gauges need to be calibrated? CalCube complies with BS ISO3567:2011 which specificallyThe largest uncertainty when using vacuum gauges on a covers the design and use of vacuum calibration systems andprocess plant is knowing when the process has caused drift or incorporates an ISO/Dis stainless steel calibration chamber withshifts of calibration. Many processes handle vapours and, if any geometry optimised to ensure that all gauges connected see thecondensation or deposition happens, the chances are it will also same level of vacuum so that comparisons may be made.happen in the vacuum gauge. Many such gauges - Pirani, coldcathose and ion gauges - use thermal or ionisation cross-section The development of a techniquemeasurements to infer the level of vacuum being experienced Having its own ISO IEC 17025:2005 accredited UKAS laboratoryand they have filaments, cathodes and other hardware, all of with the lowest uncertainties for Vacuum in the UK, Chell arewhich may be coated with by-products from the process. well placed to prepare CalCube for on-site gauge calibrations. The Transfer Standards fitted to CalCube are calibrated in theEven more rugged gauges such as capacitance manometers will laboratory both before and after an on-site calibration job sobe affected by depositions or particulates because any deposition that the confidence level of the calibration is the highest possible.will have mass and the gauge will weigh it, especially if it has alow range and therefore a very thin diaphragm.Chell’s CalCube is a convenient solution to vacuum gauge calibration CalCube comparing two manufacturer’s Capacitance ManometersAs processes move away from their design parameter due CalCube is constructed within a rugged, wheeled flight-caseto gauge “drift”, little about the quality of the process can be type enclosure having just a 13A mains plug yet containing dryinferred from the instrumentation readings, so diagnosis is down diaphragm backing and turbomolecular pumps with high vacuumto a skilled operator recognising when a batch of product does isolation valves. Over 40 year’s experience of calibrating vacuumnot conform. gauges have gone into CalCube’s design, which includes such capabilities as calibrating both rising and falling pressures veryThis is too late! If the process is sensitive to the level of accurately using a pair of ultra-fine Chell CMF valves.vacuum being achieved, then the cost of losing a batch couldbe astronomical - many times the cost of maintaining the plant Fitting easily into almost any estate car, CalCube comes withproperly in many cases. lifting handles to aid safe removal from a vehicle or lifting up steps, etc. A removable side panel is foam lined with cut-outsWith the inherent lack of ruggedness of many vacuum gauges, it to hold all the common mating vacuum connector systems - ofis imperative that plant gauges are regularly calibrated and that course, custom connectors may be purchased and housed forthe operator has spare, calibrated gauges ready to substitute specific applications.as soon as he fears the process may have drifted away fromspecification. Choice of vacuum Transfer Standards will be an important decision, which is aided by Chell’s years of experience. TheseThe difficulties of calibrating vacuum in-situ standards, when not fitted to CalCube are housed in another,Unfortunately, it is very difficult to carry out in-situ vacuum matching flight-case, ready for convenient return to Chell’scalibrations due to the amount of hardware needed to establish a calibration lab. for scheduled UKAS calibration. Chell’s in-housesuitable level of vacuum in a situation where a calibration standard vacuum standards consist of three high-accuracy capacitancegauge may be compared. Not the least of concerns is the possible manometers having 20 years of continuous calibration historycross-contamination of the standard by a contaminated sensor at national Standard level and these are monitored on a dailyunder test. Another is the difficulty of access to many on-plant basis by a Spinning Rotor Gauge whose ball-flange assemblygauges. So it has become tradition for gauges to be removed is also calibrated annually at National Standard level. At theregularly from the plant and shipped to an external calibration atmospheric pressure end of the scale, the vacuum straight linelaboratory for re-calibration and, in many cases, adjustment to generated by the capacitance manometers is calibrated againstcompensate for the effects of contamination. our 32” Schwien Merco-Master manometer giving us the lowest uncertainties in that pressure regime. Chell’s customers thus enjoy the accumulated vacuum calibration skills of over 40 years and, should they have specific different requirements, Chell has the skills to customise CalCube to suit. For more information contact:- CalCube showing its useful vacuum coupling storage Chell Instruments Ltd Folgate HouseWith the development of Chell’s on-site UKAS calibration service, Folgate Roadthey have developed CalCube both as a portable vacuum North Walshamcalibration system with which to offer an on-site service but, Norfolkfor customers who would prefer their own facility, a convenient, NR28 0AJtried and tested system. Tel: 01692 500555 Fax: 01692 500088 e-mail: [email protected] Website: www.chell.co.uk34 PECM ssue 15

Implementing acalibration system?Our calibration and IT expertise helps you face calibration process improvement www.beamex.comprojects that are typically complex and consume a lot of time and resources. [email protected] 20% to 30% of a calibration system upgrade is tools and technology, the rest isbusiness culture and process. Therefore, the success of a new calibration system dependsespecially on the implementation of the system and the ability to define and adopt a newcalibration process. We are the experts in both technology and implementation, so youcan focus on the opportunities, while we support and guide you in the evolution of yourcalibration system and successful implementation of the calibration process change.Learn more at: beamex.com/CalibrationProcessImprovements

Large CommutatorRefurbishmentA Specialist OperationS everal industries - including steel industry. This is quite a common can weaken the plate and may cause mining, steel, rail and task and involves dismantling the cracking. power generation - rely component, cleaning and then reusing the original copper plates with new Based on the information available, on large motors equipped mica insulation. Sulzer advised the customer that it would be better to completelywith commutators to produce the The in-house commutator production refurbish the commutator, including the facility at Sulzer’s Birmingham Service manufacture of new plates. Followingpower required by their applications. Centre is able to refurbish almost any this advice, the customer agreed and commutator or slip ring assembly and the project got underway.However, without precision Sulzer is the only facility capable of building new Pollock commutators. The next step was to measure all ofmaintenance, these vital components The design capability combined with the dimensions and compare them to machining expertise and supported the original drawings and with Sulzer’scan become inefficient and eventually by a dedicated team of experienced own drawings from the previous engineers enables Sulzer to deliver refurbishment job. This commutatorfail. John Bird, Commutator Supervisor commutator and slip ring projects to consisted of 816 copper bars and budget and on time. 816 mica segments that separate theat Sulzer’s Birmingham Service copper. Overall the component weighed To reinsulate or not? in at close to 4 tonnes.Centre looks at the processes involved When the job arrived in the workshop, a previous Sulzer job number was Jig manufacturein delivering a fully refurbished noticed on the component and the For every job a jig is required to records showed that it had already arrange the copper bars and micacommutator. been reinsulated once before. Sulzer segments in the correct shape. Since recommends that commutators are this particular commutator had beenThe first, and possibly most important only reinsulated once before being previously repaired by Sulzer, thestep, is communication with the rebuilt with new copper. This is correct jig was already available. In thecustomer to ensure that all the because the job requires an amount of more extreme cases a brand new jignecessary information has been copper to be machined off the plates has to be manufactured by the Sulzerreceived; especially the history of the and if this is done more than once it workshop, such as the one that wascommutator, which will have a bearingon the type of refurbishment to becarried out. The best way to illustratethe process is using an example thatwas completed by Sulzer’s engineersrecently.Initially the customer sent over aset of drawings and asked for aquote to reinsulate a 1.9m diametercommutator that was used in the

Main Picture The in-house commutator production facility at Sulzer’s Birmingham Service Centre is able to refurbish almost any commutator or slip ring assembly The angle is very carefully calculated so that when all the segments are assembled they form a perfect circlecreated for a 3.5 metre commutator the bolts of the jig being tightened the commutator will run true whenwhich contained 2,400 copper bars. so the sections are drawn together it is reinstalled. On this particularOnce all the measurements have been compressing the copper bars and mica component, the specification was for arecorded, the original copper is stripped sheets together. This starts with the maximum run-out of 30 thousandthsout and the steel frame is cleaned and bolts being torqued to an initial value of an inch or 0.76 mm over the 1.9 mprimed ready for the new copper bars before the complete assembly is placed diameter.that are manufactured in house. in a stove to soften and consolidate the mica. Once out of the stove the bolts The bolts are then tightenedThis involves starting with a flat are tightened again and the process progressively and the entire componentrectangular piece of copper and milling repeated until the required bolt torque is replaced in the stove before the boltan angle onto one surface so that the is achieved. torque is increased again. This processplate is very slightly wedge-shaped. is repeated until the steel frame holdsThe angle is very carefully calculated With the mica consolidated, the entire the copper in place and the jig can beso that when all the segments are jig assembly is mounted in a large released.assembled they form a perfect circle. lathe to allow the machining processTherefore, the larger the diameter of to be completed. This is where the Testingthe commutator, the smaller the angle rectangular plates are machined to the Once the commutator has beenon the plate. exact shape and dimensions required reassembled and checked it moves by the drawings. In essence, two ‘V’ to the testing bay where high voltageThe copper plates are then assembled, profiles are machined at each end of tests, insulation resistance testswith the mica sheets between each the bars to allow them to be located and bar to bar resistance tests areplate for insulation, into the prepared in the steel frame that has been completed. With a clean test sheet,jig, which consists of a number of previously stripped and cleaned. the commutator is placed back on thesections that are all bolted together. At lathe for the final machining process tothis point it is crucial to be certain that While the machining is being produce the finished external diameter.the correct number of bars have been completed, the steel frame is All of the electrical tests are thenassembled and so they are counted and reinsulated to allow the new repeated to ensure complete integrityrecounted, just to be sure. commutator to be positioned on the of the insulation after which the bottom section before the top section component is packaged and shippedConsolidation is added and bolted down. At this point back to the customer.The process of consolidation involves the run-out is measured to ensure that

The Biomass industry isjust one of many that canbenefit from our soundsolutionA sound solutionto ash build up inbiomass power plantsBy Donald F CameronE stablished in 1998, Acoustic technology, a green, non- the timber drying kilns. Primasonics® International polluting efficient means to prevent Ltd is the worldwide leader ash build up - and it is certainly The company needed to find proving to be the case! an innovative, effective and in design, manufacture and Claymark based in Rotorua, New environmentally friendly solution Zealand are specialists in milling, and so made initial contact withsupply of Acoustic Cleaning Systems manufacturing and distribution of high Primasonics International. We quality timber products. recommended the installation ofand Technologies. Our products are two Acoustic Cleaners with a 230 Hz The problem they faced was essentially frequency to be sounded together. Inused in a variety of industries such fouling of the biomass/wood waste addition, to comply with local plant fired boiler which provided hot water to noise regulations, acoustic covers wereas Power Generation, Cement, Petro designed and installed.Chemical, Food, Gypsum, Carbon After three months operation an inspection was made and no ash buildBlack, Chemical, and many more. up was found on the boiler tubes. The total project cost was easilyThis non-intrusive, affordable fully recouped within the first year oftechnology can increase the efficiency operation and Claymark now have anof process plant, provide improved efficient, green and environmentallythermal conductivity, prevent material friendly solution to their previousblockage and remove particulate build serious ash build up.up wherever ash, dust, powders orgranular materials are processed, Email: [email protected], stored or transported. Tel: +44 (0)17684 80372 www.primasonics.comThe Biomass industry is just one ofmany that can benefit from our soundsolution, yet there is a unique synergybetween the technologies that seemsto make a perfect combination –Biomass a green, low carbon footprintalternative to burning coal in powergeneration plants and Primasonics38 PECM ssue 15



Control & Automation iTRAK modular transport system Drives for process technologyincreases flexibility and drives machine applications performance At the ACHEMA exhibition in Frankfurt, Germany, NORD DRIVESYSTEMS recently presented distributed drive concepts that meet the typical demands of the process industry. Variable-speed drives with IP66/IP69K ingress protection are suitable for applications that require regular cleaning with high-pressure steam jets. All components are manufactured in-house: gearboxes, smooth-surface motors, and frequency inverters. The nsd tupH anti-corrosion treatment – developed by NORD and FDA-certified (Title 21 CFR 175.300) – gives the aluminum housings a smooth and durable surface. Even blows and scratches do not impair the corrosion resistance. Since no coating is applied but the surface itself is hardened, there can be no pollution of products or process media as for instance with chipping paint.Rockwell Automation is about to make life dramatically easier for engineers Email: [email protected] www.nord.comand production technologists. At least that’s the idea behind iTRAK,a modular, scalable motion control system that provides independent New All-Gigabit Stratix 5400control of multiple magnetically propelled movers on a track. The simple Industrial Switch Helps Manufacturersconfiguration and patented pitch-less technology solves different motion Address Growing Network-Bandwidthand speed needs. It enables production/handling systems and assemblylines to be readily designed with the aid of a number of accurately Requirementspositioned carriages.Several carriages, consisting of a frame and a linear permanent magnetmotor, can move individually along straight or curved rails. The iTRAK canbe used, for example, on packaging lines, in the medical industry (fillinglines for IV bags), but also on assembly lines for machine construction. Thecombination of iTRAK technology with the Rockwell Automation integratedArchitecture (programmable with Studio 5000 Logix Designer) lays thefoundation for a new standard in dynamic linear transport solutions.Carriages are available in a standard versions and with customization forspecific applications. Customers can also design their own carriages if theychose to. Take a look at the following video in which a bag filling line usingcustom-made carriages can be seen:http://embed.vidyard.com/share/vQa5C7hRqLrN7dxsQl7M7w Tel: 0870 242 5004 Email: [email protected] Rockwell Automation has expanded its Allen-Bradley Stratix family of industrial switches with the Allen-Bradley Stratix 5400 switch, an all- gigabit option that helps manufacturers achieve higher network speeds for their increasingly high bandwidth applications. The switch also supports both Layer 2 switching and Layer 3 routing for a range of network configurations. “Network convergence, increased reliability and the growing adoption of high-speed devices across The Connected Enterprise are driving the need for a higher-performing and more versatile industrial switch,” said Mark Devonshire, product manager for Rockwell Automation. “The Stratix 5400 switch provides this capability and helps confirm that manufacturers have a robust architecture in place as network demands continue to broaden.” When used as a Layer 2 switch, the Stratix 5400 switch is ideal for industrial environments experiencing an influx of high-performance, gigabit-speed end devices, such as IP video cameras and telephony. It’s also fit for heavy-industry applications that require resilient network topologies. When used as a Layer 3 switch, routing is enabled between segmented networks to help achieve better performance. The switch uses an all-gigabit design for high-performance network and end device support. The GE Power over Ethernet (PoE) and additional GE fiber port options enhance scalability and help meet a wide range of application needs. Tel: 0870 242 5004 Email: [email protected] PECM Issue 15

PUSHING THE LIMITSChoose WAGO’s TOPJOB®S terminal blockswith Push-in CAGE CLAMP® for total reliabilityAs the world’s leading innovator in tSuitable for all conductor typesinterconnection technology, WAGO has once tRange of multifunctional jumpersagain set the industry standard for excellence. tThe fastest marking system availableOur TOPJOB®S Push-in CAGE CLAMP® range tIndustry-leading safety reservesof rail mounted terminal blocks offers unique tIdeal for switch cabinets and terminal boxesbenefits. They ensure totally dependable tEx approvals as standardconnections, whatever the application.Solid and stranded conductors can simply bepushed in while for fine stranded conductors,an easy-to-use operating tool is provided.To find out more contact us today. Telephone 0870 264 0773 E-Mail [email protected] Internet www.wago.com

FANUC UKis the leading globalmanufacturer of factoryautomation and industrialrobotics.FANUC launchesworld’s first heavylifting collaborativerobotP reviously the which automatically stops to 35 kg. The collaborative Chris Sumner, vice president collaborative the robot if it touches of FANUC Europe and robot has only a human operator. This robot is also available with managing director, FANUC removes the need for UK said: “Collaborative been seen in safety fences, a previous patented iRVision technology. robot technology opens up requirement for all a new era for manufacturingworks of science fiction. industrial robots, increasing Servicing a variety in which humans and production efficiencies and of manufacturing robots will work even moreHowever, today marks the enabling a higher level of industries, the closely on tasks; increasing automation. CR-35iA can productivity and efficiencieslaunch of the world’s first perform both across the plant floor.” Servicing a variety of simple and complexheavy lifting industrial manufacturing industries, tasks lifting payloads Tel: 024 7663 9669 the CR-35iA can performcollaborative robot, the both simple and complex of up to 35 kg. Email: [email protected] tasks lifting payloads of upFANUC CR-35iA, working www.fanuc.euhand-in-hand with humanemployees.FANUC’s collaborative robotensures safety through theuse of intelligent sensors, FANUC UK offers the most complete range of industry-leading products and services for robotics, CNC systems and factory automation solutions, helping to transform the manufacturing industry through innovation in automation.

Let’s worktogether! NEW COLLABORATIVE ROBOT CR-35 A /
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RVision supportLIFTS UP Strong and sensitiveTO 35 KG FANUC’s new CR-35 A is the world’s first collaborative robot with a payload capacity of up to 35 kg. Fenceless, it opens a whole new world of possibilities. Working safely side by side with human operators, it is space as well as cost saving. And because inside it’s like any other FANUC robot, it operates like all FANUC robots. That’s future made by FANUC. WWW.FANUC.EU [email protected]

Control & AutomationReduce down-time, the likely risk of a system overheatingequipment failure and which could lead to equipment trippingenergy use or failing. The survey will review any existing cooling solution andR unning manufacturing A typical electrical component’s determine how suited it is to that automation systems at high life expectancy is approximately particular working environment. It temperatures will have a halved for every 10 °C increase in will then provide recommendations its ambient temperature. Controlling around remedial action – for example, major negative impact on the temperature within enclosures is changes to the system’s service and therefore critical for manufacturers to maintenance regime to help improvethe system’s performance and reduce avoid premature component failure and its efficacy or the need to invest in the interruption to production if the different climate control technology.its service life. By not keeping their automation system falls over. A basic checklist for reviewing climatedrives at or close to their optimum A Rittal RiAssure3 survey will identify controls in a manufacturing automation system:operating temperature, manufacturers • Equipment tripping or failing due to high temperatures which is havingrisk huge consequential costs when the an impact on production lines, in that they are either slowing or stoppingproduction line grinds to a halt as a completely • Enclosures which feel hot to theresult of system failure. touch • Enclosure doors regularly left open or a need for large fans blowing into the panels as the weather improves • An inadequate chilling of process fluids which results in production down-time • Or simply the opportunity of a health check for the cooling solution As summer approaches, ambient temperatures will rise which could push operating temperatures beyond the limit of the existing equipment, so tackling the issue now could be a timely call. Further information at www.rittal.co.uk and www.friedhelm-loh-group.com, or on twitter @rittal_ltd.Enclosuresfrom the smallestto the largest. ENCLOSURES POWER DISTRIBUTION CLIMATE CONTROL44 PECM Issue 15

Control & AutomationNew whitepaper on“Industry 4.0”nowavailable from RittalM anufacturing can become between them. To faster and much more function effectively and flexible with consistent, maximise the benefits afforded by Industry IT-assisted value chains. A 4.0 the differences between these twonewly published whitepaper from Rittal parts of the business must narrow.shows the key role IT plays in what The whitepaperis termed Industry 4.0 and explains identifies data quality as one of the key requirements to deliverhow companies can establish the success under Industry 4.0. There are also some suggested practicalinfrastructure that is required to bring ways that businesses can start to apply Industry 4.0 methodologiesthe concept to fruition. and a demonstration of how Rittal The basis of Industry 4.0 is components and solutions can help underpinned by IT systems thatThe new “IT infrastructure in the create an Industry 4.0 infrastructure. represent the entire value chaincontext of Industry 4.0” whitepaper across design and manufacturing. Itfrom Rittal is now available to Why Industry 4.0 is important is a network of intelligent machinesdownload. Manufacturing needs to rapidly that communicate with one another and flexibly adapt to new customer creating self-regulating manufacturingThe document is aimed at decision- requirements and market demands. processes and providing highly efficientmakers as well as anyone responsible volume production (even with smallfor production and IT and details the The concept of Industry 4.0 is one batch sizes).opportunities that Industry 4.0 is where businesses can automate theircreating through new and existing production processes to a greater The “IT infrastructure in the contextinfrastructures. degree, and where machines can of Industry 4.0” whitepaper can be network with each other, making obtained free of charge from the RittalThe whitepaper shows how IT production processes more flexible. website: www.rittal.com/whitepaperand production can be effectivelyinterlinked, and outlines the Further information atinterdependence of “back office” and www.rittal.co.uk and“factory” functions. It also highlights www.friedhelm-loh-group.com orthe similarity of the challenges on twitter @rittal_ltdfaced by production managers andsystem administrators as well as thedifferences that continue to exist IT INFRASTRUCTURE SOFTWARE & SERVICES www.rittal.co.uk Issue 15 PECM 45

Supporting automationin food and beverageproduction By Jarn Gill, Head of Corporate Sales, RS ComponentsT he manufacturing and bringing new technology to deliver back-end, starting with the initial processing industry has extra functionality and helping them preparation of raw product through seen massive changes to reduce production downtime while to packaging the product in the final also meeting demands for higher stages. with increasing integration levels of hygiene, traceability and data measurement. RS has an enviable This is where RS can bring itsof technology and the automation portfolio of leading manufacturers experience with access to technologies including brands such as Siemens, and know-how from leadingof industrial processes, and perhaps Schneider Electric and Rockwell Allen- manufacturer partners offering process Bradley, and many specialists including control solutions from intelligent visionno more so than in the area of food SMC, Sick and Ambersil, which deliver sensors and energy saving pneumatics, custom solutions targeting specific to automated lubrication systems andand beverage production. It has gone areas of production and packaging. food-safe cleaners.from employing little or no automation Investing in production automation RS has long experience in providing is key to delivering energy efficient solutions for hygiene and productto a situation today where an entire processes with minimal human traceability as well as helping involvement to reduce costs, while companies with data capture andbakery or dairy can be run by a maintaining quality and consistency. energy management challenges. A growing number of companieshandful of people operating largely are looking to automate their entire uk.rs-online.com operations from the front- to thecomputer-controlled machinery in themanufacturing process.Like any industry, the challengesare many, such as compliance,consistency, traceability and thereliability of measured data in additionto meeting demanding price pressuresas manufacturers compete in a globalmarketplace.At RS, we understand that the paceof technological change has increasedfrom a low- to a high-tech automationenvironment where every singlepart of the process is monitored andcontrolled and performed at very highspeed. RS has been a leading supplyof automation components, electricalparts and consumables in this industryfor many decades now, helpingcustomers to keep their productionlines running. Within RS is a wealthof experience in maintenance andrepair operations and procurement,enabling its customers to attainhigh efficiency in its managementof maintenance costs. RS has beenat the forefront in working with itscustomers to improve their processes,46 PECM ssue 15

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Page Title Control & Automation Email: [email protected] Web Site: alldrivesandcontrols.co.ukWhy go to Rio!It’s SAMBA time in the UK.Samba up your competitive advantage.R epresented in the UK by the Samba PLCs support a variety software and applications are a free authorised distributor of optional communication modules download, so no hidden extra costs. Alldrives & Controls, such as Ethernet, Serial, and CAN bus The full range of Unitronics products allowing the unit to communicate with, are available from Alldrives & Controls, Unitronics announces the and control, other devices. a Unitronics authorised full service stocking distributor.release of the Samba™ 7, the latest The Samba 7 features data tables for recipe programming, data logging, Great look, Great power, Greatmember of the Samba Series of trends & alarm displays, as well as Service; - incredible price. multiple language support. Sambacombined PLC+HMI`s. units can be remotely accessed using Tel: 01543 241899 GPRS/GSM and other IP networks for Email: [email protected] its wide screen dimensions, the data acquisition, program download. www.alldrivesandcontrols.co.ukSamba 7 is an integrated 7 inch touchscreen (800 x 480), controller with In addition the Samba 7 supportsdigital and analogue I/Os. e-mail and SMS notification messages for real-time remote management.Competitive pricing, yes, powerfulcontrol, yes, easy to program, yes, the Compatibility with VisiLogic™Samba 7 is an ideal PLC for OEMs small The Samba 7 is supported byscale systems, for machine builders to VisiLogic™ version 9.7.55 and up. Asreplace a smart relay, and low budget is the norm all Unitronics programmingapplications.The Samba 7 comprises a mini USBprogramming port, and in addition, Issue 15 PECM 49

Drives, Gears & Motors50 PECM Issue 15