Mepca november 2013

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November 2013

make it how you want it* profile assembly solution fast. versatile. simple. *we mean MiniTec solutions as well as sandwiches

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design samples advice

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contents Editor Jess Unwin – editor@mepca.com 07903399150 Publication manager Sean French – sean@mepca.com 01795 509105 Fax: 01795 591065 Account executive Sean Elliott – seanelliott@mepca.com 01795 509105 Studio manager Paula Smith – paula@cimltd.co.uk 01795 509107 Design and production Grant Waters – grant@cimltd.co.uk 01795 509108 James Taylor – james@cimltd.co.uk 01795 509108 Credit facilities manager Vickie Crawford – vickie@cimltd.co.uk 01795 509103 Fax: 01795 591065

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onitoring and controlling temperature is key to many aspects of manufacture, engineering and product storage and distribution. That’s why it’s the subject of our first special focus in this edition (pages 12 and 14).

We look at how food giant Nestlé is keeping its chocolate cold and how a major component manufacturer successfully completed the upgrade of a special oven used to bake carbon at temperatures of 3,000°C. Our second special focus looks at process control (pages 26, 28 and 30). We examine diverse subjects in this area: acoustic volume-mapping for stock control, the bottom-line benefits of an adaptive approach to process control and the development of an intelligent process field device.

As ever, there’s much more besides. We have articles on design software, health and safety, pumps and valves, fluid and gas handling, sustainability, innovation and product news. Enjoy!

Jess Unwin, Editor Facebook.com/mepca1

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EEF & MTA The latest from two of the industry’s trade associations

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News Brompton Bicycle MD’s call to manufacturers and counterfeit bearings warning

Chief executive John Denning jdenning@cimltd.co.uk 01795 509100 www.mepca.com

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© 2013 CIM Online Limited, The Goods Shed, Jubilee Way, Whitstable Road, Faversham, Kent, ME13 8GD. No part of this magazine may be reproduced or stored in a retrieval system or transmitted in any form – electronic, mechanical or physical – without express prior permission and written consent of the publisher. Contributions are invited and when not accepted will be returned only if accompanied by a fully stamped and addressed envelope. Manuscripts should be typewritten. No responsibility can be taken for drawings, photographs or literary contributions during transmission or in the editor’s hands. In the absence of an agreement the copyright of all contributions, literary, photographic or artistic, belongs to CIM Online Limited. The publisher accepts no responsibility in respect of advertisements appearing in the magazine and the opinions expressed do not necessarily represent the views of the publisher.

The publisher cannot accept liability for any loss arising from the late appearance or non-publication of any advertisement.

@MEPCA1

Special focus: temperature monitoring & control Chocolate-maker Nestlé keeps cool and West Control Solutions has the right ingredient (pictured) for a special carbon-baking process

http://www.linkedin.com/pub/mepca-journal/36/ba6/64

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Health & safety Christopher Knollys, of sara LBS, on the benefits of integrating machine protection doors into your production area

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Fluid and gas handling Stephen Hart, MD at Frese, comments on why dynamic balancing valves are the future

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Special focus: process control Learn about acoustic volumemapping with Magnetrol; Adaptive Process Control from Aspentech; and an intelligent field multitransmitter/ controller from Bürkert

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Engineering Companies that rely on older CAD systems risk falling behind competitors who utilise modern, more innovative tools, says Ken Christie, director of EPLAN UK

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Sustainability Quick wins blinding manufacturers to real energy savings, says report

www.mepca.com

November 2013

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EEF & MTA

Rolls-Royce the latest big name to sign up to MTA’s MACH 2014

EEF calls for 12-month traineeship model

*Photographs are reproduced with the permission of Rolls-Royce plc, copyright © Rolls-Royce plc 2012*

The EEF has welcomed news from Skills Minister Matthew Hancock that an additional £20m will go into the Traineeship programme.

Steve Radley, EEF’s Director of Left: The Rolls- Policy, believes the extra investment Royce RB211- “will mean more young people have a better chance of stepping onto the 542H powers career ladder, whether this is into an the Boeing apprenticeship or into employment”.

747-400 However, he adds: “If government wants more employers to get Below: A on board, it should extend the Rolls-Royce Traineeship model to a maximum Industrial 501 power station in of 12 months. This will enable learners to really grasp the skills and Ireland experience that employers demand, whilst having the opportunity to take relevant vocational qualifications which employers value.”

Chancellor urged to clarify funding priorities

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olls-Royce is the latest company to agree to exhibit at MACH 2014, organised by the Manufacturing Technologies Association (MTA).

The integrated power solutions provider for the civil and defence aerospace, marine and energy markets will be taking space in the exhibition’s UK Manufacturing Zone, joining other original equipment manufacturers (OEMs), including Airbus and Messier-Bugatti-Dowty.

Iain Low, Engineering Programme Manager at Rolls-Royce, says: “It

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is great to see that the MACH exhibition has chosen Engineering Innovation as its theme, and we are delighted to participate in this industryleading event.”

At MACH 2014, RollsRoyce will be focusing on the importance of building strong supply chain relationships and enthusing the next generation of engineers.

The UK Manufacturing Zone at MACH 2014 is designed to bring together some of the UK’s most innovative manufacturing technologies suppliers with leading OEMs from a range of sectors.

The zone’s position within the exhibition will showcase some of the latest advances and encourage greater networking between the exhibiting companies. mta.org.uk machexhibition.com

Terry Scuoler, Chief Executive of EEF, describes Chancellor George Osborne’s moves to provide more certainty on infrastructure budgets as positive but adds this now “needs to be matched by clarity on the projects that will be prioritised for funding”. He says: “We need to see a cross-Government vision and commitment to co-ordinate measures for growth that support investment, innovation, and the creation of skilled jobs.”

Extra £200m will help rebalance economy An extra £200 million of funding for universities teaching core science, technology, engineering and maths is good news, says Tim Thomas, Head of Employment Policy at EEF. “Manufacturers are already finding the supply of engineers a block on expansion, with too few graduates, particularly women, entering the sector. A rebalanced economy will only become a reality if the supply of scientists and engineers can meet the increasing demand...with universities and employers investing together to achieve this.”

news

High-flyers commended at coveted awards ceremony Keynote speaker at prestigious Manchester event calls for manufacturing businesses to stick to best practice to remain competitive in continued challenging economic times

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he man behind a British manufacturing success story was the keynote speaker at a prestigious annual awards ceremony attended by 150 senior executives from all sectors of industry.

Will Butler-Adams, MD of Brompton Bicycle Co, which designs and produces more than 30,000 folding bikes each year from its UK factory, talked about the success of the company and the need for manufacturing businesses to ensure they adhere to best practice to remain competitive in continued challenging economic times.

His was one of many presentations at the 2013 Manufacturing Forum and Awards, organised by Brammer, distributor of industrial maintenance, repair and overhaul products and services, and Buck & Hickman, distributor of tools, maintenance and health and safety products.

The Manchester event, now in

its seventh year, was hosted by TV presenter Sasha Twining and showcased examples of best practice, innovation and continuous improvement in maintenance spares procurement and management.

Other presentations were given by representatives from companies including the Royal Mint, Siemens, Diageo and EDF, who shared their own experiences and successes in the areas of vendor consolidation and best practice in supply chain management, and how they deliver measurable commercial benefits.

The award winners were Pepsico (Improved Production Efficiency); Royal Mint (Reduced Working Capital through Inventory Management); Lynemouth Power (Reduced Total Acquisition Costs); Royal Mail (Improved Production Efficiency); Npower (Reduced Total Acquistion Costs); Siemens (Supplier Relationship Award).

Ian Ritchie, Managing Director of Brammer UK and Buck & Hickman,

Will ButlerAdams, MD of Brompton Bicycle Co, gave the keynote speech at the awards

says: “The awards recognise those who have achieved outstanding results and it is wonderful to see so many companies of all sizes and in a broad range of sectors continuing to demonstrate best practice.” brammeruk.com

Warning after destruction of fake rolling bearings

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ompanies should be on their guard against counterfeit bearings and the threat they pose both to safety and the income of legitimate businesses.

The warning comes after 26 tonnes of counterfeit bearings – with

a value of more than one million euros – were destroyed this summer after being seized in raids on bearing distributors across Europe, including Italy, Germany and the UK. Not only is damage caused to legitimate companies that research, develop and manufacture bearings, but also to those companies that install counterfeit components and to their customers.

Failure of a sub-standard counterfeit bearing can be a very serious matter, particularly if it is a safety-critical component on a machine or production line.

Trade associations such as the World Bearing Association work closely with national authorities to create the required legal and organisational framework to effectively fight counterfeit products and to protect

Counterfeit bearings being destroyed earlier this year

manufacturers and their customers.

The recent haul of fake bearings was destroyed by Schaeffler, which is actively pursuing the counterfeiting of rolling bearings and the distribution of these products, which in some cases leads to prosecution.

“Brand and product piracy is not something that is limited to China or South East Europe. It also takes place right on our doorstep,” warns Ingrid Bichelmeir-Böhn, leader of the Global Brand Protection Team at Schaeffler.

“The German and European markets are no longer flooded with just counterfeit luxury and consumer goods, there has also been an increase in counterfeit safety-critical industrial products such as rolling bearings.” schaeffler.co.uk www.mepca.com | 5

events

First-ever chance to tap into vast knowledge bank Post-event access to presentation material, via a personal log-in to all attendees, is a benefit that’s brand-new for the Advanced Engineering UK group of events 2013

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rganisers of the Advanced Engineering UK group of events 2013 have announced that attendees this year will receive – for the first time – postevent access to material from the open conference programme.

Ian Stone, Managing Director of UK Tech Events, explains: “The value of the information presented at this year’s group of events is such that we know there will be many attendees keen to receive the material presented. Post-event access to presentation material, via a personal log-in to all actual attendees, provides the luxury of tapping into the vast array of innovation, process and capability, applications, strategic and general business material for more considered longer-term usage.”

Expert speakers – big names, big themes…

Representing the UK’s largest open conference programme covering the advanced engineering sector, Advanced Engineering UK 2013’s parallel open programmes will present some 200+ expert contributors, with dedicated presentation 6 | www.mepca.com

streams for aero engineering, composites engineering, automotive engineering, auto electronics, printable electronics plus a whole host of content aimed at general cross-industry interest – from test and measurement, digital manufacturing, regional initiatives, SME finance and more.

Dr Neil Calder, Conference Programme Director for the Advanced Engineering UK 2013 group of events, comments: “Our intention has been to provide a useful landscape for all participants within the advanced engineering supply chain, sufficiently detailed and insightful to allow lower-tier companies to either create or develop their own business plans.

“We have drawn in invited contributions from a selection of strategic infrastructure players as well as more tactical practical presentations from niche specialist organisations.”

The Advanced Engineering UK group of events 2013 – Europe’s most important annual advanced engineering sector showcase for technology innovation, processes and industry supply chain capability – is being staged 12-13 November

Above: Advanced Engineering UK 2013’s parallel open programmes will present some 200+ expert contributors

at the NEC in Birmingham.

600+ specialist exhibitors, 200+ speakers, multiple features – biggest show yet!

Increasing in size year on year, and in 2013 by 25% on 2012, this year’s portfolio will provide 600+ specialist exhibitors of engineering technology, equipment, components and specialist services in one giant hall, together with five show floor-based open conference auditoriums, playing host to some 200+ expert technical and strategic presentations over the 2 days. Mepca looks at little closer, below, at this year’s line-up of adjoining show streams.

Aero Engineering Show – bringing together the UK’s world-class industry The UK aerospace industry embraces 3,000 companies nationwide and generates £20 billion a year. The largest aerospace player in Europe, the UK’s core specialisations include wing development, aero structures, aero engines, landing gear, helicopters

events and aerospace systems.

Attracting UK-based engineering and industry professionals plus international OEM and tier 1 manufacturers, together with tier 2 and 3 supplier groups and related aero sector supply chain partner groups, the Aero Engineering Show provides a crucial technology transfer, supply chain development and networking environment.

Composites Engineering Show – UK’s annual composites showcase event gets bigger Reflecting increasing demand for harnessing the benefits of composites materials, the Composites Engineering Show provides a showcase for composites processing equipment, tooling and technologies, related design and simulation technology, specialist composites processing services, composites test and inspection technologies and more.

Attendees will see the latest in composites raw materials, semifinished and intermediate product suppliers, design, analysis and simulation, composites processing and fabrication services, processing technologies, equipment and ancillaries, machining, joining, assembly and automation technologies, finishing technology, composites test, measurement and inspection, and composites recycling.

Automotive Engineering Show – supporting UK supply chain development Representing the UK’s only 100% dedicated show and open conference for automotive body, chassis, powertrain and supply chain engineering, this event has doubled in size from 2012.

DIARY DATES

It provides a tailored showcase of specialist UK and international engineering services, design/ production technology, plus specialist parts and component suppliers supporting multiple vehicle engineering programmes – including passenger car, performance vehicle, CV, truck, motorcycle, specialist, low-carbon vehicle and engine sectors. The Automotive Engineering Show provides a crucial technology transfer, supply chain development and business networking environment for national and international engineering and industry professionals in the automotive sector.

Automotive Electronics 2013 – supporting new levels of drivability, safety, functionality and efficiency

Right: The Advanced Engineering UK group of events 2013 – Europe’s most important annual advanced engineering sector showcase for technology innovation, processes and industry supply chain capability – is being staged 12-13 November at the NEC in Birmingham

This brand new ‘extension’ event to the Automotive Engineering Show reflects the tough competition between vehicle manufacturers that is driving vehicle electronics technologies to support new levels of functionality, safety, efficiency, infotainment and telematics. The Auto Electronics Show provides all sides of the vehicle electronics sector with a showcase of leading supply chain partners and technology capability supporting auto electronics design and test, manufacturing, assembly, integration, and supply chain programmes, supported by a daily programme of open conference expert presentations.

new range of flexible functionality devices and innovative products, with the added benefits of cheaper and more environmentally friendly production methods. The sector is forecast to have a global value of $120bn by 2020. Aimed at crossindustry design and engineering professionals, the event will reach out to sectors looking to harness the new technology.

More exciting feature displays The 2013 Advanced Engineering UK group of events also offers numerous special feature zones, showcasing an eclectic mix of topical examples of innovation from across the UK’s advanced engineering sector. This year’s exhibits are set to include wing structures, landing gear, aero engine technology, high-performance sports cars, advanced materials, electric aircraft land speed vehicles, microlights, Formula 1, advanced engineered components and more.

Don’t forget to preregister You can pre-register now (via any of the individual show websites OR simply go to www. advancedengineeringuk.com for a FREE ENTRY badge, which covers all five show streams and linked open conference programmes.

Pre-registered visitors will additionally have the opportunity of networking with other pre-registered organisations via the events’ online networking portal. advancedengineeringuk.com

Printable Electronics – the game changer enabling technology Printable electronics is a rapidly developing technology, enabling circuits to be printed onto a wide range of surfaces. This enables the design and development of a whole

Event

Venue

Date

Website

Skills Show

NEC, Birmingham, UK

Nov 14-16

worldskillsuk.apprenticeships.org.uk

Sustainable Oil/Gas Symposium

Edinburgh, UK

Nov 25-26

icheme.org/sog2013

SPS IPC DrivesV

Nuremberg, Germany

Nov 26-28

mesago.de

The future for UK manufacturing following the Foresight Project (seminar)

Central London venue TBC

Nov 28

westminsterbusinessforum.co.uk

www.mepca.com | 7

training

Put your CAD training on the right tracks Man and Machine offers an extensive range of Autodesk 2014 courses to help your company optimise its software investment by equipping staff with the right skills

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an and Machine offers a range of Autodesk®accredited 2D and 3D CAD training for both design professionals who are new to CAD drawing software and those

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who need a more advanced understanding. Since the launch of the Autodesk 2014 software updates, Man and Machine is now implementing the 2014 training courses.

Man and Machine offers a flexible learning platform

The company’s standard training courses include AutoCAD®, Autodesk® Inventor® Introduction to Solid Modelling and AutoCAD® Electrical. For all of these courses there is a substantial schedule throughout 2013.

However, if you are unavailable to make the advertised dates or are interested in some of the specialised training, then contact Man and Machine to discuss your requirements, as the company can be flexible in its solutions.

Alternatively, if you want your staff to progress further in their understanding and productivity using any of the CAD products that Man and Machine offers, but have very specific training requirements, then Man and Machine can provide flexible training courses that empower your staff with the skills they need to maximise their CAD design capabilities. The content is entirely up to you.

All courses currently take place in the Man and Machine training centre in Oxfordshire or at your own offices.

To ensure that learning outcomes are met, all scheduled CAD training solutions come with posttraining support and, if needed, free telephone or email support is available for questions asked up to one month after the training course has finished.

Man and Machine training courses can help to get the most out of your CAD software investment and equip you and your staff with the skills your industry demands.

For more information on all of the Man and Machine training courses, please visit the website at www. manandmachine.co.uk/training, email training@manandmachine. co.uk or call on 01844 263 700. manandmachine.co.uk

Man and Machine Training Academy

Man and Machine offer an extensive range of Autodesk 2014 training courses

Man and Machine specialise in Autodesk training for Manufacturers, Engineers, Architects & Product Designers.

All courses are taught with the official Autodesk courseware and 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 Essentials

E: marketing@manandmachine.co.uk W: www.manandmachine.co.uk T: 01844 263 700

Connect with us

innovation

Infrared image solutions will increase efficiency Instrument manufacturer says innovations bring significant improvement in thermography

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and Testo 890 saves time and solves problems. Use of SRT with measurement site management allows the recognition, storage and management of thermal images after an inspection.

Periodic inspection tours can be conducted efficiently and all thermal Site Recognition images can be accurately analysed Technology (SRT) on a PC. Simply identify the different The thermography of similar measurement sites with markers on measurement objects, and in the measurement object, and the particular the correct archiving of imager does the rest. these recorded thermal images, In addition, easy-to-use search is a significant challenge in functions will quickly and easily find industrial maintenance. The correct images, based on the name of a identification and allocation of the measurement object, a date or a images on-site is important. certain temperature. This allows, If the images are not sorted and among other things, uncomplicated allocated until after the inspection direct call-up of comparative tour, an image can easily be allocated to the wrong measurement images from past periods. Thus SRT ensures better maintenance object. In such circumstances, efficiency, security and all-round machines can be diagnosed with reassurance. thermal irregularities which in fact belong to other objects. The problem becomes even more Panorama Image complex when temperature changes Assistant (PIA) need to be traced over time: if the A second challenge in thermography images are incorrectly allocated, is that it’s not always possible to error diagnoses are made more record very large objects with one difficult, or even impossible. image. An engineer may not be able The SRT of the Testo 885 to move far enough away from the ampshire-based Testo believes it has come up with innovations that will bring significant improvements in two challenging areas of the use of infrared cameras, aka thermography.

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Testo believes its Testo 890 and 885 products, enhanced

by SRT and PIA, will make thermography more efficient

object and sometimes going further away just does not work because walls, neighbouring buildings and streets can present problems.

And even at sufficient range with nothing in the way, users often reach the limits of the imager’s resolution. This will mean the thermal image may no longer be sufficiently detailed.

One way out of this dilemma is to record several images separately. However, viewing and analysing several separate images increases the required time and workload. A full analysis of the whole measurement object at a glance, in one single image, is often more useful and in this way thermal irregularities can be better illustrated than in the separate analysis in several image sections.

Testo thermal imagers have light, wide-angle lenses as standard – so they are better at taking thermal images of larger image sections than an imager with normal lenses. If this is not enough, the new PIA in the Testo 885 and Testo 890 can help: you simply take your thermal images of the object in several sections, and the PIA creates an overall image for you.

You benefit not only from the overview but also from greater attention to detail. For example, this allows you to present an area of 176m² in one image at a distance of 10m. With the PIA you can inspect large objects while retaining full detail, increasing efficiency in your daily work and preventing long, unnecessary image searches.

Testo is the UK subsidiary of Testo AG, a leading manufacturer of highquality measuring instruments for many applications and sectors, such as the manufacturing, engineering and maintenance sectors. testolimited.com

MXXXX - Magazine tbc TI Kit Offers.indd 1

9/12/2013 5:32:52 PM

special focus: temperature monitoring & control

Chillers a sweet solution for Kit Kat maker Nestlé Installation of new chillers at food giant’s York distribution centre improves temperature and humidity control, reduces energy consumption and helps maintain product quality

The installation of Honeywell’s EBI building management system improved control significantly and paid for itself within the first year of operation

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oneywell has installed three liquid-cooled chillers at the York distribution centre of global food giant Nestlé, whose popular brands include Kit Kat, Aero (pictured, above) and Smarties.

The 136,000 square-foot distribution centre is on the same site as the Nestlé York production facility, one of the world’s largest confectionery factories.

The distribution centre consists of a fully automated high bay with

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six cranes and a conventional storage and picking hall. In total, the distribution centre holds up to 33,000 pallets with a typical value in excess of £25 million.

Temperature and humidity in the distribution centre need to be controlled to a very precise specification to preserve the quality of Nestlé’s products. Under the project, Honeywell replaced the centre’s aging chillers with three five-stage propane alternatives that

perform more efficiently, offer more accurate temperature control and are easier to monitor.

“The new chillers are much more efficient at maintaining temperatures and were a cheaper alternative to other options for Nestlé,” explains Barry Hetherington, business development manager for Honeywell Building Solutions. “The lower cost of our solution enabled Nestlé to make other investments to improving the plant room.”

In 2006, Honeywell’s maintenance and support for the Nestlé site were expanded to include the warehouse facility. The installation of Honeywell’s EBI building management system at that time improved control significantly and paid for itself within the first year of operation, which has helped the site reduce its energy consumption by nearly half.

“The installation of the new chillers, combined with the improvement measures we are making in other areas of our control regime, will enable us to further reduce our costs and lessen our impact on the environment,” says Paul Roberts, customer logistics engineering manager for Nestlé UK&I. “It is vital to maintain product quality throughout the supply chain and, within the distribution centre, that means close control of temperature and humidity – in as an environmentally friendly way as possible.”

Honeywell is a diversified technology and manufacturing leader, serving customers worldwide with aerospace products and services; control technologies for buildings, homes and industry; turbochargers; and performance materials. honeywell.com

product news

Putting a test case for integrity management

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indicators & displays... conventional to fieldbus visit our website www.beka.co.uk BEKA associates Ltd Old Charlton Road, Hitchin, Hertfordshire, SG5 2DA UK Tel +44 (0) 1462 438301 Fax +44 (0) 1462 453971 e-mail sales@beka.co.uk

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idely-publicised catastrophic failures of forged materials in deep water applications have called into question the structural integrity of such products and focused industry attention on the need for carefully-managed ‘integrity management’ of key components. Errors in material selection at the design stage, the use of incorrect heat treatment techniques and inconsistent mechanical testing regimes, often involving test pieces not taken from the actual components, can lead to product failures during operation, typically resulting in significant environmental, safety and financial costs.

With suppliers to the oil & gas and marine industries particularly appreciating the need for integrity management of deep sea components to prevent expensive failures or prolonged shutdowns, Yorkshire-based independent heat treatment and metallurgical testing specialist Keighley Laboratories is experiencing an upturn in demand for first article inspection of pre-production components, to ensure meeting operators’ engineering specifications. It is a preventative measure that the company believes could be adopted more widely, especially with the life expectancy of products extending from ten years to 25 years or more, often in extremely harsh and corrosive environments.01535 664211; lstott@keighleylabs.co.uk, keighleylabs.co.uk

British Assembled Italian Passion * UK assembly to meet quicker response times * Assembly of Medium size range in almost all configurations and ratio’s up to size 250 * Local component stock holding of helical, helical bevel and planetary range * Investing in people, infrastructure and tooling to meet growing sales demands * Now, with Rossi’s Global assembly standards in Britain

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3

Rossi UK Ltd

Unit 8/9, Phoenix Park Estate Bayton Road, Exhall - Coventry CV7 9QN Ph. 02476 644646 - Fax 02476 644535 www.rossi-group.co.uk Email: info.uk@rossi-group.com

www.mepca.com | 13

special focus: temperature monitoring & control

Just the right ingredient for 3,000°C oven refit success New heating system for baking carbon at high temperature and turning it into graphite electrodes needed a sophisticated temperature controller. The answer was the KS98-1...

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mproved product quality after an upgrade on a major component manufacturer’s process oven shows why West Control Solutions’ KS98-1 is a powerful solution for temperature control.

The special oven concerned provides temperatures approaching 3,000°C as part of the process to make graphite electrodes that carry the electricity that melts scrap iron and steel in electric arc furnaces.

The component company was using an old-fashioned oil burner to heat the oven but wanted to upgrade by replacing the old ¼ DIN controller, while also adding a special gaseous combustion control.

Another aim of the upgrade was to improve product quality.

A graphite electrode needs to be evenly heated throughout, but a gas burner may heat areas of the oven at different rates and intensities. This can result in expensive wastage if electrodes are damaged through overheating or because they have not been heated evenly. A new heating system was duly designed, but it would not work with a standard controller; the new design required a more sophisticated controller with, for example, sequence controls, but one that would also be easy to operate.

The KS98-1, a compact mini PLC and DIN controller proved the right retrofit solution because it fitted the existing ¼ DIN housing, with all the

The KS98-1 enabled a swift and energy-efficient upgrade to the process oven of a major component manufacturer

necessary I/O options already on board. The KS98-1 was also costeffective because other units would have taken longer to programme.

For example, the KS98-1 provides a library with a lot of tested Programmable Logic Controller (PLC) and maths function that is not normally available in a DIN controller.

Another significant benefit of the KS98-1 is that it has a communication interface for modern fieldbus systems; in this case the complete process is controlled via Profibus.

Figures show the customer is now making monthly energy savings of around 20% and also reducing CO2 emissions.

West Control Solutions is a global specialist in temperature control.

The company HQ is based in the UK with offices worldwide. Products are sold directly from West Control Solutions or via distributors. west-cs.co.uk

Video helps improve temperature control efficiency European Technical Support Manager Ian Parnell uses the video guide to discuss avoiding overshooting during a set point change

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est Control Solutions has released the latest in its helpful series of video guides designed to 14 | www.mepca.com

assist customers in achieving the best possible temperature control efficiency.

The new guide, Set Point

Ramping and Ramp Soak, deals with issues such as avoiding overshooting during a set point change, and making a smooth transition from one operating point to another.

The guides are intended to show better solutions to handling potential problems, as well as offering a stepby-step approach to ensuring good practices. No other manufacturer in the control systems industry has yet provided audiences with videos of this kind that discuss and explain how control systems work and their suitability for a viewer’s application. youtube.com/user/ WestControlSolutions

HYDROTECHNIK Test & measurement equipment

MINIMESS™ TEST POINTS

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• A lifetime leakfree guarantee • Suitability with almost any fluid or gas • Connect and disconnect under full stem pressure without the loss of fluid or gas.

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CANpro USB from Softing: High Speed USB to CAN Interface

DEVELOPMENT TOOLS

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Real-time responsiveness for a real-time network

www.hitexautomation.co.uk automation@hitex.co.uk 024 7669 2066

www.mepca.com | 15

product news

A multitude of applications for PMD sensors installed in direct proximity of the machining centre. The coolant used here would put the photoelectric sensors out of action within a short time and cause malfunction.

Time of flight measurement of the light

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n many applications of conveying and material-handling it’s important to reliably detect the presence of an object, and lots of different sensors, operating with various measurement methods, are available for this task.

So-called photonic mixer devices (PMDs), based on a time of flight measurement of laser light, provide lots of advantages at a low price, and ifm electronic is now able to offer new PMD sensors at a price which compares well with conventional photoelectric proximity sensors, therefore opening up many potential uses for this technology.

Photoelectric sensors are often used in material-flow applications, but in some cases this is problematic. A typical case is gear housing finishing. The machining centres where gear housings are finished in a chip-removing process are automatically controlled and fed. To avoid collisions – for example, of feeding equipment – it is necessary to detect the exact position of the gear housing and the carrier. This task can sometimes be difficult when using conventional photoelectric sensors, for example diffuse reflection sensors or light barriers, since they have to be

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A solution for such difficult tasks is provided by PMDs, which measure the time laser light transmitted from a sensor needs to reach an object and come back again – known as a time of flight measurement. To achieve this, the light of a laser diode is frequency-modulated, then the sensor measures the phase shift of the reflected light and can thus determine the time of flight and therefore the distance with a high degree of precision.

PMD sensors have many other advantages, including range. ifm’s new O5D and OID PMD sensors, for example, have a 2m range.

In addition, installation is flexible and comparatively easy. With conventional photoelectric sensors, the switch point has to be set in the application for which the real object to be detected is required.

This is much easier with the PMD sensors as sensing range can be set before start-up. The user can either measure it or adopt it directly from the 3D design drawing. PMDs measure distances irrespective of an object’s surface and, furthermore, the background suppression of such sensors functions almost perfectly.

Even reflective surfaces in the beam path of the sensor – a typical example being the safety vests of staff – do not cause any incorrect measurements.

Two different operating concepts This innovative technology can

The O5D PMD sensor can be set via two buttons – the integrated display shows the current sensing range

be used in many price-sensitive applications. The housing also corresponds to that of photoelectric standard sensors. The O5D’s dimensions are 56 x 18, 2 x 46.5mm and can be easily installed using the fixing accessories available as an option. The OID can be easily fixed via the M30 thread of the housing. The two new PMD sensors not only differ in housing but also in operating concepts. The switch point of the O5D can be set conveniently and intuitively via two buttons. The switch point of the OID is adjusted via a setting ring.

Set-up of both is very easy. The user can select one of the two housings according to his preferences. The new PMD sensors have an IO-Link interface, through which distance values can be read, for example.

Laser distance measurement allows new options The new PMDs from ifm electronic provide many new possibilities for the use of this technology. The sensors use the chip design from A scaled setting pmdtechnologies – a company that joined the ifm group in January. ring ensures Many applications that have so easy and far been reserved for other sensor reliable setting types can now benefit from the of the sensing advantages of PMD sensors. range for type ifm.com OID

FullMetalUKA4.pdf

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health & safety

Close the door on dangers of automated production Christopher Knollys, MD of sara LBS, explains how integrating machine protection doors into your production areas can reduce the risk of accidents while boosting productivity

The Rapid Protect range has been designed to cause minimal interference with the production process while still delivering absolute protection

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ccording to the HSE, almost 700,000 workplace injuries occur every year in the UK. This is estimated to cost employers a total of £3.17 billion.

Unsurprisingly, the manufacturing industry has one of the highest accident rates, meaning that it bears the brunt of these costs. To avoid injuries and costly insurance payouts, employers need to be aware of the latest technologies available to make the workplace safe.

Automated production lines bring huge benefits as they can operate continuously with no risk of human error. Automated cells which may cause welding splatter or flying sparks etc are often positioned behind machine protection doors which improve the efficiency of a work space by reducing the area that needs to be kept clear due to potential hazard.

However, as with all safety equipment, it’s important to ensure that machine protection doors incorporate all the required features.

As an example, access to a machine may need to be repeated regularly and in some cases the machine may need to be isolated prior to entry.

This means proper integration with

18 | www.mepca.com

production systems is crucial. The need for integration means many industrial door manufacturers now offer bespoke products. sara LBS, for instance, has developed the Rapid Protect series of high-speed roller shutter doors in consultation with its clients.

A major part of the design is the materials used to produce the finished product as they must simultaneously provide protection from hazards and enhance reliability despite frequent use. The use of transparent sections of curtain to allow visibility of machinery may be required, or in the case of welding equipment, the use of flameretardant material or the provision of anti-UV windows. All aspects of operation must be considered in order to deliver not only the customer’s requirements but also those of the Health and Safety at Work Act. The sara LBS range of machinery protection doors includes doors suitable for most locations and environments, including the Rapid Protect 2000, a high-speed aluminium door designed for machinery and laser protection, or the Rapid Protect 300, which comes

as standard with a noise-reducing RollTex curtain, plus optional alternatives including transparent PVC with coloured safety stripes.

The Rapid Protect range has been designed to cause minimal interference with the production process while still delivering absolute protection.

The door can be integrated into the automated assembly process and features a fail-safe Category 4 PLe - ISO 13849-1 switch which detects when the door is fully closed and prevents machine start-up until then. This enables a rapid switch from complete isolation of a production stage to easy access in seconds.

The fast operation is made possible with sara LBS’s patented MCC Vector Control System. This allows the Rapid Protect doors to reach operating speeds of up to 2.4 m/s and gives operators the chance to programme separate opening heights for different components passing through.

Automated production is a fantastic tool for improving a site’s efficiency. However, because of the inherent lack of supervision it is essential that safety is treated as a priority.

Most good suppliers will be able to specify and install a bespoke system of machine protection doors, as well as provide after-sales servicing and maintenance support. sara LBS offers outstanding design and performance which has led to the company being a registered supplier of almost all major automotive manufacturers and its equipment can also be found in a large number of distribution depots across Europe. saralbs.co.uk

pumps & valves

Safety and performance with medium-pressure valves

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ifold, official partner of the Marussia F1 team, has linked safety with performance to broaden its valve line with a range of mediumpressure ball and needle valves, delivering safe, reliable operation to 20,000 psi / 1379 bar.

Both valve types are available in 1⁄4”, 3/8”, 9/16”, 3⁄4” and 1” tubing sizes, comprising a coned and threaded connection.

The connection method allows for increased flow rates due to the larger bore sizes, common within this range. The valves are constructed from high-tensile 316L CW stainless steel (exotic materials available).

The range comprises needle valves, ball valves, manifold valves, check valves, fittings and adaptors.

The valves are designed with unique features alongside many standard features, which makes the product far superior to conventional products on the market.

The medium-pressure ball valve range is available as a floating or trunnion style and incorporates an innovative locking device.

20 | www.mepca.com

This design allows the valve to maintain its through panel mount function and is pressure-tested in accordance with API 598 & BS EN 12266-1; it is also proof-tested to 1.5 times maximum working pressure. These valves are offered in a wide range of configurations, with an operating temperature range of -46°C to +225°C (-20°C to +180°C) as standard.

The medium-pressure needle valve range is designed with a unique maintenance-free stemsealing system.

Advantages This eliminates the loss of integrity often experienced overtime with traditional packing glands. There is also a secondary metal-to-metal seal system which reduces potential leak paths.

Further product advantages include the unique stem treatment to prevent galling, non-wetted threads, fail-safe open and closed system and many more features and benefits.

These valves are offered in a wide range of configurations, with

The Bifold Group has broadened its valve line with a range of mediumpressure ball and needle valves

an operating temperature of -73°C to +315°C (-20°C to +170°C) as standard.

Bifold is constantly carrying out vigorous research and development on all our products, ensuring that its valves represent the best of what it does.

The Bifold Group is supported worldwide by a global network of agents and distributors. Bifold is a world-class supplier of the widest range of switching instrument and piping valves and pumps for use in the oil and gas upstream and downstream sectors.

Its innovative and reliable range of high-tech products and accessories, specifically designed with the customer in mind, has gained worldwide approvals and credibility for the onerous conditions as found in hazardous (classified) locations, hostile, corrosive and sub-sea environments.

For innovative and reliable valve solutions, visit the company’s website, where more detailed information and a PDF brochure can be downloaded. bifold.co.uk

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fluid & gas handling

Dynamic valves help you get the balance right Stephen Hart, MD at Frese, comments on why dynamic balancing valves are the future

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control signals with a flow setting mechanism and an integral differential pressure controller to maintain a constant pressure across the valve seat.

The design flow can set below the maximum for any valve by adjusting the area past the control valve seat or past a second seat within the valve body. Neither method offers accurate temperature control at low flow settings.

If a separate regulating seat is used to set flow the valve authority is reduced, distorting the control characteristic toward a fast-opening Complicated and valve at low flow settings. If a expensive Waterborne heating/cooling systems reduced modulating stroke is used to set flow below the maximum typically consist of a plant room a dead band or loss of valve and circulating pumps to distribute rangeability will result unless an heated/chilled water through pipework to plant room air handling expensive self-calibrating electromechanical actuator capable of or in room fan coil units or other heat exchangers. reducing step increments at shorter Until recently water flow through strokes is used. Some PICVs have a coil in these heat exchangers a flow setting device that neither was usually controlled by three-port reduces the available modulating temperature control valves that stroke nor distorts the control modulated water flow through a characteristic as the flow is set below the maximum. bypass to regulate power output from the heat exchangers. Manual The Frese Optima is a balancing valves ensured each heat dynamic PICV valve which offers exchanger received enough heated a more economic alternative. A or chilled water to maintain the self-regulating valve, it reacts indoor air temperature. Two-port independently to changes in system pressure to throttling has also been used, but maintain flow rates in both cases the end result was a and includes the system that still wasted energy and functions of a twowas difficult to adjust. port automatic Throttling two-port control valves temperature results in fluctuating water pressure control valve, a in the system which can be used to change pump speeds to save flow-limiting balancing valve and differential energy but also creates unwanted underflows and overflows, leading to pressure control valve within poor temperature control. a single valve body rather Standard pressure independent than as separate units.

By automatically adjusting control valves consist of either their flow coefficient within preset a rising plug or characterised parameters, the valves do away with ball which can be actuated by stablishing hydraulic balance within a wet climate control system can be expensive, complex and inefficient. Even modern variable speed pump systems suffer from energy wastage due to their complexity of design and the need for many valves to control fluid flow. But advances in valve technology now mean that systems can be controlled more accurately, with fewer valves, more efficiently, helping businesses save money on operating costs.

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Right: Frese Managing Director Stephen Hart

Below: Dynamic valves combine different functions within a single valve body rather than as separate units

the need to manually balance the system.

Greater efficiency The Frese Optima simplifies system design by doing away with double regulating valves at branches, risers and pumps.

Instead, valves are only required at terminal coils. Dynamic balancing is particularly beneficial in variable-flow systems with inverter pumps, pressure sensors and twoport control valves. At full load the balancing valves apply a constant limit to the fluid flow.

When the two-port valves close, pump pressure downstream of pressure sensors increases while upstream it decreases.

To counteract this Frese Optima protects against underflows in the system by opening up and reducing resistance when less pump pressure is available.

Despite fewer valves in the system they maintain 100% authority regardless of fluctuations in pressure using its own balancing and thermostatic components...

For much more on the benefits of the Frese Optima dynamic PICV valve, ring 01704 896012 or email info@frese.co.uk frese.co.uk

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www.mepca.com | 23

fluid & gas handling

Cider company toasts fuel and water savings

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estons Cider is saving around £42,000 per year in fuel and water costs following the installation of a reverse osmosis (RO) water treatment unit from Spirax Sarco.

The new RO system has reduced water and energy losses by cutting the amount of boiler blowdown and water needed. Accurate metering of fuel oil and water has pinpointed the savings, including 3,800 litres of oil saved over a 15-day period.

What’s more, the savings are likely to be even higher than these measurements suggest because of reduced CO2 emissions and a lower Climate Change Levy (CCL).

There are also other clear signs that confirm the savings, according to Westons Cider’s Jason Roberts.

“Before we installed the RO system I could put my hand on the boiler blowdown pipe and it was warm, so there must have been hot water being discharged frequently into the

blowdown vessel from the boiler,” he says. “Now it’s almost always cold, so we’re definitely losing less water and energy.”

Regular boiler blowdown is needed to prevent dissolved solids from accumulating in the boiler, where they can cause problems such as foaming and scale. The RO system from Spirax Sarco treats water before it reaches the boiler feedtank and removes more than 98% of contamination.

The project has shown a stepchange in control and efficiency and has enabled an increase in the boiler cycles of concentration, resulting in reduced boiler make up and boiler blowdown. A cut in blowdown from 3% to less than 1% has been achieved, saving oil, water and boiler treatment chemicals.

In fact, the RO-treated water is so clean it has effectively descaled the boiler, reports Jason: “It started out by descaling and cleaning up the

Westons Cider is saving money by investing in a Spirax Sarco reverse osmosis unit

steam system, but the blowdown rate soon dropped back to a much lower level than before.”

The Westons Cider site in Much Marcle, Ledbury makes cider and perry. The 2,000kg/h boiler produces steam for various process duties, including pasteurisation and cleaning.

Spirax Sarco, which has manufacturing operations in Cheltenham, is the world’s leading provider of steam system solutions across many different industries. spiraxsarco.com/uk

Water-quality monitor proving itself in tough conditions The Intellisonde chlorine sensor operates over an extended lifetime compared with other equipment

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ntellitect Water’s new V2 Intellisonde (IV2) in-pipe water quality monitor is proving its ability to operate well in a variety of conditions, including water containing high levels of manganese and iron salts.

The chlorine-monitoring problems associated with manganese and iron have been well known for many years, so the Intellitect development team gave this a high priority, and Intellisondes now feature a unique

24 | www.mepca.com

electrochemical configuration that effectively eliminates the issues experienced by traditional sensors.

The problems caused by these salts are the result of metal deposition on sensor electrodes, and whilst some of this will re-dissolve, the time taken for equilibrium to be achieved means that these sensors suffer from long settling times and can fail completely.

In contrast, the Intellisonde

chlorine sensor efficiently reaches equilibrium and operates over an extended lifetime compared with other equipment.

Intellitect’s Jo Cooper says: “Clients with high levels of manganese or iron salts have been delighted with the performance of the Intellisondes in comparison with traditional technologies.

“And what’s more, the facility to measure other parameters has proved very popular because it enables easy evaluation of processes such as flushing.”

The head of an Intellisonde is a mere 3.6cm in diameter, but fully populated can provide continuous water quality data for up to 12 parameters.

Measurement options include free chlorine, mono-chloramine, dissolved oxygen, conductivity, pH, ORP/redox, flow, pressure, temperature, turbidity and colour.

An ISE channel is also available for fluoride, nitrate or ammonium. intellitect-water.co.uk

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special focus: process control

Make the move to acoustic volume-mapping

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raditional methods of inventory measurement of bulk solids inside silos and warehouses include either single-point level measurement technologies such as capacitance switches and mechanical rotary paddles, which are used as alarms switches, or continuous level measurement such as ultrasonic, radar, laser, plumb bobs (manual or electronic), and ropes.

These technologies yield estimates of the levels of stored bulk solids but provide unreliable measures of volume, especially in large silos and warehouses.

Due to the limitations of basing estimates on sampling a single point on the material surface, these technologies have inherent accuracy error that can be 20% or more, and which may translate into higher investments in safety stock, excess ordering costs and non-optimal usage of storage capacity. Nuclear technology has been used for realtime inventory measurement, but has rarely been adopted because of major on-site complications related to licensing, safety, material deterioration and other factors.

These limitations are overcome by acoustic volume-mapping

26 | www.mepca.com

measurement error, guaranteeing that any stock-outs are not due to measurement error. This scenario of overcompensating with higher levels of safety stock clearly illustrates the disadvantages of imprecise level instrumentation technologies applied to the task.

Therefore, better awareness of inflows, outflows and current stock levels would allow companies to reduce required safety stock, while protecting them against supply chain changes and loss of inventory and providing greater accuracy in reporting bulk material assets. With its ability to significantly improve the accuracy of volume measurement in a wide range of inventory instrumentation, which utilises 3D environments, acoustic volumeAcoustic scanning technology to provide mapping technology can decrease volumeprecise silo volume measurement. carrying costs of safety stock. mapping The CONTOURTM acoustic volume- instrumentation, Furthermore, by reducing average inventory levels, utilisation of existing which utilises mapping device from Magnetrol storage space can be further 3D scanning accurately detects random surface optimised, allowing for additional technology to irregularities and material buildprovide precise capacity to increase production. up on silo walls, enabling the silo volume visualization of true consumption measurement over time.

Other benefits More importantly, the accurate Implementing acoustic volume volumetrics generated by acoustic mapping eliminates the need for volume-mapping allow inventory manual volume measurement, which managers to realise cost savings is the case in a variety of bulk solids from two sources: the reduction of and powders inventory scenarios stock levels, which can decrease where traditional process level inventory carrying costs, and the instrumentation is used currently. removal of labour-intensive inventory Among the other qualitative management processes. benefits of acoustic volumemapping are more accurate accounting, better awareness of Reducing stock levels yields and alerts to unexpected Many companies deploy inventory inventory changes (as experienced policies that maintain a minimum from theft or damaging events). stock over a set period of time.

Magnetrol International provides These minimum inventory levels advanced measurement and control cushion against demand spikes and solutions across a wide product and supply disruptions. If real inventory technology portfolio. Magnetrol’s drops below the minimum without strategic global network includes being measured as such, the manufacturing facilities on four chance of stock-out is higher than continents, linked by a distribution, the supply chain was designed for. sales and support system with 125 To avoid this situation, the locations worldwide. minimum inventory level is inflated magnetrol.com by the maximum possible positive

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3/10/13 11:50

special focus: process control

Adaptive approach means continuous assessment Rachel Lowell, APC Products Group of AspenTech, discusses how ensuring Adaptive Process Control is in place can deliver built-in, bottom line benefits for companies

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ptimising plant operations and maximising the profitability of assets is essential for oil, gas and petrochemical companies. Their challenges include the need to maintain product quality, reduce energy consumption, maximise throughput and increase yield, while meeting safety and environmental standards. Advanced Process Control (APC) and innovative modelbased predictive control techniques help to address these issues.

Continuous process APC eliminates the need for operators to repeatedly adjust PID controller setpoints manually.

It provides models that automate regulatory and constraint control, while optimising the process.

Savings of up to 2-6% of annual operating costs can be gained with payback often measured in months.

However, many users of APC solutions have suffered from steadily degrading benefits due to process changes, equipment aging and changing economic conditions.

Adaptive Process Control developed by AspenTech eliminates the need to approach APC maintenance as a disruptive project and creates a continuous process 28 | www.mepca.com

of assessing model quality, collecting current data and generating new models as the behaviour of the plant changes over time. The software can detect, isolate and correct problems without increasing the burden on engineering staff.

Under Adaptive Process Control the controller is modified over time in more of a continuous process. The update of the model occurs without the need to take the controller off-line and enables a company to reap the benefits of control and optimisation while the model is under maintenance. Model quality analysis, which continually runs and assesses the accuracy of the model, can detect when degradation of performance occurs.

Companies now have the ability to collect new model identification data using small perturbation background testing. The new model identification algorithm also supports the use of high degrees of closed loop data. This reduces the need for the aggressive step-testing methods traditionally used. As the new data are collected they are monitored in real time and, using AspenTech’s new automated slicing technology, bad data are automatically removed to produce a clean data set for model identification.

Adaptive modelling creates candidate models and those are automatically presented to the engineer for review. This entire process is monitored by an automated test agent and the engineer is notified in real time of

Adaptive Process Control provides a set of innovative, patented techniques for automatic adjustment of controllers in real time, says Rachel Lowell

any problems that occur.

The additional benefits of Adaptive Process Control include: • Minimising erosion of benefits • Returning controllers to service faster after turnarounds • Reducing controller maintenance costs by 25% • Increasing benefits by continually improving performance.

Conclusion Adaptive Process Control provides a set of innovative, patented techniques for automatic adjustment of the controllers in real time and elevates maintenance to a built-in and continuous part of the management process.

For process industry companies operating today the message is simple. Adaptive Process Control software delivers sustainable measurable benefits and allows companies to operate their facilities with greater profitability, safety, cost effectiveness, reliability and compliance with environmental regulations.

Adaptive Process Control delivers very significant built-in, bottom line returns. aspentech.com

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special focus: process control

Reduce costs by managing sensors and transducers

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he first areas that spring to mind when a process professional is challenged to reduce process control costs are usually purchase cost and installation. However, purchase cost plays only a small part; managing the multiple signals from sensors and transducers differently can radically affect the total cost of ownership for that process system.

Analysis Analysis by Volker Erbe, Sensors Product Manager at process control specialist Bürkert Fluid Control Systems, has revealed there could be larger savings from making changes to product selection at the initial stage of a project, changes that can have huge cost repercussions for training, start-up, process operator time, service, repairs and documentation.

Volker looked at field devices in process applications and their increasing use because of higher levels of automation. He ran simulations and drew data from a range of real applications. He also 30 | www.mepca.com

analysed initial and operational costs and all this research was taken into account in the design of the multiCELL 8619 compact field-based process controller.

This meant investing in multiple interchangeable control boards for pH, conductivity, inputs and outputs, plenty of on-board intelligence with intuitive menus and parameter settings, plus set programs for controlling a variety of analogue and digital process signals via a simple menu structure that included text and icons – all displayed on a large, clear, backlit screen that could be easily interacted with in a process environment.

The result of all this application knowledge in one product means it is hugely less expensive than a system including a separate controller, separate I/O, comms gateways and an HMI, let alone the attendant commissioning, wiring housing and install cost.

With a multiCELL it is possible to configure once, then copy and paste to other devices via an SD card, or just adapt the settings and save time. User-configurable display views mean the device can be configured once for different users or different processes, and then used to switch between different stored views.

Maintenance, monitoring interrogation and data upload/ download are all possible via one operator interface. It also means that selective access via password can provide data security and minimise handling errors by selective allocation of activities to different user responsibilities.

Thinking about usability throughout a product’s life cycle and the real TCO has led Bürkert to create a product it believes indicates the future for intelligent process field devices

Integrated menus also support calibration routines for sensor, analogue inputs and outputs, allowing configuration without having to use separate tools and wiring. The device also has a signal simulation function for sensors, input and output signals and so supports easy start-up procedures, winning time on verifying the causes of errors. Not only is the device easy to use, reducing the training required, but because it performs so many functions, standardisation is easy and the cost of on-going support and maintenance is minimised.

Plug-and-play If a device ever needs to be exchanged it can simply be replaced and the SD card used to transfer the operating parameters, providing a totally plug-and-play replacement.

“The strongest argument for the future of usability is that by using scrolling functions and icons with a very user-friendly keypad, we have effectively created a multi transmitter for various types of sensors in combination with a full process controller that you can install, use and interact with as you would use a mobile phone,” says Volker.

A typical customer for this type of new intelligent intuitive field multitransmitter/controller has a process application with multiple sensor types and arrangements in use, plus actuators and valves for performing functions in recurring applications; all providing a variety of different signals at different rates and in different formats requiring a lot of different know-how just for daily operation.

Thinking about usability throughout the product life cycle and the real TCO has led Bürkert to create a very different type of product and one that the company believes indicates the future for intelligent process field devices. bürkert.co.uk

For those who want it all… and more.

For those who want it all… and more.

multiCELL controller

ELEMENT transmitter

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ELEMENT transmitter

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Blind or full display performance? No matter which process instrumentation solution is the right one for you – Bürkert offers the matching concept! Whether this means our blind Blind or full neutrino display performance? whichseries process instrumentation solution ELEMENT transmitters orNo thematter ELEMENT with removable display, it‘s is up the right one for you – Bürkert offers the matching concept!

Whether this means our blind to you. And if you want more, why not take a look at our multiCELL multichannel transmitELEMENT neutrino the ELEMENT series withmeasurement, removable display, it‘sasupa ter/controller – with transmitters customized or display for flow and analytic as well to you. And if you generic 4-20 mA want input.more, why not take a look at our multiCELL multichannel transmitter/controller – with customized display for flow and analytic measurement, as well as a generic 4-20 mA input.

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engineering

EPLAN: electrical design tool that’s leading the way Companies that rely on older CAD systems risk falling behind competitors who utilise modern, more innovative tools, says Ken Christie, director of EPLAN UK

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omputer-aided design (CAD) systems have, since their introduction over 25 years ago, been well accepted by businesses worldwide, with each successive generation of electrical CAD software empowering users to be much more productive. However, companies that rely on old systems risk falling behind those who utilise modern, more innovative tools.

Electrical design in the UK is often still performed using simple, two-dimensional CAD systems that produce flat drawings. However, users are increasingly turning to tools that not only allow functions to be performed automatically and instantaneously, but also deliver cost savings while significantly improving design integrity and project turnaround times.

Leading the way is EPLAN software, which contains all the tools and report generators required across disciplines, ensuring greater speed, accuracy and flexibility in product development and order fulfilment. What sets 32 | www.mepca.com

EPLAN software apart from other electrical design packages is that it is database-driven. The scope of device data and components that can be accessed via EPLAN’s database is extensive and includes macros of sub-circuits, assembly drawings, function templates for an intelligent device selection, international designations, preview images and entire manuals.

EPLAN’s Data Portal currently has more than 51 industry partners and offers what is believed to be the most comprehensive list of components on any system of its kind. The EPLAN database enables users to easily select and apply the data or components required during a project, reducing project drafting and documentation by up to 80%. The database contains every type of component from the IEC symbol library, from a simple fuse to information about a PLC. Intelligent macros can be created that allow common sub-assemblies like motor drives to be inserted into projects within seconds, generating

all wire and terminal numbering and greatly simplifying production of product variants. The database can also be linked via a company’s PLM, PDM, ERP or other enterprise systems to sales, purchasing, accounting, manufacturing, service and other departments. This links engineering disciplines not only with one another, but also with other business disciplines, as well as customers and suppliers.

EPLAN’s software fosters collaborative workflows, interdepartmental and global integration, the standardisation and reuse of content and data reliability and consistency.

For EPLAN users, value comes from the capabilities and flexibilities offered by the software, EPLAN’s What sets wide partnership network and the EPLAN EPLAN Data Portal and its websoftware apart based database. Ultimately, the from other electrical design biggest benefits are realised by companies that leverage the EPLAN packages software to change how design is that it is workflows are structured and to databasestandardise product content to fully driven exploit the capability of the common platform to store and reuse data. eplan.co.uk

product news

Mono-block pumps ease installation and service

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anner International has introduced an optional monoblock-style pump head on its Hydra-Cell G03, G13 and P200 seal-less pump models.

The new mono-block pump head combines the traditional valve plate and manifold into a single component, allowing easy access to the cartridge-style valve assemblies.

The valves are accessed easily without the need to disassemble the pump or disturb the system pipework.

Routine maintenance, valve inspection and, if necessary, replacement, can be carried out quickly and efficiently and causes very little downtime while cutting service and maintenance costs.

A further benefit of the Hydra-Cell with mono-block pump head is its ability to prime quickly at slow speeds. Monoblock pump heads are available in brass or 316 stainless steel. Diaphragms are available in a range of materials from PTFE and Viton to Buna, Neoprene and EPDM, to suit the requirements of the liquid being pumped.

The mono-block pump head is reported to be a further improvement to the design superiority and operational excellence of Hydra-Cell pumps. hydra-cell.eu

www.mepca.com | 33

product news

Stop the power guzzling with energy-saving technology The improvement of energy efficiency by deploying energy-saving technologies is a solution that Murrelektronik’s customers are finding increasingly beneficial.

Just one example is Murrelektronik’s Emparro power supply unit, which has a remarkable efficiency rating of about 95%. By comparison, conventional power supply units have an expected efficiency of 90%. Moreover, Emparro emits only a little heat energy so the components next he time of the power guzzler to Emparro are exposed to less thermal stress, something which can is over. Sustainability, low energy consumption and less extend their lifetime considerably.

Murrelektronik’s MB Redundancy waste production in the process are increasingly important requirements Balance works hand in hand with Emparro to create an even more when it comes to machine and energy-efficient solution. This systems design and installations.

Left: Murrelektronik’s MB Redundancy Balance works hand in hand with Emparro to create an energy-efficient solution

T

intelligent control cabinet module puts both power supply units under an equal load, which is the best operating mode for energy efficiency. MB Redundancy Balance operates using MOSFET technology so the internal consumption of the modules is up to 87% lower than conventional diode modules.

Evolution is a great alternative choice for an energy-efficient power supply unit. The units from this series also achieve high marks when it comes to energy efficiency. They feature a unique stand-by mode that reduces energy consumption to an extremely low level. By using an MB Redundancy Basic along with an Evolution power supply they can be integrated into a system in such a way that the redundancy module will put the power supply to sleep. This equals the lowest possible energy consumption for the system. For many more energy efficiency options call 0161 728 3133. murrelektronik.co.uk

Labelling to help you meet demands of legislation Today’s tight controls and legislation put the emphasis on the employer to clearly identify potential hazards

A

n efficient workplace has never been more important and that is why you should rely upon the innovative label and signage solutions from Fine Cut Graphic Imaging Ltd to ensure your process controls and work environment is both safe and effective.

Clearly identifying potential hazards, process requirements and important information can be difficult, especially within a busy and often cluttered workspace. Today’s

34 | www.mepca.com

tight controls and legislation put the emphasis on the employer and often involve a number of measures to ensure compliance, which is why Fine Cut and the company’s diverse manufacturing capabilities can help create the most appropriate solution for your specific requirement.

Standard identification labels are offered ‘off the shelf’ via its competitively priced Fine Cut Labels Direct website (www.finecut.co.uk/ labelsdirect). The range of quality labels includes hazard warning,

electrical safety, prohibition and mandatory labels, which are all available with fast delivery and no minimum order quantity.

Bespoke label solutions are also available. Manufactured using the company’s cutting-edge facilities, all Fine Cut labels and nameplates pass stringent quality assurances and are of the highest quality.

Capabilities include state-of-the-art direct digital printing onto virtually any substrate and up to 2.5m x 1.5m in size, screen and hot foil printing, as well as laser and CNC engraving.

With an in-house design studio and an experienced technical team, Fine Cut can guide you on the latest legislation, most appropriate material, adhesive and manufacture process for your particular label or signage application. For more information or to receive a competitive quote please call 01903 751666 or visit our website. finecut.co.uk.

sustainability

Quick wins blinding manufacturers to real energy savings

Scrapped car parts given new life at recycling plant Manufacturers are still looking in the wrong places for energy savings, according to a report

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anufacturers are still looking in the wrong places for energy savings, according to an energy report sponsored by ABB. The Works Management Energy Report 2013 reveals that when it comes to saving electricity costs, some 70% of manufacturers intend to make energy savings by switching off unnecessary lights, with 67% intending to invest in more energy-efficient lighting.

Although easy to achieve, this focus on lighting costs is blinding manufacturers to the much more substantial savings that can be achieved with energy-efficient motors and variable-speed drives.

Making compressed air use more efficient was also favoured by manufacturers. John Guthrie, Energy Manager for ABB’s drives and controls business in the UK, says: “Reducing lighting costs is always worthwhile, but the real savings are achieved by reducing energy use within manufacturing processes.”

The survey reveals that many manufacturers are still not aware that motor-driven applications account for some 65% of all electricity use in industry.

Yet, only 10% of these applications have an efficient method of speed control to match motor speed with process demand.

36 | www.mepca.com

Targeting these energy-intensive applications, like pumps, fans and compressors is the way to make substantial long-term cuts in energy bills.

“Most companies can save thousands of pounds worth of electricity and some can even save hundreds of thousands of pounds by upgrading existing industrial processes, often at comparatively low cost,” says John.

Some 72% of respondents to the survey have seen their energy costs rise this year, a figure that is 12% up on last year. Fifteen per cent have seen a rise of 10% or more and a third have seen a rise of 5-9%.

“The potential energy savings in industry are staggering. Realising these savings could help to substantially reduce CO2 emissions.

However, once again, our survey suggests people are looking for savings in the wrong places and need to look beyond the obvious if they are to make a lasting difference to their costs,” John concludes.

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

The pioneering Manchester plant turns waste plastics from old cars into granules used in making new goods

A Manchester recycling plant is turning mixed waste plastics from old cars into high-quality granules suitable for use in the manufacture of new goods.

The pioneering Shredder Waste Advanced Processing Plant (SWAPP) at Trafford Park, Manchester, which is designed, built and operated by Axion Polymers, separates non-metallic fractions from the equivalent of about 800,000 cars a year.

Further processing of plastic concentrate at the multi-million pound facility creates a range of high-quality plastic chip and extruded pellets, including Axpoly PP51.

Axpoly is suitable for extrusion and injection moulding and has been used in a wide range of applications including audio equipment components, automotive parts and electronic white goods.

• Axion Polymers will also purchase post-industrial waste plastics such as pipes, conduits, crates, stillages and waste rigid plastics from the food, beverage and chemical industries.

It is also interested in sources of rigid plastics from supply-chain and logistics operations, such as transit packaging and plastic parts containers in manufacturing operations. Call 0161 925 8760. axionpolymers.com

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PKR Series Uninterruptible Power Supplies • Ideal for IT or Telecomm applications, etc • 2U, 4U & 5U 19” rack mounting or free standing • 5 models with output ratings of 1KVA, 2KVA, 3KVA, 6KVA & 10KVA • Online double conversion technology with pure sine wave output • Available with either 230VAC or 115VAC 50/60 Hz inputs and outputs • High input Power Factor • Automatic Bypass as standard • Intelligent RS232 communication port • Comes with UPS management software as standard • External SNMP, USB or Dry Contacts optional • LED and LCD display shows operating parameters • LCD display can rotate for vertical or horizontal mounting • Fitted with Yuasa NPW45 series batteries as standard for enhanced reliabilty and hold up time, optional 10 year life batteries can be fitted • Additional battery racks available for extended hold up time • EMC conforms to EN61000-3-2, EN61000-3-3, EN50091-2, CE marked • Safety conforms to EN62040-1-1 for UPS Systems, CE marked • 5 years warranty period

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product news

Light Weight industrial robots from The LBR range is groundbreaking in both performance and looks

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UKA is looking to the future with the development of the revolutionary Light Weight Robot (LBR). Groundbreaking in both performance and looks, the LBR range opens up new areas of

38 | www.mepca.com

application for safe interaction with humans that were hitherto off-limits for robots.

Program creation for sensorbased robots is simplified with state-of-the-art software support.

This also simplifies applications with multiple kinematic systems.

Its responsive collision detection function is its seventh sense for intelligent teamwork. Torque sensors in every axis enable intuitive teaching by means of direct manual guidance. This reduces costs and throughput times, and it can follow contours under force control.

The LBR’s sensors allow direct, safe interaction with humans. The way is paved for new cell concepts without physical safeguards. For the first time, humans and robots can work together on highly sensitive tasks in close cooperation.

Its sensors qualify it for sensitive joining processes that were previously only possible with expensive, external hardware and software.

The LBR’s 7 axes enable flexibility and accessibility not previously possible in industrial applications.

Its low weight, optional battery operation and installation on mobile platforms allow flexible operation.

The LBR is also a lightweight when it comes to energy consumption. This reduces costs in production operations.

LBR technology has been used in industrial series production since 2009. At automotive manufacturer Daimler, it is used for assembly of the rear-axle transmission – a demanding assembly task that requires utmost precision, and a sensitive but powerful touch.

Already, over 500,000 units have been assembled by KUKA Light Weight Robots.

KUKA Robotics UK Ltd is a wholly owned subsidiary of KUKA Roboter GmbH, Europe’s largest manufacturer of industrial robots with an annual turnover of €1.9bn.

The company is a market-leader in Europe, and No.3 in the world.

KUKA Robot Group employs more than 3,000 people globally. kuka-robotics.co.uk

When will your robots perform like this?

Ask KUKA.

The KUKA LBR iiwa

Flexible. Sensitive. Compact.

The future is a KUKA industrial robot.

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innovation

Chemical engineering is fishing for new solutions Institution’s praise for ‘exciting’ pilot plant trial which, if successful, could see the introduction of salmon food that is made from protein-rich waste of whisky production

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otential benefits of chemical engineering could soon include the conversion of waste from whisky production into feed for salmon and fish farming.

More than 500 million litres of whisky are produced in the UK each year. But for every litre of whisky produced, up to 15 litres of potentially harmful waste can be generated.

Chemical engineers from HeriotWatt University in Scotland are looking to solve this problem by converting some of the waste into protein-rich feed, which could have the added benefit of providing a sustainable and economic supply of feedstock for the growing Scottish fish farming industry.

A pilot plant trial of the Horizons Proteins project is under way at a whisky distillery to assess the economic, nutritional, environmental and chemical engineering processes involved in large scale production of the proteins.

David Brown, chief executive of the Institution of Chemical Engineers (IChemE), explains: “Distillery effluent

40 | www.mepca.com

can be damaging, but also contains potentially valuable nutrients and micronutrients. The waste can also be used to produce a microbial biomass, which has the potential to be a cheap and sustainable source of protein-rich feed.

“The academic team at HeriotWatt University have already been recognised for their excellent work by IChemE’s Food and Drink Special Interest Group. Their work and others looking at the microbial treatment of waste is very exciting and has many potential applications including crude oil recovery, healthcare and in environmental protection like bioremediation of sites affected by heavy metals and other contaminants.”

Chemical, biochemical and process engineering is the application of science, maths and economics to the process of turning raw materials into everyday products.

Professional chemical engineers design, construct and manage process operations all over the world. Pharmaceuticals, food and

A pilot plant trial is under way which, if successful, could see the introduction of whiskyfed salmon to boost sustainability

drink, synthetic fibres and clean drinking water are just some of the products where chemical engineering plays a central role.

IChemE is the hub for chemical, biochemical and process engineering professionals worldwide. With a growing global membership of over 38,000, the institution is at the heart of the process community, promoting competence and a commitment to best practice, advancing the discipline for the benefit of society, encouraging young people in science and engineering and supporting the professional development of its members icheme.org

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SM3300 SERIES 3300 WATT NE μPROCESSOR CONTROLLED PROGRAMMABLE POWER SUPPLIES

The Delta SM3300 Series of power supplies offer unparalleled performance against any other programmable power supply available on the market today. They are the culmination of 50 years of experience in the design and manufacture of high quality, high reliability power supplies. Below are some of the features associated with this product range:-

Features • AC input of 180-528V single or 3 phase 48-62Hz, with active Power Factor Correction • Five models available, with auto ranging DC outputs on four of them.

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SM660-AR-11 0-330VDC/0-660VDC 0-11A/0-5.5A • Fully programmable 0-100% for both Voltage & Current via front panel digital settings or Ethernet Controller for programming and monitoring • Options include Isolated Analogue Programming or High Speed Programming which is 10 to 20 times normal programming speed, Software Control & Interfaces and Two-Quadrant Output-Powersink.

• Excellent dynamic response to load changes • Protected against overload and short circuit conditions • EMC surpasses CE requirements for low emissions and high immunity • Power supplies can be operated in serial or parallel configuration • Designed for long life at full power with MTBF figures of 500,000 hours • Compact 2U 19” rack or bench mounting robust enclosure

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product news

Longer life and more reliable sealing in hoses, gaskets and O-rings for aggressive biofuels

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herever aggressive biodiesel and alcohol additives are utilised in motor fuels, it poses particular problems associated with unstable chemistry for the companies involved in production, blending, transportation and dispensing of such fuels. Biodiesel is subject to degradation, particularly when combined with contamination, as the increasingly aggressive fluid progresses through a production and distribution network.

Contaminated fuels can attack the hydrocarbon rubbers that are used as the sealing medium for hoses, gaskets and O-rings in the fuelhandling processes.

An additional problem of permeation is also encountered with nitrile rubbers where fuels incorporate ethanol. This can lead to the potential loss of expensive fuel and the emission of dangerous

VOCs. As biodiesel moves through the production/distribution network, it is increasingly contaminated with water and microbes, becoming more acidic in the process and causing nitrile rubber to swell and soften. This results in diminishing seal strength and hardness, leading to eventual seal failures.

For many years, however, Viton® fluoroelastomer compounds from DuPont™ have successfully withstood such attacks from a growing range of solvents and fuels.

Viton® has also proved effective overseas, having been tested with US ethanol/gasoline blends, together with butanol, which is also now being considered.

Viton® is also widely recognised for outstanding performance at elevated temperatures, as well as its suitability for conditions of -50°C to -65°C with certain biofuels when used for static sealing applications.

Viton® fluoroelastomer compounds from DuPont™ have successfully withstood attacks from a growing range of solvents and fuels

However, it is important to assure sealing products are made with genuine Viton®, with the appropriate material and formulation fluoroelastomer supplied for each application. Except for the few instances where the Viton® product is not recommended, resistance levels indicate either excellent or very good results for the applications tested. DuPont™ Viton® products are available from the UK authorised distributor, Dichtomatik Ltd. 01332 524401 dupont@dichtomatik.co.uk viton-orings.co.uk

Precise control of gaseous fuels and process media Belgas pressure regulators and gaseous control products are highperformance products ideally suited for many commercial and industrial applications

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he range of Belgas pressure regulators and general gaseous control products are available in the UK from Marsh Bellofram Europe Ltd. These highperformance products have a well established pedigree for applications in offshore oil and gas locations, and their diaphragm design is ideally

42 | www.mepca.com

suited for many other commercial and industrial applications. These can involve the low to mediumvolume supplies of non-liquid fuel and process gasses, including nonvolatile or chemically hazardous but not corrosive media.

Typical applications include gas boilers and engines, heaters,

ovens and other general gasburning products where the control of high and low-pressure supply conditions are important to safely maintain production and process outputs. Further applications also occur at gas storage and distribution terminals, or wherever there is interconnecting distribution pipework, which can also include steam supplies for power generation, food-processing, sterilising (cooking, autoclaves), industrial HVAC, textiles and paper-making etc. The precise control of non-potable or waste water supplies for specialised manufacturing processes can also be accommodated.

Dependable and cost-effective control solutions are available for applications involving natural gas, LNG, propane and butane with developing potential for shale gas requirements.

0115 993 3300 marshbellofram.eu

product news

Fascia Graphics – 20 years of manufacturing excellence but still investing to deliver the very best continued growth is a testimony to its ability to satisfy those customers across many sectors, such as medical, security, fire and instrumentation.

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Sign of quality

ascia Graphics is set to turn 20 years old and through its recent investment in two Sakurai servo-driven cylinder presses (MS80-SD) – the only ones in the UK – it continues to lead the market for the production of membrane keypads and graphic overlays. This investment provides both performance and energyefficiency improvements, and puts more distance between Fascia and its competitors with regard to performance, quality of product and energy efficiencies.

Today, Fascia serves in excess of 800 customers. The company’s

Investment in equipment provides both performance and energyefficiency improvements

As a sign of its quality, Fascia is ISO 9001:2000-accredited. ISO is an international standard for an organisation’s quality management systems (QMS). The company has also been accredited with the Underwriters Laboratories’ UL PGDQ2 status. The UL mark is the most widely recognised safety certification mark in the world, and achieving this opened up a vast US market for UL-approved products.

Understanding its customers Fascia regularly researches its

The Key to Your Success

customers to measure service levels and customer satisfaction and its most recent survey of its top 500 customers found that 90% stated the company’s membrane keypads and graphic overlays were superior in quality to its competitors.

Ivan Harris, Chief Marketing Officer of PowerOasis, commented: “Fascia are highly responsive, collaborative and professional. They have helped us identify the most appropriate materials for our membranes and have accommodated an engaging approach to turning our requirements into a finished product.

The quality of the shipped items has been exemplary.”

To speak to Fascia’s highly experienced team call 01249 460606 or email sales@ fasciagraphics.co.uk fasciagraphics.co.uk

Fascia Graphics

20 years as the Market Leader for Graphic Overlays and Membrane Keypads

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48 hour digital prototyping for new products and exhibitions

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“Delivery, quality and service are of the highest standard.”

Graphic Overlays Labels Nameplates Prototypes Reel Printed Products

Tel: 01249 464580 Fax: 01249 460404 sales@fasciagraphics.co.uk www.fasciagraphics.co.uk www.mepca.com | 43

fluid & gas handling

Control system success for off-shore gas operation ethernet cards and switches. The SCADA/HMI is formed of three operator stations, an engineering work station, a redundant server for data acquisition, a historian server for data warehousing, a terminal server for WAN connection and a GPS clock for time synchronisation.

Finally, PlantPAx formed the basis for the complete visualisation and management solution coupled to the radio and satellite links.

Results

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n offshore gas operation has optimised production and met safety targets at the same time.

The Izabela field is a gas extraction and production plant in the Adriatic Sea – comprising two offshore platforms, Izabela South and North, and an onshore Central Control Room (CCR) in Croatia.

The platforms are operated by Edina, a joint venture by Italian company Edison Gas and Croatian company INA. The facility’s role is to treat gas that is to be distributed in Italy, using existing pipelines that connect the onshore treatment plant with the offshore platforms.

Rockwell Automation and Fores Engineering Srl were selected by Edina to implement a control system and an Emergency Shut Down and Fire & Gas (ESD/F&G) solution for the offshore platforms and onshore CCR. Edina’s requirement was the installation of a user-friendly, Integrated Control and Safety System (ICSS) – in line with IEC 61511 SIL3 rules – for both the offshore platforms and the onshore

44 | www.mepca.com

CCR. The aim was to maximise production flexibility by capitalising on Edison’s experience at another offshore platform where Triple Modular Redundant (TMR) solutions from Rockwell were used. The ICSS was to be integrated onshore/ offshore through a radio link and a satellite back-up link.

Solution The design and installation of the solution was handled by Fores Engineering Srl. With help from Rockwell Automation Process Safety specialists, Fores installed a PlantPAx Process Control System onshore with remote access to the two offshore platforms.

The CCR has three operator work stations and an engineering work station with redundancy and hot back-up. The control system hardware comprised an Allen-Bradley ControlLogix PAC in Hot Backup, with I/O, serial link and ControlNet cards, alongside ethernet cards and switches. The safety system comprised a Trusted SIL 3 in Hot Backup, with I/O and remote communication cards and

The ICSS system has now been operational for a year and is performing very well with a cut in maintenance/operational costs while maintaining production capacity.

The ease of use of the PlantPAx system with TMR has provided engineering and commissioning The control and savings. Running costs have also been cut. Starting from the early safety system phase of the project, costs have being used by been saved by a number of factors: the offshore • Engineering and design phases platforms has produced a cut were undertaken without any in maintenance/ serious issues, due to the system knowledge of both the customer operational and the integrator. costs while • Information exchange with Edina maintaining has had no technical impact, since production Edison personnel already knew the capacity Trusted solution and other Rockwell Automation products.

• The experience of Fores in developing/installing several control systems over the past 10 years meant commissioning and start-up phase time scales were reduced.

• In-depth training was not a requirement due to existing system knowledge.

• Spare part inventory can be kept at a very cost effective level.

Says Pasquale Troianiello, of Fores Engineering Srl: “The complete automation systems provided by Rockwell Automation are some of the most flexible on the market.” fores.it rockwellautomation.com

• Pumadur, Pumaflor and Pumathane Specialist Resin Flooring Systems • Sealants and Coatings • Self-levelling Flow Applications • Heavy Duty Screeds • Decorative Quartz & Terrazzo Systems • Car Park Decking • Wall Renders & Coving • Ancillary & Maintenance Products

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Another NEW addition worth closer inspection.

Introducing the new Albion Solenoid valve.

Albion’s new Solenoid valves are just the latest addition to our ever-expanding industrial valve range. Brass, Stainless Steel and high temperature options come as standard and, like all of our products, they have been designed and manufactured to deliver optimum performance time after time. All of which is worth checking out, even before you check out the price.

But don’t take our word for it - ask your local distributor for Albion and see for yourself.

Ask your local independent distributor for more details or visit

www.albionvalvesuk.com

www.mepca.com | 45

directory Circuit Protection

Level & Flow Instrumentation

SCHURTER Group A global leader in Circuit Protection, Connectors, Switches, EMC Products, Input Systems T: +41 41 369 31 11 F:+41 41 369 33 33 E: contact@schurter.ch W: schurter.com

Magnetrol International UK Magnetrol is a manufacturer of high quality industrial instrumentation for level and flow measurement of liquids and gases. Magnetrol is active in the following industries: petrochemical, chemical, power, water/waste water, pharma, and food & beverage Regent Business Centre, Jubilee Road, Burgess Hill, West Sussex, repRH15 9TL or01444 T: 871313 ts & ana E: sales@magnetrol.co.uk lys

Multi–tool maintenance Drives & Controls

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Alrad TE Instruments AllDrives & Controls Ltd MA K Alrad offers High speed-precise control, with OR range of CCD Unitronics PLC’s/HMI, NanotecW and CMOS stepper motors, WEG en&t Engel m cameras for use in Machine Vision gear motors equip applications as well as suitable T: 01543 271899 illumination systems. Also a range E: sales@alldrivesandcontrols. of low power laser modules incl. co.uk spot & line emitters and structured W: www.alldrivesandcontrols. light lasers, offered in a variety of software benefits co.uk• Over 20 years of delivering maintenance wavelengths and output powers suit the application.

• Range of solutions to matchtoyour specific requirements T: 01635 30345 Industrial Drum E: sales@alrad.co.uk • Proven& byJacket hundreds of customers across Heaters W: www.alrad.co.uk a wide range of industries

Mixers & Agitators

Euromixers Euromixers manufacture Industrial Fluid Mixers for a wide range of applications from general chemicals, food & beverages to pharmaceuticals – please visit our web site for further details or contact our office, we will be pleased to help.

T: + 44 (0) 161 449 8559 E: sales@euromixers.co.uk W: www.euromixers.co.uk

Rapid Manufacturing Bureau Service

Laser Lines Ltd Specialists in offering rapid manufacturing solutions for low volume production parts typically 100-off or less, eliminating the need for expensive mould tools and long lead times. We offer a cost effective and rapid turnaround of parts.

T: +44 (0) 1295 672500 E: parts@laserlines.co.uk W: www.laserlines.co.uk

Resin Flooring

Maintenance • Now even simpler to implement, to use, and to own

Safety Flooring DeckSafe Solutions Ltd Decksafe Solutions has over 20 years experience as one of the UK’s leading distributors of moulded fibreglass grating panels, constructed using continuous glass fibre strands cured with industry approved polyester resins, and anti-slip safety products, tested in accordance with BS 7976 – 2, suited to all industries.

T: 01206 395 465 E: sales@deck-safe.co.uk W: www.deck-safe.co.uk

Valves - Actuated & Manual

Dixon Dixon offers manual and custom actuated valve packages with accessories. Dixon actuators are 1 million cycle tested. On-site 3D design and applications engineer.

Full Hygienic Products Catalogue available.

T: +44 (0)1772 323529 E: sales@dixoneurope.co.uk W: www.dixoneurope.co.uk

Water & Chemical Storage

Software

• Fully feature systems start from only £1,490 Cayman Visit www.cayman.co.uk or call Venture today to find out more Limited Multi–tool solutions Tel: 0191 296 3816maintenance • Fax: 0191 296 3856 for Advanced Industry info@cayman.co.ukCentre • www.cayman.co.uk Coble Dene, Royal Quays North Shields, Tyne & Wear, NE29 6DE T: 0191 296 3816 Laser Equipment F: 0191 296 3856 E: info@cayman.co.uk Supplies W: www.cayman.co.uk

Measurement Instrumentation

ACC Flooring Ltd Safe floors?

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This is the time for Export Your customers prefer to read in their

own language.

Drayton Tank & Accessories If you received a catalogue in Japanese or Ltd Arabic, would you read it? You’d probably just throw it away. But if it was in English, GRP and plastic water tanks, you’d look through it to see if it contained anything of interest for your company.

WRAS Approved, 45 – 100,000 We can translate your sales literature, ltr. One piece & two piece tanks, tenders, manuals, legal documents, etc. fittings and connections.into any language.

T: 0871 288 4213 QUICK – ACCURATE – LOW COST E: enquiries@draytontank.co.uk Our translators have worked in the industries concerned – they know the W: www.draytontank.co.uk vocabulary – they know how things work.

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Contact us for a free-of-charge quote:

TLM Laser Ltd For a solution that’s tailored to meet your laser equipment needs, just contact TLM Laser.

T: +44 (0) 845 260 2220 F: +44 (0) 845 260 2221 E: info@tlm-laser.com W: www.tlm-laser.com

46 | www.mepca.com

Castle Group Ltd You will spend so much time measuring and monitoring that you don’t want to be spending more time searching for the equipment. At the castleshop. co.uk we have a broad range of measuring and monitoring equipment to keep you on track.

T: +44 1723 584250 E: enquiries@castlegroup.co.uk W: www.castlegroup.co.uk

Resdev Limited We manufacture specialist seamless, hygienic, epoxy and polyurethane resin floor, wall and car park decking systems for application throughout the world.

Resdev has the ideal complete resin flooring solution.

T: +44(0)1422379131 E: info@resdev.co.uk W: www.resdev.co.uk

Oxford Translations Find new customers in the up and coming countries – Brazil, Russia, India, China – Tell them about your products and services in their own language.

Oxford Translation Ltd, John Eccles House, Robert Robinson Avenue, The Oxford Science Park, Oxford OX4 4GP T: 0330 332 6000 (in UK) T: 44 (0)1869 240 560 E: info@oxtran.com W: www.oxtran.com

Tektran Translation

John Eccles House, Robert Robinson Av The Oxford Science Park, Oxford, OX4 4 tel: 0330 332 6000 (in UK) tel: +44 (0)1869 240 560 fax: +44 (0)1869 240 916 email: info@tektran.co.uk www.tektran.co.uk

The Bifold Group Broadens its Valve Line with a Range of Medium Pressure Ball and Needle Valves, Delivering Safe, Reliable Operation up to 20,000 psi / 1379 bar.

The range comprises of needle valves, ball valves, manifold valves, check valves, fittings and adaptors. The valves are designed with unique features and offered in a wide range of configurations, alongside many standard features which makes the product far superior to conventional products on the market.

Our medium pressure ball valve range is available as a floating or trunnion style, with an operating temperature range of -46ºC to +225ºC (-20ºC to +180ºC) as standard.

Our medium pressure needle valve range is designed with a unique maintenance free stem sealing system, with an operating temperature of -73°C to +315°C (-20°C to +170°C) as standard.

High tensile 316L CW stainless steel.

Innovative locking device available on the ball valve design, which does not compromise through panel mount function.

Maintenance free stem sealing system eliminating loss of integrity.

A secondary metal to metal seal design provides a failsafe open and close system.

Tested in accordance with API 598 & BS EN 12266-1.

For more information Bifold, Greenside Way, Middleton Manchester, M24 1SW, UK. Tel: +44 (0)161 345 4777 Fax: +44 (0)161 345 4780 Email: marketing@bifold.co.uk Web: www.bifold.co.uk

A4 Advert for MEPCA November Issue 2013.indd 1

Official Partner of the Marussia F1™ Team

www.bifold.co.uk 09/10/2013 11:57:58

Sweep Easy.

Finance available on all Kärcher sweepers*.

To find out more visit www.sweepeasy.co.uk, call 01295 752142 or email cleaning@karcher.co.uk

Kärcher sweepers combine ease of use, clever ergonomics and optimal efficiency to offer you a simple and highly effective solution for cleaning your business.

From push sweepers to ride-on sweepers, Kärcher’s state-of-the-art machines work both indoors and outdoors; removing dirt, dust and debris with ease.

Whatever your sweeping needs, Kärcher has a sweeper to match your requirements.

www.sweepeasy.co.uk *All offers of credit are subject to underwriting and approval by Kennet Equipment Leasing Ltd. Please ask your Kärcher dealer for more information.