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Global Success Through Innovation

Process Engineering Control & Manufacturing Issue 13 ÂŁ3.95

practical advice & solutions on the technical and management challenges faced by engineers and managers in the process engineering & manufacturing industries.

Control & 34 Automation

Electrical & Electronics

24 Air, Gas & Odour Control

Facilities 54 Management

Health & Safety 68

Measurement Process 102 & Monitoring 88 Technologies


Machining & Machinery 75

Storage, Handling & Equipment 120

industry news & events || boilers & maintenance || fluid handling || manufacturing || software & systems || water & effluent treatment

Man and Machine Training Academy

Man and Machine offer an extensive range of Autodesk  training 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

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Global Success Through Innovation

Process Engineering Control & Manufacturing Editor: Elizabeth Hutton Assistant Editor: Justine Sanders Sales Director: Benjamin Dubois Sales Manager: Sophie Plowman Circulation Manager: Josh Holmes Digital Manager: Jamie Bullock Publishing Director: Martin Holmes

Issue 13 Contents Tel: 01227 392575

Email: elizabeth@pecm.co.uk

Tel: 01227 392575

Email: justine@pecm.co.uk

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Email: benjamin@pecm.co.uk

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Email: sophie@pecm.co.uk

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Email: josh@jdholmes.co.uk

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Email: jamie@pecm.co.uk

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Email: martin@pecm.co.uk

M H Media Global Ltd. St Augustine’s Business Centre, 125 Canterbury Road, Westgate On Sea, Kent, CT8 8NL Tel 01843 830249 Fax: 08721 152240 www.pecm.co.uk All web addresses are inter-active, simply click the web address of your choice to view the company website. There is also a useful tool bar where you can search for a specific product, or simply view the index on page 3 and then type in the page number of the section that you wish to view. Please mention Process Engineering Control & Manufacturing when responding to items in this issue. Every effort is made to ensure the accuracy and reliability of material published in Process Engineering, Control & Manufacturing however, the publishers accept no responsibility for the claims or opinions made by the contributors, manufacturers or advertisers. No part of the publication may be reproduced or transmitted in any form or by any means, mechanical, electronic (including printing), recording or stored in any information retrieval system without the prior written consent of the publisher.

News & Events Editors Choice Air, Gas & Odour Control Connectors & Fittings Control & Automation Electrical & Electronics Facilities Management Fluid Handling Health & Safety Lubricants Machining & Machinery Maintec Preview Measurement & Monitoring Motors & Gears Process Technologies Southern Manufacturing Software & Systems Storage, Handling & Distribution Tools Valves & Flow Control Waste Management

7 11 24 31 34 42 54 61 68 74 75 80 88 100 102 108 111 120 126 128 130


Y-type strainers 3 asket strainers 3 Duplex strainers 3 T-type strainers 3 Radial fin cartridge filters (to 1 micron) Filter separators and demister pads 3 Quick release closures Materials available include: Carbon Steel & LTCS 3 Stainless Steel 304/316 3 Duplex and Super Duplex Stainless Steel 6Mo 3 Monel 3 Aluminium ,*)2e 3 Cunifer 3 Hastelloy 3 Incoloy 625 & 825 3 Titanium 3 Norsok MDS

Based in the UK, Barton Firtop manufacture and stock hold an extensive range of ASME/CE Marked Y-type, Basket and Duplex strainers.

Contact: sales@bartonfirtop.co.uk or visit our website: www.bartonfirtop.co.uk Issue 13 PECM



ollowing David Cameron’s announcement that both will be taken into service with the Royal Navy, renewed excitement has gripped the engineers building Britain’s two new Queen Elizabethclass aircraft carriers. With renewed excitement comes renewed innovation, including specially coated enclosures from Spelsberg UK.

The 280m-long carriers are the largest-ever ships built for the Royal Navy. The ships will be equipped with a variety of aircraft types including F-35B Joint Strike Fighters and helicopters. As the future flagships of the Royal Navy, every technical detail of these giant, cutting-edge warships has been carefully thought through.


PECM Issue 13

Ten thousand people have been involved in their design and construction; and longterm jobs have also been secured as the vessels will need continued maintenance throughout their service life. Unsurprisingly, there are innovations – both small and large – relating to these ships and the many systems within them.

Ten thousand people have been involved in their design and

construction In fact, to drive all the onboard systems, each ship is

capable of generating 110MW of power. This is distributed around the ship via 1.5 million metres of cable, so an enormous number of junction boxes and enclosures are required. The boxes need to be incredibly tough, withstanding the salty marine atmosphere, the rigours of naval exercises and possibly the actual heat of battle. They also have to be safe and completely predictable in the event of a fire.

It might be expected that, due to their inherent strength, metal junction boxes would be used in the multitude of electrical systems on board each carrier. However, metal units are prone to damage caused by corrosion and denting, so the Aircraft Carrier Alliance which is building these ships, has opted for

The 280m-long carriers are the largest-ever ships built for the Royal Navy.

polycarbonate units. Spelsberg UK enclosures were previously specified during the first stage of the project, but now the company has been asked to supply models from its TK range – each one precisely customised for its particular duty. Chris Lloyd, General Manager at Spelsberg UK, explains his company’s contribution to this massive national project: “The enclosure requirements were anything but ordinary, so it was inevitable that we have developed a bespoke solution. “Each box is internally spraycoated with a special metallic paint that inhibits EMC [electromagnetic corruption] transmissions. Then they have several coatings applied to their outer surfaces; one is anti-reflective, while another ensures that in the event of a major fire they do not melt and drip, but instead turn into a foam that continues to protect the electrical connections within it. “Each enclosure is also CNCmachined so that it exactly meets its duty requirements and fits within the - usually tight - space allowed for it. A special lid-sealing mechanism was also developed to replace the usual steel screws, which could come undone due to the constant vibration.

The enclosure requirements were anything but ordinary, so it was inevitable that we have developed a bespoke solution. contributes to significant performance gain, lowers delivery costs, improves installation times, and therefore contributes to the schedule and budget requirements.”

“Another consideration, and one which surprised us initially, is weight saving. A junction box may only weigh a fraction of a kilogramme compared to the 65,000 tonne super carriers, but the cumulative effect of many individual weight savings

To see if plastic enclosures would be suitable for the project, designers working for the Aircraft Carrier Alliance approached Spelsberg UK to recommend the best products for the job. Spelsberg UK is the largest supplier of nonmetallic enclosures ex-stock in the UK and offers complete customisation and assembly on nearly all of its products. It was able to recommend its polycarbonate IP65 TK enclosure for the project. By supplying the enclosures fully assembled (including terminals), Spelsberg was able to help the shipbuilder greatly reduce on-site installation time.

As the future flagships of the Royal Navy, every technical detail of these giant, cutting-edge warships has been carefully thought through.

The two carriers, HMS Queen Elizabeth and HMS Prince of Wales, are far from conventional designs. For instance, instead of the usual single control tower to the side of the flight deck, it has two control islands. In normal

times the forward island controls the ship’s navigation and the rear controls aircraft movements. However, they can swap roles, or perform both roles simultaneously, should the situation demand. This gives the carrier a far higher than usual level of redundancy; meaning it can continue operations even if badly damaged. The flight control island is closely linked to the ship’s operations room, navigation bridge, flight deck and hangar operations centre; has a groundbreaking 300⁰ field of view through some of the world’s toughest glass; and equipped with a state-of-theart flying control solution, similar to that used at RNAS Yeovilton and at the RAF airfield that was established in Camp Bastion, Afghanistan. Spelsberg UK is a specialist supplier of non-metallic enclosures with a range of designs that covers most application requirements. It offers an in-house CNC and assembly service to all of its customers – helping them to specify the perfect enclosure and delivering it ready to Issue 13 PECM


go. In addition, its coating service allows enclosures to be treated to withstand almost any environmental challenge on the planet. To learn more about the Spelsberg range of enclosures and its customisation capabilities get in touch with a member of the sales team or visit www.spelsberg.co.uk. “Space for you” Spelsberg’s company philosophy is based around the idea of providing flexibility and freedom to its customers. The space provided within each junction box; the large distribution and warehousing space; and the freedom to customise almost any product, irrespective of quantity, all equates to “Space for you”.

Spelsberg is one of the largest manufacturers of electrical enclosures in the world. With over 4,000 enclosures available as standard and further customisation possible, it offers solutions for almost any application. With the largest supply of non-metallic enclosures, ex-stock in the UK, its products are often available for delivery within 24 hours; customisation is possible on any product, including bespoke entries, engraved corporate logos or fitted terminals, within 48 hours. Products can be ordered direct from Spelsberg or from most leading supply specialists including RS, Rapid, Farnell and CPC.

Each box is internally spray-coated with a special metallic paint that inhibits EMC [electromagnetic corruption] transmissions.

News & Events LumaSense presents the PULSAR 4 for Condition Based Monitoring of Petrochemical Combustion Vessels at SOGAT 2015 LumaSense Technologies, Inc.® will showcase the next generation petrochemical infrared sensor, the PULSAR 4 at SOGAT 2015, a very targeted congress for Sour Oil and Gas Advanced Technology in Abu Dhabi. With installations at over 550 petrochemical facilities worldwide, the PULSAR 4 is LumaSense’s latest addition to its E2T line of petrochemical infrared sensors. Oil & Gas operations are heavily dependent on combustion based processes to supply the world’s growing energy needs. The PULSAR 4 is intended for monitoring the Refractory and Gas temperatures inside Sulfur Recovery Units, Sulfur Burner Furnaces, and Thermal Oxidizer Furnaces frequently found at these facilities. “Any one of these vessels can force a shut down that will cost $1M or more per day”, said LumaSense CEO, Steve Abely. “Unplanned downtime eats into planned profits, whereas increasing uptime increases profit. The PULSAR 4 is a condition based maintenance system to protect refinery profits”, continued Abely. The PULSAR 4 is an explosion proof infrared thermometer (pyrometer) with the ability to see through flames and simultaneously deliver the Refractory Temperature and Gas Temperature with precision to 0.3 °C and a range of 350° to 2000° C. The PULSAR 4 Advanced features LumaSense’s propriety Smart Flame Measurement Algorithm (Smart FMA™) which accounts for flame transparency that can affect the temperature readings for a more precise view of activity inside these vessels. LumaSense’s updated and powerful InfraWin software interprets the data from the PULSAR 4 for analysis inside control room.


APS Showcases Innovative Hinowa Access Platforms at Maintec The unique Hinowa Lithium range of powered access platforms use advanced lithium-ion batteries to enable clean, quiet and emissionsfree working at height. Versatile Hinowa machines are ideal for facilities maintenance operations. Compact dimensions ensure they can pass through doorways and between buildings; while utilising tracks instead of wheels distributes the ground pressure, making them suitable for use indoors as well as on rough terrain. Access Platform Sales (APS) is the exclusive UK distributor for Hinowa lifting and material handling products, providing a comprehensive customer service including sales, finance, product support and spare parts. Visit APS on stand M32K.

Innovation of Great Value ZF Technology in wind turbines ZF Wind Power is a globally established designer, manufacturer, and supplier of tailor-made gearboxes for wind turbines. The business unit is part of the Division Industrial Technology within the ZF Group and the result of a successful integration between two technology leaders. The merger between ZF, one of the world’s leading automotive industry suppliers, and the former Hansen Transmissions, one of the global leaders in wind turbine gearboxes, is propelled by a combination of experience, expertise, efficient production, and innovation. With state-of-the-art manufacturing plants and worldwide service locations, ZF is moving together with its customers into new markets with optimal supply flexibility. ZF supports customers to remain competitive responding to shifts in regional demands. Producing multi-megawatt gearboxes efficiently in serial production with a consistent high level of quality and reliability requires excellence in manufacturing, logistics, assembly and testing. These critical activities are all performed in-house. Over three decades of know-how in the wind industry have enabled ZF to confidently meet any challenge customers may address.



Bite-sized training

Good to Go Safety

A new series of short, fully customisable, costeffective health, safety and environmental courses is now available from RRC International. They offer the knowledge, expertise and professionalism for which RRC is known in a bite-size, topic-focused format.

Good to Go Safety has been shortlisted for “Contribution to Safe Working at Height” at the prestigious International Awards for Powered Access (IAPAs) in March 2015.

Aimed at giving the non-specialist confidence in working safely, the training can quickly be tailored with a company’s own policies and procedures, systems and documentation to feel like their own in-house course. Delivered RRC’s fully qualified and experienced trainers, the programmes are intended to inspire and invigorate the workforce, bringing each subject to life. They can be legislation-neutral, so are also relevant to a wide international market.

Tel: 0208 944 3100 www.rrc.co.uk

Email: info@rrc.co.uk

Their tagging and checklist systems are available for a wide range of workplace equipment including MEWPs, harnesses, ladders, scaffolding, forklifts, racking and vehicles amongst others. The innovative range helps companies to improve safety, reduce maintenance costs and comply with legislation. Pre-use inspections allow the status to be displayed on the equipment whilst duplicate copies are retained for management records. The full range is available to purchase online at www.goodtogosafety.co.uk and the company will be exhibiting on Stand E46 at the Health & Safety Event, NEC, 24-26th March 2015.

Tel: 01592 655 646 Email: enquiries@goodtogosafety.co.uk www.goodtogosafety.co.uk

Issue 13 PECM


News & Events Radleys launch new website

There’s no room for slip-ups on a roof

Radleys (Saffron Walden, UK) is pleased to announce the launch of its new website www. radleys.com which, with improved navigation and functionality throughout, makes finding a product, learning more about applications, or searching for a distributor easy and intuitive.

The Brymore Group are a successful property and estate management company. One of the many properties they own is an office block in Guildford Business Park, Surrey. They had an issue with the roof, because workers needed to access the air conditioning units to service them.

The site includes extensive product information, Frequently Asked Questions, technical data, videos and case studies to help customers understand Radleys complete range of chemistry productivity tools.

Brymore sub-contract to Montagu Waterproofing, who provide a comprehensive flat roof waterproofing and roof maintenance service to property owners and facilities management companies. Montagu Waterproofing had a secret weapon in their arsenal – FibreGrid, or rather FibreGrid’s GRP Walkway System, which is both high performance and low maintenance.

The new website means that customers can now benefit from richer online content that is easier to navigate and share with others. Mark Radley, Managing Director of Radleys says “The new website is just the start of a series of exciting digital information and marketing initiatives for Radleys to help our customer’s find the information they need.”

Glass reinforced plastic grating has many advantages over traditional steel and aluminium, which makes it particularly pertinent to the roof of a building. It is lightweight yet tough, won’t rust and, most importantly, is anti-slip. For the record, it is fire retardant, chemical resistant and non-sparking too, which means you can use it in sensitive areas, such as facilities where flammable gases might escape.

Tel: 01799 513320


Tel: Mark.Goater@fibregrid.com

IPP Logipal, part of Pooling Partners, Europe’s #1 in pallet pooling and production, and the UK & Ireland’s second largest pallet pooler, last year achieved its tenth successive year of doubledigit growth since its foundation in 2005.

Chancellor opens University of Chester’s Thornton Science Park

Carl McInerney, country director, IPP Logipal UK & Ireland, part of Pooling Partners, commented: “2014 has been another great year for Pooling Partners in the UK & Ireland with double-digit growth once again achieved. This not only reflects the rising demand for smart pallet solutions but also our concerted focus on exceeding our customers’ service expectations over the past decade. “Our team in the UK has earned a strong reputation for customer service excellence, backed by awards won last year, and it has established win/win relationships with customers. This has resulted in more customers using Pooling Partners’ services than ever before. “The UK senior management team brings together unrivalled industry-specific experience and our grass-roots approach to employee recruitment, induction and training is proving effective. This has meant that, as we continue to grow, we retain the right skills and experience to maintain our momentum and continue to raise customer satisfaction levels.


Officially opened by The Chancellor of the Exchequer, The Rt Hon George Osborne MP, Thornton Science Park provides a major research and innovation hub for the North West blending academic excellence with commercial enterprise and has a key role to play in the changing landscape of a Northern Powerhouse. It is home to the University of Chester’s Faculty of Science and Engineering and the High Growth Centre, co-funded by the ERDF, which offers SMEs and new start-up businesses valuable advice and support. Investment in the Thornton Energy Demonstrator will also enable energy companies to test at scale new power saving and distribution technologies, for the development of low cost, environmentally responsible sources of energy.



William Hughes opens £3 million new factory to meet growing demand for wire products

System UVEX – the natural, sustainable way to stop Legionnaires’ Disease Managing Director Max Hughes and his daughter, Technical Director Emma Burgon, inside the new factory at Stalbridge.

William Hughes, the specialist manufacturer of wire based products and springs, formally opened its new offices and manufacturing facility in Stalbridge, Dorset at the end of last year. Following a £3 million investment, with refurbishment and building works taking over 9 months to complete, the new 87,000 sq ft facility, is situated just a short distance from William Hughes’ existing factory. Incorporating sales, design, engineering, and manufacturing activities all within the same site, the new facility will provide much needed additional space for manufacturing operations in support of the continued growth of the business.

Email: sales@wmhughes.co.uk


Boulting moves nuclear team to Widnes In a significant move for the future development of the business, North West based engineering company Boulting Group has opened up dedicated, new offices for the fast growing Boulting Nuclear team in Widnes.

The senior Boulting Nuclear team (left to right) Howard Ireland, Business Manager, Terry Marston, Director, Bob Bianchi, Business Development Director, Ronald Watson, Nuclear Mechanical Estimator.

Boulting has over ten years’ experience in the nuclear industry specifically covering new build, plant life extension and de-commissioning. This is now complemented by S&B Nuclear Services Ltd, a new joint venture company with French electrical contracting company Groupe SNEF, and provides a host of services to the existing and forthcoming new build nuclear power station market. ‘The Nuclear sector is set for significant growth and we are well positioned,’ said Bob Bianchi, Boulting’s Nuclear Business Development Director. ‘We have wide-ranging experience in delivering mechanical, electrical and instrumentation services to the nuclear industries. The Boulting Nuclear team supports clients through all stages of the nuclear build cycle, by bringing together integrated teams from across our technical business units into one seamless solution,’ concluded Bianchi.



PECM issue 13

A new version of a proven clean, low energy, highly effective cooling water management product range has recently been launched. System UVEX® produces UV treatment systems that are highly effective in treating the water for cooling, water features and humidifiers as well as rainwater harvesting without using multiple chemicals. The system is not only effective in helping prevent waterborne problems such as Legionnaires’ Disease but it does so in way that is cleaner, greener and cheaper than traditional systems. System UVEX enables building managers to be ACoP L8 and also HSG274 compliant whilst avoiding the hassle and cost that comes from dosing with traditional chemical systems. There is a System UVEX option for any size or type of water cooling system.

Tel: 01707 642 358 Email: enquiries@systemUVEX.co.uk www.systemUVEX.co.uk

Cement manufacturer improves maintenance operations with help from NOV Mono One of the UK’s most advanced cement production facilities has improved its maintenance operations and safety levels by installing new equipment from NOV Mono. Hanson Cement has achieved these improvements by adding a duty/ standby Mono™ Munchpump package to the sewage handling operations at its Padeswood plant in Mold, North Wales. Mono™ designed and installed an above-ground Munchpump package which proved to be an excellent fit for Hanson’s needs. The package includes two EZstrip™ progressing cavity pumps and two SB Munchers™, in a duty/standby arrangement, transferring the sewage at 25m3/h to the main sewerage system. The Munchers macerate any solids within the flow to a small particle size, therefore protecting the pumps from any large solids, which could cause blockages.

Tel: 0161 339 9000


As you know Rosemor celebrates their 30 year anniversary

News from Rosemor!!

We are here to make things even better !!! Currently we offer you a unique opportunity to take your old Rotomac in part exchange against a new Rotomac ET15B. Rotomac ET15B has been developed for a better performance. It is the new generation of the machine more efficient and for future longer term use (more details on www.rosemor.com). The comparison between your Old Rotomac and Rotomac ET15B: • Rotomac 360 has 11 brushes v Rotomac ET15B has 15 brushes • New tanks, trolley and hood design. • Rotomac ET15B has a battery back-up for removing the machine safely from the escalator should there be a power surge or a fault with escalator. • New stainless steel buttons on control panel- More durable. • Plug in located on the ET15B for the T10 attachment (Moving walkway machine). • Time settings increased to include a 15 seconds option for maintenance and quick cleaning. • Manuals include more pictures to help the operator or technician. • Same quality, makes and materials used for most parts.



“The T10i - the most competitive and ultimate automatic escalator/travelator deep cleaning machine for the horizontal part of the escalator/travelator step”

Please call us for any feedback or more information. Tel 01491838011

www.rosemor.com www.rosemor.net www.rosemor.ru info@rosemor.com Rosemor House, Moses Winter Way, Wallingford, Oxfordshire, OX10 9FE, UK

News & Events The sweet smell of success? Babcock Wanson has completed a project for the design, construction, erection and commissioning of a Regenerative Thermal Oxidiser at Moy Park’s Grantham, Lincolnshire, facility to provide an effective odour abatement solution for the sites frying and oven based cooking processes. One of Europe’s leading food companies, Moy Park specialises in fresh poultry and complementary convenience food products. Its Grantham premises is a large further processing site for breaded and ready to eat produce, which has grown rapidly over recent years. With this growth has come the need for improved odour abatement, especially important because of the site’s location close to the town centre. A customer of Babcock Wanson for more than 30 years, Moy Park turned to the company for an effective solution. After a detailed review with the site engineering team, Babcock Wanson recommended replacing the existing Catalytic Thermal Oxidisers with a more effective Regenerative Thermal Oxidiser capable of treating the complete cooking exhaust stream irrespective of the process heat load, an important feature in the fast moving food industry. For more information, please contact Babcock Wanson on 020 8953 7111 or info@babcock-wanson.co.uk or go to www.babcock-wanson.co.uk

Rainford Solutions Ltd Established in 1982, Rainford Solutions is a world-class UK based designer and manufacturer of standard and bespoke indoor and outdoor electronic equipment enclosures, racks, cabinets and overhead cable management systems. With over 30 years of expertise Rainford have been providing enclosure solutions to a diverse client base across a wide range of industries, which is supported by an extensive in-house design, engineering and manufacturing capability. All Rainford products are designed and manufactured at their UK manufacturing facility in Rainford, St Helens, and are sold globally. With a strong customer service approach Rainford are also BS EN ISO 9001:2008 accredited.


Liverpool University chooses Stokvis Plate heat exchangers Liverpool University is nearing completion of a long-term M&E upgrade that has seen Stokvis plate heat exchangers replace nearly all the existing calorifiers used to provide hot water to its buildings. Over the past 10 years, the University has been taking its old calorifiers (each one used to store up to 3,000 litres of hot water) out of service as they reach the end of their service lives or become uneconomical. Replacement is with plate heat exchangers, usually accompanied by a 300 - 500 litre buffer vessel, to supply hot water on demand. “Stokvis plate heat-exchangers are our preferred solution for hot-water generation” confirmed Jonathan Cave, senior mechanical engineer at Liverpool University’s Facilities Management department. “We don’t wait until the equipment falls over; when a calorifier is costing too much to maintain or is nearing the end of its service life, we replace it”, says Jonathan. For further information on Stokvis Energy Systems, please call 020 8733 3050 or visit www.stokvisboilers.com.

Heraeus Noblelight Relocates Arc & Flashlamp Laboratory to Cambridge Heraeus Noblelight has moved its applications laboratory from the Technical University of Kaiserlautern, in Germany, to Cambridge, UK, the headquarters and manufacturing facility of its Arc and Flash division where it will provide expert resource in developing Xenon flash lamp technology to meet the latest industrial challenges. The newly named “Photonics Application Centre”, headed up by Applications Manager, Martin Brown, assisted by project engineer, John Gregory, bringing expertise from the Printed Electronics Industry, is fully equipped to offer a full Xenon Flash Photonics service. It offers customers capabilities ranging from blue sky radical ideas testing, through trials and prototype manufacturing to full equipment design and manufacturing.


Protecting sumps and floors

Offline coders stand up to pouches

Archco-Rigidon reports it has over 40 years of global experience in the field of resilient materials for heavy-duty coating and lining applications. It has now introduced a new medium-duty product, Archco-Rigidon FibreTrowel 750, a three-coat lining system designed for the protection of concrete bunds, sumps and floors.

According to Euromonitor, stand-up pouches are among the fastest growing packaging formats and will continue on their growth trajectory up to 2017. Their versatility allows them to convey both portability and quality and shelf-stand out in snack products.

Designed specifically for spillages, Fibre-Trowel 750 is said to be ideal for use where a continuous immersion grade or heavy- duty lining would be prohibitively expensive to use or too labour- intensive to install. FibreTrowel 750 system can be quickly and easily applied as a three-coat system using a combination of brush, trowel and roller. It is resistant to spilled water, oil, as well as certain solvents and chemicals.

Tel: O20 8670 7511


CamLink - CadCam for Mazatrol CNC Applications Ltd are pleased to announce their new partnership with Griffo Brothers Inc to distribute and support their CamLink product in the UK. CamLink gives users of Mazak Mazatrol not only the ability to download and save their machine programs to a PC, but also view, edit and even create new offline programs in a Mazatrol format. CamLink is a PC based application that brings the look and feel of your Mazatrol control to your desktop. CamLink has been designed by Mazak users, for Mazak users, so that anyone who knows how to operate and program a Mazatrol control, can very easily use this offline programming system, to increase your companies efficiency. CamLink has been in existence for over 25 years, so it is fully compatible with the majority of Mazatrol systems including: M+, T+, 640 M/T/MT, Nexus, Fusion, Smart.

Tel: 0121 288 3366


PECM issue 13


Whilst the shapely forms of doy-style packs, block-bottom bags and quad packs add aesthetic appeal, they are causing headaches for the coding operation. Rotech has developed the RF1-V, a standalone vacuum feed overprinting system that has been engineered specifically for pouches, bags and other otherwise awkward to feed products. By using a thermal printer with a print width of up to 128mm and printing continuously, a very large print area of almost any length can be accommodated.

Tel: +44 01707 393 700 email: sales@rotechmachines.com www.rotechmachines.com

Success for online machine tool auction site as easy to use system hits the right note An innovative online service designed to help manufacturing businesses buy and sell CNC machinery with complete confidence and ease has not only attracted UK buyers but has also reached a significant buying audience in Europe too. The CNConlineauctions.com website is an easy-to-navigate online auction system for buying and selling CNC machine tools, both new and used, in the UK and Europe, with a location set up in the United States to cater for the global market. To find out more visit www.cnconlineauctions.com, call 0333 202 0850 or email info@cnconlineauctions.com

Conveniently Calibrate Plant Vacuum Gauges Why do vacuum gauges need to be calibrated? The largest uncertainty when using vacuum gauges on a process plant is knowing when the process has caused drift or shifts of calibration. Many processes handle vapours and, if any condensation or deposition happens, the chances are it will also happen in the vacuum gauge. Many such gauges - Pirani, cold cathose and ion gauges - use thermal or ionisation cross-section measurements to infer the level of vacuum being experienced and they have filaments, cathodes and other hardware, all of which may be coated with by-products from the process. Even more rugged gauges such as capacitance manometers will be affected by depositions or particulates because any deposition will have mass and the gauge will weigh it, especially if it has a low range and therefore a very thin diaphragm.

Chell’s CalCube is a convenient solution to vacuum gauge calibration

As processes move away from their design parameter due to gauge “drift”, little about the quality of the process can be inferred from the instrumentation readings, so diagnosis is down to a skilled operator recognising when a batch of product does not conform. This is too late! If the process is sensitive to the level of vacuum being achieved, then the cost of losing a batch could be astronomical - many times the cost of maintaining the plant properly in many cases. With the inherent lack of ruggedness of many vacuum gauges, it is imperative that plant gauges are regularly calibrated and that the operator has spare, calibrated gauges ready to substitute as soon as he fears the process may have drifted away from specification. The difficulties of calibrating vacuum in-situ Unfortunately, it is very difficult to carry out in-situ vacuum calibrations due to the amount of hardware needed to establish a suitable level of vacuum in a situation where a calibration standard gauge may be compared. Not the least of concerns is the possible cross-contamination of the standard by a contaminated sensor under test. Another is the difficulty of access to many on-plant gauges. So it has become tradition for gauges to be removed regularly from the plant and shipped to an external calibration laboratory for re-calibration and, in many cases, adjustment to compensate for the effects of contamination.

CalCube complies with BS ISO3567:2011 which specifically covers the design and use of vacuum calibration systems and incorporates an ISO/Dis stainless steel calibration chamber with geometry optimised to ensure that all gauges connected see the same level of vacuum so that comparisons may be made. The development of a technique Having its own ISO IEC 17025:2005 accredited UKAS laboratory with the lowest uncertainties for Vacuum in the UK, Chell are well placed to prepare CalCube for on-site gauge calibrations. The Transfer Standards fitted to CalCube are calibrated in the laboratory both before and after an on-site calibration job so that the confidence level of the calibration is the highest possible.

CalCube comparing two manufacturer’s Capacitance Manometers

CalCube is constructed within a rugged, wheeled flight-case type enclosure having just a 13A mains plug yet containing dry diaphragm backing and turbomolecular pumps with high vacuum isolation valves. Over 40 year’s experience of calibrating vacuum gauges have gone into CalCube’s design, which includes such capabilities as calibrating both rising and falling pressures very accurately using a pair of ultra-fine Chell CMF valves. Fitting easily into almost any estate car, CalCube comes with lifting handles to aid safe removal from a vehicle or lifting up steps, etc. A removable side panel is foam lined with cut-outs to hold all the common mating vacuum connector systems - of course, custom connectors may be purchased and housed for specific applications. Choice of vacuum Transfer Standards will be an important decision, which is aided by Chell’s years of experience. These standards, when not fitted to CalCube are housed in another, matching flight-case, ready for convenient return to Chell’s calibration lab. for scheduled UKAS calibration. Chell’s in-house vacuum standards consist of three high-accuracy capacitance manometers having 20 years of continuous calibration history at national Standard level and these are monitored on a daily basis by a Spinning Rotor Gauge whose ball-flange assembly is also calibrated annually at National Standard level. At the atmospheric pressure end of the scale, the vacuum straight line generated by the capacitance manometers is calibrated against our 32” Schwien Merco-Master manometer giving us the lowest uncertainties in that pressure regime. Chell’s customers thus enjoy the accumulated vacuum calibration skills of over 40 years and, should they have specific different requirements, Chell has the skills to customise CalCube to suit. For more information contact:-

CalCube showing its useful vacuum coupling storage

With the development of Chell’s on-site UKAS calibration service, they have developed CalCube both as a portable vacuum calibration system with which to offer an on-site service but, for customers who would prefer their own facility, a convenient, tried and tested system.

Chell Instruments Ltd Folgate House Folgate Road North Walsham Norfolk NR28 0AJ Tel: 01692 500555 Fax: 01692 500088 e-mail: info@chell.co.uk Website: www.chell.co.uk Issue 13 PECM


Editors Choice


low Measurement has been around since the Romans measured the flow of water in the River Nile, in more recent times the measurement of viscous fluids has been one of the many features demanded of flowmeters spanning across a wide range of industry from automotive to marine technology to chemicals. With the automation of industrial production especially in the automotive sector, flow meters and pumps make up a fair share of instruments required on the production line. UK Flowtechnik has met this demand with a range of flow meters appropriate for industrial & automotive manufacturing. As time passes the technical aspects of flow meters and pumping have evolved to meet the technological developments of the products they have to move and measure. For instance UK Flowtechnik now accurately meter and pump viscous adhesives of up to 1 million cSt, which was extremely difficult to achieve 20 years ago.

Throughout the past 20 years UK Flowtechnik have been suppliers of flow meters, instrumentation, pumps, magnetic couplings & hydraulic system components. We offer products from quality brands such as: VSE, Beinlich, DST, HBE, Flomec, GPI, Lake Monitors, Seametrics, Elis Plzen, Bopp & Reuther and Comeco as well as many others & also offer a competitive Calibration & Repair service. For our latest range of flow meters and pumps please visit: www.ukowtechnik.com

UKFlowtechnik 1 Central Park, Lenton Lane, Nottingham NG7 2NR Tel:- 0115 9007111 Email:- sales@ukowtechnik.com

For more information look at : www.moisturemeasuring.eu


PECM issue 13

JTEKT’s Koyo brand of bearings is recognised globally as a leader in bearing design innovation and manufacturing technology. Providing Ball, Needle and Roller Bearing Solutions to the World’s Industrial & Automotive Markets

Koyo UK Ltd Whitehall Avenue, Kingston, Milton Keynes Buckinghamshire, MK10 0AX, UK +44 (0)1908 289311 info-eu@jtekt.com


Editors Choice Parker Chomerics enhances thermal management solutions with the release of its latest THERM-A-GAP™ gel with conductivity extensions to 6 W/m-k

Advanced Water & Waste Limited, an A+ Group Company


dvanced Water & Waste Limited, an A+ Group Company, specialises in the collection, pumping, storage, treatment and reuse of all types of liquors, effluents, wastewaters and sludges, with class leading and innovative carbon saving technologies. iCLEAR-ADTM Anaerobic Effluent Treatment Commercialisation of proven technology now means that high COD trade effluents can be used as a fuel for CHP whilst reducing sewer discharge costs. Even small scale food and beverage producers with 200kg/d of COD can benefit from iCLEAR-ADTM carbon and cost saving technology, with funding available.

s more and more high performance electronics are utilised across a wide range of applications, it has stimulated a growing need to provide new innovative thermal materials that can effectively manage the heat dissipation challenges. In line with this need Parker Chomerics is constantly evolving its range of THERM-A-GAP™ thermally conductive dispensing gels in order that customers can maintain both system performance and reliability. As the market leader in this domain Parker Chomerics has recently extended its range of gels to offer thermal conductivity up to 6 W/m-k and typical applications include high performance devices requiring minimal thermal resistance, ranging from automotive electronic control units (ECUs), power supplies and semiconductors, through to memory/power modules, microprocessors/graphics processors, flat panel displays and consumer electronics.


Heat generated by high performance devices must be removed to the ambient environment to maintain the junction temperature of components within safe operating limits. Often this heat removal process involves conduction from a package surface to a heat spreader that can more efficiently transfer the heat away. The spreader has to be joined carefully to the package to minimise the thermal resistance of this newly formed thermal joint.

Geyser Air Pulse Pumps® Whoever thought the airlift pump could be improved? Now Geyser innovative large pulsed air bubbles have revolutionised that thinking! Installed inside or external to tanks with no moving parts in contact with the water, liquor, effluent or sludge to be handled. The air flow and pressure determines the liquid flow rate and head to be pumped. This means low energy; low maintenance and controllable pumping with just a simple air blower. VacSAFETM Effluent Collection AWW has pioneered the use of vacuum sanitation systems to collect hazardous effluents from laboratories and other premises where biosecurity and flexibility of drainage are key requirements. Vacuum sewerage can also be used for commercial property external drainage systems as well as villages, hotels and leisure facilities. Baleen Filters® Its good bye to DAF’s and chemicals with this energy saving and highly efficient microscreen able to treat a range of effluents. The high quality water discharge is in tandem with a dewatered sludge ready for re-use as a feedstock; for composting or AD without further expensive treatment.

Typical thermal interface materials include THERM-A-GAP™ gels, which are supplied as pre-cured, single component compounds that can be dispensed over the heat generating package or component. These materials are silicone-based formulations loaded with conductive fillers, which are crosslinked to form a low modulus gel. The latest additions to the innovative THERM-A-GAP™ family, are setting new benchmarks in performance as they need only ultra-low compression force to conform over irregular interfaces and can be applied to single devices with minimum bond-line thickness as well as to multiple devices with variable Z-axis tolerances. The gel structure provides superior long-term thermal stability and reliable performance over conventional greases, which suffer from pump-out and dry-out issues. Offering low thermal impedance and high bulk thermal conductivity, further advantages of the new gels include the elimination of a cure cycle and the ability to be readily reworked, thus offering a highly attractive performanceto-price ratio. They require no refrigeration, no mixing and have no filler settling issues. THERM-A-GAP™ also eliminates time consuming hand assembly, and reduces installation costs and customer manufacturing and purchasing (logistical) complexity. www.chomerics.com Issue 13 PECM


INVEST FOR SUCCESS Chris Horsley, Managing Director of Babcock Wanson, puts the financial case for businesses operating aging, inefficient heat raising equipment to update to modern systems to improve efficiency and reduce energy consumption.


o compete in modern manufacturing, efficiency is key: energy efficiency, cost efficiency, time efficiency.

Heat raising equipment in the form of fire tube boilers and steam generators manufactured 30 plus years ago

weren’t designed with efficiency at the top of the list of requirements. They didn’t need to be; fuel was considered plentiful and low cost. Different times though mean different priorities. These days fuel is far from low cost and energy usage and a company’s

carbon footprint are hot topics; which is why organisations with aging equipment really should look to review their heat raising equipment if they haven’t done so already. The idea that keeping old equipment up and running, rather than investing in modern heat raising systems, will save money is often a false economy. That’s because they often guzzle fuel and lack the temperature control that is now possible with modern systems, which can result in further wasted energy. Savvy organisations look at longer term cost benefits. Investing in modern heat raising systems may well actually save you money over a relatively short period of time. Keeping your existing equipment, on the other hand, may cost you dearly in fuel, maintenance and operation costs. One of the key developments in the heat raising field that has led to dramatically reduced bills is the development of high efficiency thermal fluid heating systems, the best of which will include integral economisers to ensure very low fuel consumption even when operating at high fluid temperatures.

There are a number of reasons this type of system has proved so popular in industry, but top of the list comes energy savings.


PECM Issue 13

Thermal fluid heating is based on a similar basic principle to a low pressure hot water system. It consists of a heater connected to carbon steel flow and return pipework which can provide heat to one or more users or systems. Instead of water running through the

pipework, a thermal fluid - most often a simple mineral oil - is used as the heat transfer medium. There are a number of reasons this type of system has proved so popular in industry, but top of the list comes energy savings. Thermal fluid heating systems can use 20-50% less energy to transfer the same amount of heat when compared to traditional steam heating systems. With a large energy user, such a difference makes for considerable savings, both financially and environmentally. One of the key factors in achieving very high levels of system energy efficiency is the ability of a thermal fluid system to work at high

TRB Lightweight Structures is a further prime example of investing in equipment to actually save money. temperatures (up to 350°C in standard form) in a simple closed loop. When compared to a steam system this means no change of state of the fluid so no condensate and therefore no flash steam losses, no blow down losses or make up water required, no effluent discharge and completely corrosion free without the need for expensive chemical treatment. It all adds up to substantial savings. Investment in thermal fluid heating systems may well cost less than you think. That’s because a thermal fluid heater is very compact and needs no specialist site work meaning it can usually be sited in the most convenient location, often close to the user. This also removes the need for specialist plant rooms and distribution pipe work. Wire and Strip manufacturer Webster & Horsfall converted from steam generators to thermal fluid heating in 2011 in its Birmingham premises where it manufactures high-strength drawn wire. This was undertaken as part of a project to reduce costs and carbon footprint and improve efficiency through modernising machinery and infrastructure. The work was carried out in conjunction with The Carbon Trust which identified areas where efficiency could be improved. Replacing the existing inefficient steam boiler was identified as key and a Babcock Wanson TPC600B thermal fluid heating system was fitted to heating tanks for metal treatment. The new system precisely matches fuel input to plant energy requirements for high efficiency.

As a result of this change to thermal fluid, Webster & Horsfall has seen a 35% drop in annual kW usage from 2006 to 2011. Robert Horsfall, Finance Director of Webster & Horsfall, is understandably pleased with the savings made: “The new heater is one third more efficient than our previous steam based system, which allows us to operate more efficiently, reduce our energy bills and have a considerable impact on reducing our Carbon footprint. “What we hadn’t expected initially though is the level of control the new system provides us with; it’s amazing. It alerts us to any potential issues, is easy to maintain (no annual statutory inspection is required) and is quick to respond. All that and it doesn’t take up much room.” This tale of energy savings is repeated time and time again by companies investing in modern heat raising systems. TRB Lightweight Structures is a further prime example of investing in equipment to actually save money. TRB is a leading OEM for the rail, aerospace, defence and marine industries, designing and manufacturing tailor-made lightweight solutions and bespoke fabricated assemblies, including train doors and aircraft galleys. The company moved away from steam heated platen presses to a gas fired Babcock Wanson TPC600B thermal fluid heating and cooling system, whilst at the same time installing new platens. A single fluid – Paratherm MR – is used throughout the system which has a very flat viscosity curve so is readily able to switch between heating and cooling functions. The move has proved good news for TRB as Tim Britt, Marketing Manager explains: “we estimate that we have received around a 70% cost saving since we have had the new system installed. It’s a cleaner system as it does not corrode and requires less maintenance. We’re obviously not burning heating oil now so our emissions have also been greatly reduced.” For TRB, energy savings are important, but just as crucial is the ability to maintain constant temperature control.

The previous steam system did not provide a constant temperature without strict operating guidelines and was labour intensive. With a thermal fluid heating and cooling system temperature control is far more accurate and you don’t get temperature drop off. The thermal fluid system also provides programmable ramp up temperatures and a controlled cool down over a set time which can be important with many of the latest adhesives and resin systems. For TRB, the new heating and cooling system has provided a genuine competitive edge. It makes for a better product, has increased the range of products the company can process and has also considerably increased production capacity. That’s not to say that everyone should run out and buy a thermal fluid heating system today! Whilst they have become the heating method of choice in industry at large, there are some applications and processes - most notably where both direct and indirect heating are required simultaneously where they are unsuited. Here Steam Generators remain an excellent option, but once again you should consider moving to the new breed of high efficiency coil type steam generators. They consume less energy, have reduced emissions, offer improved safety and simplicity of control and are considerably quieter, cleaner and cooler in operation. Modern Steam Generators include a very accurately controlled burner which creates an defined heat input Issue 13 PECM


to a double coil of steel tube through which a precise quantity of feed water is pumped. Only a small amount of excess water is fed into the coil. A steam / water separator is incorporated at the coil outlet to ensure good conditions for steam production within the coil itself and good quality dry steam at the separator outlet. Using this method, Steam Generators maximise efficiency, reducing overall carbon emissions. Babcock Wanson ESM steam generators, for example, give operating efficiencies of up to 96% with very low overall emissions. Bedford Hospital switched to modern Steam Generators in 2010 as part of an overhaul of the boiler house and have been reaping the benefits ever since. Their review of the boiler upgrade, which took place in 2010, shows carbon savings of 1687 tonnes of CO2e between 2011-12 and cost avoidance on boiler fuel alone of circa £525,000. How did they achieve these impressive figures? The hospital boiler house had been home to four enormous oil fired boilers which, at 30 - 40 years old, did not provide the level of efficiency expected of current plant. They required thousands of litres of heavy fuel oil, which is expensive to store on site and has to be maintained at a constant elevated temperature. So in addition to the cost of the fuel itself, there was the financial and environmental costs of continual deliveries to site by road, as well as the costs of keeping the oil on the premises at a set temperature. The four Firetube Boilers were replaced with three Babcock Wanson 2500kg/h ESM Steam Generators fitted with high efficiency exhaust gas economisers. The primary fuel is now gas (with one unit configured for duel fuel operation as a precautionary measure), which is cheaper and has also resulted in on-site fuel storage largely being eradicated. These are just a handful of examples of savings that can be made by investing in modern heat raising systems. They are not unique – organisations the world over can quote impressive energy savings and improved production efficiency by making the move to thermal fluid systems or the latest Steam Generators. If you are a large energy user, it’s almost a no brainer. But even smaller organisations can benefit from the energy efficiency and the temperature control that these systems can bring. The longer you wait to make the investment, the more it’s likely to cost you.

Babcock Wanson offers a complete range of products and services for boiler houses and other process heating needs. These include steam boilers, thermal fluid heaters, rapid steam generators and hot water boilers to VOC and odour treatment by thermal oxidation, water treatment or process air heating solutions. For more information, please contact Babcock Wanson on 020 89537111 or info@babcock-wanson.co.uk or go to www.babcock-wanson.co.uk

Editors Choice

Trading for 35 years, Derbyshire and Sons is a precision engineering firm known nationally for quality service at competitive prices. Our commitment to quality & service is demonstrated by our full ISO9001 accreditation. In addition to general precision machining, our area of expertise includes the production of flanges, screwed stainless steel pipe fittings, block tees for the Petrochemical / Turbine & Automobile Industries as well as bespoke one off work. Our services are extensive and include:Turning – Conventional and CNC up to 6ft Diameter Boring, Milling & Drilling – Conventional and CNC Tel:- 01514231478 Or email sales@derbyshiresengineering.co.uk for more information www.derbyshiresengineering.co.uk

Ecotile interlocking PVC floor tiles are a heavyduty flooring solution with a proven track record in many of the UK’s premier manufacturing companies. • Fast installation: minimal downtime • Durable and easy to maintain – 10 year guarantee • Made in the UK • Copes easily with forklift traffic • Oil and chemical resistant • Anti-slip and anti-fatigue • Full quality ratings including: ISO9001 / 14001, CE Mark, BFI S1 Fire Rating and the R10 anti-slip rating.

Telephone 01582 788 232 or email enquiries@ecotileflooring.com

New INTELIHEAT™ Ex rated IBC Heating Jacket Launched LMK Thermosafe Limited have introduced a revolutionary new hazardous area IBC heating jacket. The ATEX Zone 1 rated jacket is constructed with patented technology using carbon rich semi-conducting heating membranes allowing safe operation even in the presence of potentially explosive gases. Heating rates are similar or better than the ‘safe area’ IBC2 high power flexible heating jacket, and temperatures up to typically 55°C can be achieved. The InteliHeat is designed for use with 1000L plastic liner, metal frame IBCs. However it may also be used to heat 4x205L drums.

LMK Thermosafe Limited have a strong history and culture of innovation and improvement. Their designs and production quality have stood the test of time, successfully being used in numerous drum and container heating applications all over the world. Indeed, their consistently growing export sales led to them winning the highly prestigious Queens Award for Enterprise: International Trade 2012. The Inteliheat jackets already compliment the unique ATEX certified THERMOSAFE and FARATHERM Induction heaters as well as their safearea Digiheat Base Heater and huge range of Flexible Heating Jackets.

Tel: 01440 707141 • Email: sales@drumheating.com Issue 13 PECM


Double Link Strengthens Approach to Asian Automation I

n a recent video made with the CC-Link Partner Association (CLPA), Balluff explained how their line-up of rugged IP67 CC-Link I/O blocks also provides easy connectivity to the popular point to point wiring system, “IO-Link”. IO-Link provides a number of wiring benefits to machine builders and end-users, the main one being only a single cable type is required to connect all devices. Balluff is already a strong partner of the CLPA worldwide, having taken the significant step of joining the board of the CLPA at the end of 2013. This made them the first European company to take this step, and was a strong demonstration of the increasing importance of the network technology to companies in Europe. They are also a key supporter of the IO-Link movement, so it was a natural step for them to integrate both technologies into their product lines. IO-Link provides an easy way for a number of different device types to be connected to a controller with only a single type of cable. This means that machine builders reap a number of benefits, including simplified designs, faster time to market and reduced costs. IO-Link also offers a number of diagnostic and set-up benefits, meaning that machines are also easier to maintain and downtime is reduced. As a global company with significant business in Asia, Balluff expects the combination of CC-Link and IO-Link will prove to be a winning one when it comes to expanding their various businesses in this critical market. A key market for them is the automotive industry, and the benefits of IP67 style devices are well understood by OEMs in this rapidly expanding Asian market. Many companies are rushing to automate their facilities as local costs increase along with the demand


PECM Issue 13

Balluff ’s line-up of rugged IP67 CC-Link I/O blocks also provides easy connectivity to the popular point to point wiring system, “IO-Link”.

for automobiles. IP67 provides a cost effective method to mount critical control devices directly on a machine, reducing the cost of installations and making parts more readily accessible for maintenance. Balluff expects that IO-Link will become the USB stick of industrial automation – simple, powerful and ubiquitous. In order to achieve this goal, it is essential to achieve a critical mass of usage, which is why Balluff has also produced a CC-Linkcompatible IO-Link device. Hence they are well placed to drive this combination of technologies into the vast Asian market place, where many companies are hungry for the kind of business advantages they can deliver, as they rush to increase output and quality with widespread automation. This trend has been confirmed by leading third party market research companies such as ARC and IHS, who have estimated that almost half the world’s total spending on automation will take place in Asia from now on. As Balluff understands, CC-Link is a key part of the solution for business success in Asia. It is a highperformance open industrial network technology, which enables automation equipment such as sensors, switches and gauges from numerous manufacturers to communicate with one another, resulting in a fast, deterministic control system. Originally developed in Japan by world leader Mitsubishi Electric, it is now an open technology with the support of 290 manufacturers offering over 1,400 products. CC-Link was an immediate success when launched in Japan and rapidly penetrated deep into the rest of the Asian market as well. It is now the leading open network used throughout

As a global company, Balluff expects the combination of CC-Link and IO-Link will prove to be a winning one when it comes to expanding their various businesses. Asia and is also well-represented in Europe and North America. The CLPA is helping European companies to strengthen their business in Asia with initiatives like the “Gateway to Asia” (G2A) programme. This assists with the promotion of CC-Link compatible products in the Asian market after a company joins the CLPA and passes conformance testing for their product.

CLPA-Europe Tel: +44 (0) 7768 338708 www.clpa-europe.com

Conductivity Measurements for demanding applications

 Conductivity  Concentration       

The products have a proven track record in demanding applications in: - chemical plants - pharmaceutical plants - power plants - digester EA/AA measurements. Due to the rugged design, Metso Conductivity Measurement units typically last +10 years – even in harsh applications/enviroments and still measuring with the highest precision.


Editors Choice Who’s that knock knocking on your door? If your business processes emit harmful substances, you will know that you need a regularly tested system to control them and that the HSE can demand to see the associated paperwork. So how prepared would you be if the HSE arrived on your doorstep? Vent-Tech, who specialise in the control of hazardous substances, have just introduced the LEV Vault - enabling companies to keep all their LEV compliance documents together and accessible - via a password protected area within the VentTech website. To see how Vent-Tech can help you stay compliant visit http://www.vent-tech.co.uk/lev-vault or call 0117 971 2163

Identification Technologies Scotland Ltd Identification Technologies Scotland Ltd are specialists in the field of industrial ink jet coding, labelling and laser coding. Our philosophy is to provide solutions to a requirement as oppose to just fulfilling our machine target for the period, this allows us to be innovative in our solutions and pick the correct type of machinery for your application. Whether you require to print directly onto your product or apply a label why not call us to discuss how we can help.

Waste heat recovery system One of our customers uses Activated Carbon in their Edible Oils processing plant at Manchester. The ‘spent’ Carbon is regenerated on site in a gas fired rotary hearth furnace and the hot exhaust gases at 6500C are a valuable source of waste heat. ThermTech have successfully harnessed this waste heat into a system which generates over 1,500 Kg/Hr of steam at 13 Bar pressure. Thus generating a gas saving at the boiler house, with a corresponding reduction in CO2 emissions and also a reduction in quench water evaporation. The system comprises a two pass horizontal shell boiler which is installed between the furnace outlet and the Venturi scrubber inlet. It is on a bypass loop with the flue gas flow induced by a centrifugal fan rated at the pressure drop across the Waste Heat Recovery system. The fan is controlled via an inverter and a differential pressure transmitter.

Tel: 0161 339 3049

Email: info@thermtech.co.uk

Grime Go! – latest invention from Eco Solutions Limited’s world-leading innovative technology The perfect surface preparation/cleaning product – degreases, dewaxes, removes grime, mould, dirt, stains …and much more…pH neutral, non-toxic, solvent & alkaline free, no fumes, no skin burns - VOC free… This latest water-based micro emulsion has been developed out of our existing patented technology adding to our range of coatings removal/ cleaning products used widely throughout industry. Eco friendly products normally have a “trade-off” between being user friendly whilst taking a little longer to take effect. Tough Not Toxic® Grime Go! works in seconds! Using Science Not Solvents® Eco Solutions is a UK manufacturing company.


Lindapter launch ‘all-in-one’ steelwork clamp Lindapter, the inventor of the Girder Clamp and Hollo-Bolt has developed the Type AAF, a new steelwork clamp for connecting steel sections, offering adjustability, anti-corrosion protection and high load capacities, even in low temperature environments. Lindapter’s flagship product is the latest addition to its High Slip Resistance (HSR) family of clamps designed for high load requirements including frictional, tensile and combined load applications. The clamp features an innovative 2-part design that self-adjusts to suit a range of flange thicknesses, allowing contractors to use a single product type for multiple connection requirements. Typical applications include securing steel framed roofs, heavy pipe supports, mechanical handling equipment and bridge strengthening apparatus.

Tel: 01274 521 444


New wing grip How to fix, secure and release easily and quickly? Use the Bülte wing grip! Bülte has added two new wing grips BPF 251 and BPF 252 to its Handwheel and Knob range. The body’s ergonomic shape and use of small raised strips enable a good grip. We offer two versions: screws and nuts. For the screws, lengths are from 8 to 50mm and are available in M4 and M5 x 28mm across the wings for BPF 251, and M5 and M6 x 31mm across the wings for BPF 252. The standard material is Polyamide, which is resistant to various chemical products. It also has excellent mechanical properties including wear resistance, low friction coefficient, a high melting point, good impact resistance, as well as being very light. The working temperature range is -30 to +100°C. Thanks to its properties Polyamide is suitable for a wide variety of industries including: medical, aerospace, railway, food, chemicals, electronics, electrical, building ETC. The standard material for the threads is ZPS (zinc plated steel) with other materials available including aluminium, brass, titanium, nylon, stainless steel etc. Bülte also offers a range of colours: white, red, yellow, blue etc. Minimum quantities on request. Samples and prices (unit of sale=100 pieces each reference) are available on request. For more information, please contact: www.bulte.com


PECM issue 13

Tel: 01934 844484 Email: info@ecosolutions.co.uk www.ecosolutions.co.uk

Panasonic HM500 Series Touch Screen HMI Panels The HM500 series combines state-of-theart features and top performance with an outstanding design in an all-metal housing. The range consists of four models in sizes from 4.3”, 7”, 10.4” and 13.4” TFT colour display with LED backlight. All models can be installed in a horizontal or vertical position. The touch terminals are equipped with an Ethernet port and support VNC technology, allowing both remote VNC applications and remote assistance. The HM500 series is programmed with the HMWIN software, a simple and intuitive program, yet equipped with advanced features. It is possible to import variables from Control FPWIN Pro, the programming software for Panasonic PLCs, thereby facilitating the synergy between PLCs and HMIs. The products have a 5 year warranty.

Email: info.pewuk@eu.panasonic.com www.panasonic-electric-works.co.uk

New Range of ATEX Certified Load Cells Specialist load measurement equipment manufacturer, LCM Systems Ltd, is pleased to announce the launch of a brand new range of ATEX/IECEx certified, hazardous area load cells and enclosures. This ATEX/IECEx certification authenticates that LCM Systems’ load cells can be used in Zone 1 and 2 hazardous areas without danger of causing or contributing to an explosion when used in flammable gas and dust environments. These environments include offshore drilling platforms, petrochemical plants, flour mills and any other industries where there is a possibility of a mixture of potentially explosive gases, vapours, mists or dusts being present in the air. As well as a standard range of ATEX load cells including load pins, load cells, load shackles and load links ranging in capacity from 2 to 1000+ tonnes, LCM Systems can also provde customised products designed specifically to meet exact customer requirements.

Email: info@lcmsystems.com


Issue 13 PECM


Air, Gas & Odour Control Do you have water and particulates in your compressed air system? Dropout provides an extremely high performance ALL IN ON, FIT AND FORGET solution to water and particulate contamination of compressed air systems. With it’s unique and patent protected high performance technology, Dropout has been certified to ISO 12500 standard and guarantees that 99.9999% of liquid water and particulates down to 1 micron are removed from air without the need for replacement filters. Working across a wide range of flow rates, Dropout acts as a stand-alone replacement for water separators and/or coalescing filters but also providing protection upstream of refrigerant dryers by (pre) filtering bulk liquid and other contaminants.

Email: sales@originaldesign.com


Salzer original ‘Only made in Germany’. Cam / Control Switches IP66. Special and Standard Control Switches in over 200 standard circuits, or one off specials to your own circuit design are available from our UK Assembly Division in Aylesbury. Panel mounting, din-rail or Enclosed IP66. Switch Disconnectors 20-315A AC21A. Enclosed IP66, Front Panel or din-rail and door-interlocked IP66. Request our catalogue or download. www.salzeruk.co.uk eMail. Debby.smith@salzeruk.co.uk Tel. 01296-399992 Salzer UK Ltd. 44 Edison Road. Aylesbury HP19 8TE.

Boskalis invests in a new, environmentally friendly high flow pump unit

Two Dimensional Instruments, in business since 1999, designs and builds sophisticated temperature and humidity monitors. Our products are used to protect vaccines and medicines stored in fridges and freezers, priceless art treasures displayed in museums, food products and highvalue materials stored in temperature controlled warehouses. Our instruments install quickly and are user friendly for non-technical people. They are the only products that monitor, alarm, log data and display charts all in one low cost, stand-alone instrument. The can log and chart up to four different areas at once. Our customers are health care providers, hospitals, laboratories, museums, and manufacturers.


Seychell capitalises on PSL Datatrack software Seychell Engineering is a successful manufacturer of bespoke engineering products, with a good customer base in the scientific, medical, aerospace, marine and motorsport sectors. The company uses modular PSL Datatrack Seychelle is using PSL Datatrack production management software for quotations production management and invoicing, scheduling, shop floor data collection, business administration software to full advantage job costing and purchase invoicing. It gives the company a very efficient and accurate method of pricing jobs, together with accurate management of manufacturing. The scheduling and shop floor data collection module gives customers very accurate delivery date estimates. Production capacity status is visible and Seychell can monitor machining and process times, enhancing the efficiency of the business.

PSL Datatrack Email: sales@psldatatrack.com


Renewed Fluke Solution Center introduces three major Fluke thermal imager ranges For engineers, researchers, designers and advanced thermographers, Fluke’s latest top-of-the-range Expert Series shows stunning images up to 640x480 pixels. The cameras have an extra-large 14.5cm articulating colour TFT LCD display with daylight operation. They are for advanced applications like R&D, quality control and predictive maintenance, and particularly for demanding sectors like industrial, oil & gas, utilities, medical and biological/ sciences. For professional, in-house, contract and service thermographers, the Professional Series gives you crisp, detailed images for more in-depth studies like reliability inspections. These models show high quality images and advanced features like LaserSharp™ Auto Focus. They have a onehanded easy-to-use touch screen interface. For routine maintenance by technicians and contractors, the affordable Performance Series models show images up to 160 x 120 pixels. The cameras feature easy operation for quick scans and/or intermittent inspections.



PECM issue 13

Boskalis Nederland was established in 1910 and has expanded from a local dredging contractor to a leading global maritime services company. Boskalis Technical Service (their internal rental company) manages several mobile pump units and has very specific requirements from their pumps which included; • A minimum capacity of 5000 m3/hr and a pressure in excess of 3 bar; • Excellent suction capabilities (NPSHr curve) and suitable for use as a dewatering pump; • High fuel efficiency combined with the lowest exhaust emissions; • The pump unit should fit into a 20 ft. container for easy transport; • The maximum weight should be no more than 12,000 kilograms. Early in October 2014, Boskalis commissioned the delivery of a BBA high flow pump unit of the type BA-C500S11 with an attractive efficiency of 86%. The auto prime pump provides a capacity of 5500 m3/hour and a maximum head of 37mwk. The pump is driven by a modern Stage IV Volvo Penta diesel engine that provides a power of 375kW and delivers the lowest specific fuel consumption in its class (207 g/kWh). The exhaust gas is treated using AdBlue®.

Email: info@bbapumps.com


Industrial prelube for critical power generators & marine engines

Built to last for industrial applications Maintenance free – no spare parts needed! Built in check valves & pressure regulators on some models Reversible model doubles as drain/fill pump • 12/24Vdc model ep4 up to 15 l/min 3 Phase AC model daisy up to 34 l/min • Any motor on CF15 up to 55l/min Up to 4 bars pressure • Turnkey control kits available

Oil prelube helps ensure your equipment starts & runs when you need it! ESE bv, Oegstgeest, Netherlands Tel: 31 715173947 • Fax: 31 20 5241506 • Email: esenl@telia.com

Process Meter, using the latest in digital technology Introducing the very latest in Process Meter design, available now from, Nesslegrove Technologies. Featuring combined easy reading analogue, bar graph and 4 digit display. Among the many functions are:• Input, display and alarm level settings by customer downloadable free software.. • 20 point input correction, for non linear functions. • Selectable display/alarm backlight colours. • Low cost and compact in size. The programmable scale and custom annunciators enable users to tailor the meter display exactly to their requirements. Two outputs can be used to control remote functions. Featuring innovative input signal optimisation accuracy of 0.1% is achieved. One of a range of advanced panel meters, see www.nesslegrove.co.uk for details or E-mail:- Tech.Sales@Nesslegrove.co.uk

Did you know that switching to energy efficient compressors can save you up to 50% on your running costs? At Pennine Pneumatic Services (PPS), we know compressors inside out – and we pride ourselves on finding the best solution for each and every customer. You won’t get pushy sales staff or baffling jargon, just solid, nononsense advice from a friendly bunch of Yorkshire folk with many years’ experience in the field. As an Atlas Copco premier UK distributor, PPS specialises in: Sales – new and second-hand air compressors, VSD+, Vacuum, nitrogen, pneumatics, heat-recovery equipment and treatments Service – highly qualified engineers, all the key accreditations and service contracts with a true 24-hour call out service seven days a week Spares – a comprehensive range at our onsite Sales Counter, including air tools and OEM kits, with next-day delivery nationwide Pipework, including galvanised, stainless steel, copper and aluminium smooth bore up to 168mm, turnkey installation packages Equipment hire – save down-time costs during breakdowns and major servicing But don’t just take our word for it… “The team at PPS really know their stuff and give great advice – I can always rely on them to solve my problems. Not only do they take the stress out of my job but they have also saved our company a lot of money over the years.” Alan Maycock, PPG Architectural Coatings


We use the latest data, pressure and flow meter logging and leak detection to identify potential energy savings.

Passionate about energy efficiency and energy savings, we offer professional advice to customers working in many industries including: Food and drink Automotive Pharmaceutical Engineering UPVC Window manufacture Glass manufacture Petrochemical Chemical Construction Joinery manufacture Paint Textiles

Winner of the Atlas Copco Compressors’ Distributor of the Year Award 2013 Pennine Pneumatic Services Ltd 5-7 Pellon New Rd, Halifax HX1 4UB Tel: 01422 321772 Fax: 01422 342430 sales@pennine-pneumatic.co.uk www.pennine-pneumatic.co.uk

Water / water treatment Paper / cardboard boxes Foam Electronics Waste management Dental surgeries and labs


s part of a £3 million investment, Northern Ireland Water is upgrading the equipment at Luke’s Point pumping station with the installation of two new Archimedes screw pumps, supplied by ECS Engineering Services. Installed in the same footprint as the original equipment, the new pumps will double the capacity of the site, reducing the risk of flooding and helping to meet Northern Ireland Environment Agency standards for water quality. This significant investment is aimed at improving the water and sewerage infrastructure in the Bangor area in

order to improve the operation of the existing network. The improvements to the Luke’s Point pumping station will increase efficiency and reliability while reducing the maintenance costs of the site. The existing screw pump arrangement at Luke’s Point had reached the end of its design life and was no longer efficient. The screws themselves were heavily worn and the drive system was in need of improvement in terms of efficiency and reliability. As a result, a contract was issued for the replacement of this equipment and it was awarded, in part, to ECS and its partner Landustrie, a leading manufacturer of Archimedes screw pumps. Jamie Wesley, Commercial Manager for the Water Control Division at ECS comments, “We have worked closely with the client to realise the objectives of the project by designing a complete pumping solution. The new installation will use direct drive gearboxes, powered by 45kW motors, to turn the new Archimedes screws which are housed in steel liners.

Photo 2: The new installation will use direct drive gearboxes, powered by 45kW motors, to turn the new Archimedes screws which are housed in steel liners

“Increasing the capacity of the pumping station while remaining within the original

Photo 1: The new screw pump installation has been designed by Landustrie, specifically for this project and it will deliver significant savings

footprint required some innovative engineering - the key aspect was to increase the diameter of the screws - which required the removal of the original concrete dividing wall. This provided sufficient space to install the pair of larger screws, housed in steel troughs to provide optimum pumping efficiency.” The new installation includes the Landustrie ECO-Friendly stainless steel, lower bearings which are sealed for life and require no annual maintenance. The design of the bearing allows for 3-dimensional self alignment, which absorbs the expansion and contraction of the screw in changing temperatures. Legacy installations such as Luke’s Point used poly v-belts to transfer drive from the motor to the gearbox, in part to lessen the shock loading on start up. With the introduction of variable speed drives (VSD) and improved drive couplings it is now possible to use direct power transmission which offers around 5% energy savings in addition to those provided by the VSD. Jamie Wesley concludes, “The new screw pump installation has been designed by Landustrie, specifically for this project and it will deliver significant savings in both energy costs and maintenance costs for the client. Capable of pumping 1,200 litres per second each, the increased capacity compared to the original will go a long way to improving the ability of the station to deal with periods of increased rainfall.”

Tel: +44 (0)1773 860001 Fax: +44 (0)1773 810003 Web: www.ecsengineeringservices.com Email: jwesley@ecsengineeringservices.com

Long established pedigree of developing and delivering engineering projects for Power, Biomass, Alternative Fuel, Coal, Quarry, Mineral, Cement, Advanced Recycling, Waste, Ports and other heavy industries.

Atlas Copco GA 250 250kW Screw Air Compressor (x4) BRAND NEW - NEVER UNPACKED £50,000 in the region (EX VAT) Due to contract reconfiguration Atlas GA 250 compressors for sale. Quality compressors held in storage – viewing most welcome – Full Technical Specification available. Each with 14 months manufactures warranty (valid until March 2016)

Screw Compressors, compact design & air-cooled; each consisting of: Motor & compressor flexibly mounted, integrated suction silencer, weather proof & acoustic enclosures. Air-cooled after cooler with condensate separator and condensate drainage. Lubrication system with oil filters, air-cooled oil cooler, three-stage oil separating system. Electronic control system. Motors ABB HXR 355 LB-4, 250 kW, 3300V, 50Hz. Base frame sandblasted to SA2,5; special coating and painting according to EN ISO 12944-02. The compressors are a winterisation version for minimum ambient temperature of - 20oC.

AZ Techniek model 1276-00 Used Biofilters x4 £20,000 each ono (EX VAT) AZ Techniek model 1276-00, manufacture 2007. Fabricated from glass reinforced plastic and plywood. Contains two layers of biomass with dirty air inlet via bottom plenum. Clean air outlet at apex level, same side as inlet. Each layer of biomass with irrigation nozzles, access manhole. Capacity 7500 m3/h air per biofilter. Supporting steelwork, access staircase and walkway also available if required as shown in the above picture. Technical Specification/Drawings available on request. FAIRPORT Engineering Ltd. Market Place, Adlington Lancashire, PR7 4EZ Tel: 01257 484 000

e-mail: Ian Tole itole@fairport.co.uk www.fairport.co.uk



BEKO drain where others can’t BEKO TECHNOLOGIES are the world leaders in condensate management. BEKOMAT zero loss drains are manufactured for multi-stage compressors, vacuum, hazardous areas and in stainless steel versions to meet the most exact specifications. FOR EXPLOSIVE ATMOSPHERES

Contact BEKO for all your compressed air treatment applications.

BEKO Technologies, Technologies, 22 West West Court, Court, Buntsford Buntsford Park Park Road, Road, Bromsgrove, Bromsgrove, Worcs, 01527 575778, 575778 Fax: www.beko-technologies.co.uk BEKO Worcs, B60 B60 3DX, 3DX, Tel: Tel 01527 Fax:01527 01527575779 575779email: email:info.uk@beko.de info.uk@beko.dewebsite: website: www.bekotechnologies.com


PECM Issue 13

Maintenance is virtually eliminated due to the dual-wall, high-density plastic body.

Tough Fans from VAF Air controlling odours and dust in confined work spaces W

hen working in confined space it is imperative that the air is changed to provide a safe working environment. Miniveyor Air VAF series portable fans can move contaminated air out of a building or work area. They effectively exhaust fumes, dust and smells, ventilate confined spaces, and increase the flow of fresh air.

are still the biggest cause of lost man work days.

Weighing up to 40% less than conventional metal skinned fans of comparable size, in terms of movement from site to site and indeed on site, this is a huge advantage. Especially when you consider that back problems

The Miniveyor Air units easily withstand blows without denting, giving less downtime and greater productivity. The casing is corrosion free and unlike its metal counterparts will not rust when they are dented, chipped or scratched.

Maintenance is virtually eliminated due to the dual-wall, high-density plastic body. The polythene casing is resistant to the normal knocks and bangs of everyday use that can stop a sheet metal fan as metal fans often dent which can obstruct the fan blade.

Visit us online at www.vaf-air.com

They simply last longer and offer greater value for money and because of that come with an industry beating 10 year warranty on the body. The VAF series range has recently been extended with the introduction of the VAF-200C Canister blower. The compact VAF-200C is ideal for confined space ventilation and fume extraction and benefits from a, simple to attach, Duct Canister that neatly clips onto the fan body and houses 7.5 metres of flexible duct. It is great for contractors that have limited storage space in service vehicles and can be carried to the job site with ease.


ow in its 8th year the Annual National Electronics Week Exhibition will be taking up residence once again at the NEC, Birmingham on 21st & 22nd April 2015. With an extra 400 meters of floorspace this year, the event will offer more exhibitors and more technical content than ever before. Claire Saunders, director of the event explains the choice of venue; ‘The NEC has always worked well for us, it is in the heart of the UK meaning that getting there is easy for everyone whether they are coming by car, train and even our international exhibitors and visitors can fly right to the doorstep, its all about making it as easy as possible for everyone in the industry to access the value that this show provides.” Staying with their winning formula of splitting the show into four sectors, here is what is on offer this year: Component & Power With exhibiting companies such as Wurth Electronics, TDK Lambda, Geyer Electronics and Ecopac there will be opportunities for students to talk to those currently working in the industry and see what the latest developments are. The Electronics Component Supply Network (ESCN) will be hosting the seminar program including topics such as wearable technology, lighting, the internet things and energy efficiency. Design & Test Industry leaders in this sector who are exhibiting include Rohde& Schwarz, Aspen Electronics, Keysight Technologies, National Instruments, JTAG, Teledyne Lecroy and many more. Again students will be able to meet with the experts on the stands and even take the opportunity to start thinking about companies they may wish to apply to.


PECM Issue 13

The PXI Show will be incorporated into this area where there will have a room showcasing the four stages of the PXI process (modules, chassis & controllers, software & system integration). There will also be Test & Measurements Masterclasses from Electronics World Magazine. Embedded & Software This area will be made up of key exhibitors & technical content with a full seminar program from The Embedded Masterclass in conjunction with Vehicle Electronics with speakers such as Freescale. Production & EMS Exhibitors here include BAE Systems, Advanced Rework Technology, Europlacer, EtekEurope & Pace Europe. And the content program is as impressive as the line up. NPL & SMART GROUP are coming together to provide the Printing & Assembly Automatic Optical Inspection Experience and we also have the N.E.W. Hand Soldering Competition, open to all and with an adjudicating panel of IPC accredited trainers from Advanced Rework Technology and E-Tek Technical Services. This year’s winner will receive a high tech prize and the annual trophy. As well as all this we have the media centre where the industry’s biggest publications will be on hand with free copies and great subscription offers. Tickets to the exhibition including all seminars are free of charge, as is parking and wifi, you can register for yours at www.new-expo.co.uk/newuk/ To book one of the remaining stands call Claire on 01483 420 229 or email claire@neweventsltd.com for more information.

Flow-Technology Ltd boasts large stocks of Stainless Steel fittings Flow-Technology Ltd, West Yorkshire have been manufacturing Stainless Steel components in house at its Brighouse base for over 35 years and the products are on site in various national and international markets including: t t t t t t t

Oilfield and Rig applications, Gas drilling and production, High Pressure pumps and process units, Nuclear new build and clean up projects, Chemical and Pharmaceutical sites, Food and Beverage plants, Power generators and turbines.

Flow-Technology Ltd boasts large stocks of Stainless Steel fittings with a diverse product range beginning with low pressure screwed fittings, flanges and butt weld fittings through to high pressure fittings rated at 10,000psi working pressure, 15,000psi and the recently introduced 20,000psi and 60,000psi range. The new high pressure range has undergone thorough design and testing procedures, with a stringent system of identification to ensure full traceability, and working pressure ratings to match the exacting demands of HP applications. The product range is ever growing with the call for combination adaptors and specialist fittings to suit complex environment demands. This range of fittings fully compliments the highly successful 10K and 15K product that Flow-Technology Ltd has produced and stocked for many years. This range already has a vast and varied product offering

consisting of adaptors, tees, elbows and couplings with thread combinations of BSPP, JIC, NPT and Metric. Exacting customer quality demands robust procedures in place to assure compliance with customer requirements and Flow Technology’s ISO9001:2008 approved quality management system has met this with accreditation for 20 Years. Traceability is a major component of this system from raw material receipt though to component laser marking and despatch. Flow-Technology Ltd uses cutting edge technology and equipment to ensure product quality and customer service is at the highest level. Parts are produced in house from European sourced raw material in a fully equipped modern production facility. Constant investment in new technology has seen the company benefit from the latest sliding head technology, CNC lathes and machining centres accompanied by semi CNC manual lathes and CAD design. This backing allows Flow-Technology Ltd to offer standard product and specialist items in quantities from one off items to batch work of thousands. Our sales engineering team are always available on 01484 400880 or 710718; alternatively fax 01484 720439 or email sales@flow-technology.co.uk with your requirements. Our details and product range can be viewed at www.ow-technology.co.uk

Issue 13 PECM



connectors t industrial t test & measurement t industrial automation solutions

www.electroustic.co.uk +44 (0) 1908 307200

Quote ELEC01 for free delivery on orders over ÂŁ50, Valid until 30/06/2014 Tel: +44 (0) 1908 307200 t www.electroustic.co.uk

Connectors & Fittings West Special Fasteners Limited Manufacturers of Stainless & Special Alloy Fasteners We have a Comprehensive range of Hot Forging and Machining facilities, manned by our skilled workforce, enabling us tomanufacture in house the products shown below:Products:• HEXAGON BOLTS • SOCKET CAPSCREWS • STUDBOLTS • ENGINEER STUDS • SOCKET CSK SCREWS

• • • •


Materials:HASTELLOY®, INCONEL®, MONEL 400 & K500®, 254SMO®, 904L, DUPLEX, SUPER DUPLEX, STAINLESS STEELS, TITANIUM, ALUMINIUM BRONZE PLUS OTHER EXOTIC MATERIALS. Beacon Corporation Limited excels in the manufacture and supply of Specialised and Non-standard Fasteners, in a wide range of materials to suit all applications. These include specialist requirements within Hazardous Area and in many different industries, including Power Generation, Oil, Gas, Petrochemical and Process Industries.

Enquiries:- Tel: 01246 291111 email:sales@westspecialfasteners.co.uk Fax:01246 291177 Unit 3B, Callywhite Lane, Dronfield, Derbyshire S18 2XR England

Specialists in Offshore Fasteners

Our many years of experience enable us to offer you a comprehensive and total package, tailored to suit your individual needs. We can offer: - Bolting and turned parts in all materials, such as; Duplex, Super Duplex, Inconel®, Monel®, Titanium, Hastelloy® and many other materials. - We manufacture to your drawings or any standards - Prompt reliable service at competitive prices - Quick response to your enquiries Please visit our website for more information, www.beaconcorporation.co.uk or call our Sales Team on +44 (0)1952 825582.


COMPETITIVE PRICES 5000+ STOCK ITEMS 25+ YEARS OF EXPERIENCE BEST CUSTOMER SERVICE IN THE INDUSTRY Minimum order charge Expensive carriage charges Early cut off for same day dispatch

ORDER NOW AT WWW.NERO.CO.UK T: +44 (0) 121 557 9000 F: +44 (0) 121 557 9092 E: info@nero.co.uk


Issue 13 PECM


Control & Automation Intelligent TFT displays with sound MMS Electronic has available a range of Intelligent TFT graphic displays for use in industrial applications. Available in 3.2”, 4.3”, 5.7” and 7.0” with LED backlight and touch-screen. These intelligent display with innovative user-friendly features reduce development time and cost. For example, a virtual keyboard, analogue rotary instrument or bar graphs can be generated on the screen with just a few simple commands. The EA eDIPTFT57-A and EA eDIPTFT70-A also provides acoustic feedback into an 8 ohm speaker. Sounds ranging from simple clicks or jingles acting as warning or status messages. Simple macro programs, pictures and gif animations can be stored and run directly from the display memory without use of an external micro-processor. Text can be freely mixed with the graphics. The unit features two analogue inputs, 8 digital inputs and 8 digital outputs. On-board interface is serial, I2C and SPI or USB, RS232, RS485 with level converter. Easy mounting into PCB with a 2.54 mm pitch socket, ZIF connector or use our stylish panel mount bezel

MMS Electronics Ltd Tel 01943 877668 • www.mms-e.co.uk

New Program Connects Manufacturers to Best-in-Class Safety System Integrators To help manufacturers identify best-inclass safety system integrators – with current safety standards expertise, a proven track record in building safety systems, and knowledge of productivityenhancing safety technologies – Rockwell Automation has created the Machinery Safety System Integrator program. “A recent Aberdeen report found best-in-class organisations are 81 percent more likely than low performing organisations to leverage outside services to design and install compliant machinery safety solutions,” said Mark Eitzman, manager of safety market development, Rockwell Automation. “The challenge comes in finding and vetting the most capable provider for the job. Rockwell Automation created the Machinery Safety System Integrator program to ease that process and connect manufacturers to machinery safety system integrators they can trust.” Program candidates must meet stringent requirements and complete a rigorous, months-long assessment and education process. Only existing Rockwell Automation Solution Partners or Recognised System Integrators can qualify for the program. Candidates must have three to five years of demonstrated machinery safety experience. Rockwell Automation recognises third-party certification from industry-accepted organisations, such as TÜV or exida. Upon meeting these initial requirements, Rockwell Automation machinery safety experts conduct a candidate assessment to determine if additional training or experience is required. The candidate’s safety engineers must then complete training modules on topics, such as global safety standards, safety risk assessment practices, and different types of safeguarding applications. Lastly, the candidate must submit a machinery safety project to ensure it demonstrates methods consistent with global standards.

Tel: 0870 242 5004 Email: ukmarketing@ra.rockwell.com


PECM issue 13

Rockwell Automation Adds Mobile Capabilities to its FactoryTalk VantagePoint Enterprise Manufacturing Intelligence Software Manufacturers now have the freedom to use any digital device to easily access optimized performance metrics and data analytics from plant floors and machines, thanks to new capabilities embedded in the FactoryTalk VantagePoint EMI v6.0 software from Rockwell Automation. The VantagePoint v6.0 software now includes VantagePoint mobile, a component that enables users to create displays and interact with data across any HTML5compliant browser and mobile platforms, such as iOS and Android. Users can now easily log in to the VantagePoint system and automatically view Web-based KPI content that is responsive to the device they are using – from smartphones to tablets to PCs. This is a significant change from the conventional, costly and time-consuming approaches that enable desktop or mobile access to manufacturing data. No user-specific configurations created by network administrators or IT staff are required, enabling manufacturers to quickly on-board more users and deliver value to increase productivity. “The VantagePoint mobile component instantly detects the type of device being used to access information and adjusts the user experience for that screen,” said Angela Rapko, product manager for FactoryTalk VantagePoint software, Rockwell Automation. “This out-of-the-box solution will enable more users to access valuable operational insight while lowering the cost of delivering that data.”

Tel: 0870 242 5004 Email: ukmarketing@ra.rockwell.com









Don’t settle for second best.







You can count on us for the parts you need. Choosing the right distributor is as important as choosing the right parts. With RS Components, you can access 100,000 automation and control products from trusted global brands. Our outstanding customer support makes it easy to find and buy what you need. No order is too small and we offer Next Working Day delivery on orders placed up to 8.30pm plus free delivery* for orders over £20.


*Business Account holders only, Terms & Conditions apply. See online for full details.

Opto 22 announced groov 2.3, adding Modbus/TCP communication to groov web-based mobile interface software.


ith Modbus/TCP support, thousands of industrial devices can now be monitored and managed using effective, scalable operator interfaces on smartphones, tablets, and other mobile devices. Modbus/ TCP is a widely adopted, TCP/IP-based communications protocol used in level sensors, rotary encoders, drives, meters, and industrial controllers and I/O, plus thousands of other devices deployed in diverse industries. Industrial automation end-users, system integrators, machine OEMs, or any authorized person can quickly and securely monitor and control these devices, as well as automation, building, and other control systems, all from a mobile device. Acting as a Modbus/TCP master, groov communicates directly with Modbus/ TCP slave devices over standard, non-proprietary Ethernet networks. No intermediary servers, protocol converters, or communications interfaces are required. This simplifies hardware planning, reduces initial hardware cost and ongoing maintenance, and streamlines device setup and configuration. More information about groov’s new Modbus/ TCP support is available at op22.co/ modbusgroov.

A fully functional version of groov Server for Windows is available to download at groov.com/see-groov-now

groov is a zero-programming, webbased way to build, deploy, and view effective, scalable operator interfaces to monitor and control systems and equipment using mobile devices and other computer-based systems. These operator interfaces can be viewed on almost any mobile device or computer regardless of its ma.

These interfaces can also be viewed in the mobile device’s builtin web browser. For mobile devices like iPhones, iPads, and Android-based smartphones and tablets, a groov View app for iOS and Android is available free of charge on the iOS App Store and Google Play Store. The groov View app provides a native mobile experience for operator interfaces built with groov. These interfaces can also be viewed in the mobile device’s built-in web browser. groov can augment existing humanmachine interfaces (HMIs) and Supervisory Control and Data Acquisition (SCADA) systems by making important information available

to authorized users at any time and in any location. groov is available as either the standalone groov Box hardware appliance or the PC-based groov Server for Windows software. In addition to Modbus/TCP networking, groov supports OPC Unified Architecture (OPC UA) to communicate with a variety of devices on the plant floor, including PLCs, DCSs, PACs, databases, and OPC-DA servers. groov also communicates directly with Opto 22 SNAP PAC System controllers. A fully functional version of groov Server for Windows is available to download at groov.com/see-groovnow. The groov free trial operates for two hours without a license and can be restarted as needed. Pricing and Availability: groov 2.3 is available immediately. Choose either the groov Box hardware appliance (GROOV-AR1) at a list price of $2895.00 USD, or groov Server for Windows software (GROOV-SVRWIN) at a list price of $2695.00 USD. Customers who already have groov version 2.0 or later and a groov maintenance contract can upgrade to groov 2.3 free of charge. www.groov.com

RACE TO THE TOP Taking rail mounted terminal block technology to a higher level

The challenging conditions found in many operating environments demand the best connection technology available. WAGO’s TOPJOB®S Ex approved DIN rail mounted terminal blocks not only feature extremely compact design but also offer outstanding dependability and efficiency. To find out more, contact us today!

tIdeal for space restricted applications such as switch cabinets/terminal boxes

tCAGE CLAMP®S technology provides tool-free terminations for all conductor types

tEx approvals are standard tRobust spring loaded jumper system for nominal current tHighly competitive prices Telephone E-Mail Internet

0870 264 0773 ukmarketing@wago.com www.wago.com

chch lele inin lalbab .6.6 aiai 1515 avav ww ww NeNeI nI ono HM HM

AllDrives & Controls Ltd AllDrives Ltd Village | Keys Park Road Epson 2 |& Controls Keys Business Epson 2 | Keys Business Village | Keys Park Road Hednesford | Staffordshire | WS12 2HA Hednesford | Staffordshire | WS12 2HA T: 01543271899 | E: simon@alldrivesandcontrols.co.uk T: 01543271899 | E: simon@alldrivesandcontrols.co.uk www.alldrivesandcontrols.co.uk www.alldrivesandcontrols.co.uk

Control & Automation


“An easy to use and understand DVD, the short informative videos make it an ideal reference tool, a must for anyone who buys, installs or maintains industrial electric motors” Ryan Johnston, Electrical Maintenance Manager

Watching the Easy Guide to Low Voltage Motors Tutorials you will discover: How to save Energy with Electric Motors.

Motors Efficiency Legislation

Motor Bearing Constructions & Types

Cable Connections for DOL

Cable Connections for Soft Start Control

Your Motor Mounting Options

Cable Connections for Variable Speed Drive Control

Get your FREE copy today Go to: www.motor-dvd.co.uk Issue 13 PECM


Pumping/VSD Installation Fires What do you do about RCCB Protection? To safely install pumping equipment containing VSDs requires a detailed understanding of the operational leakage currents and residual currents associated with the EMC filter / VSD / Motor combination including the local installation requirements.


emote pumping stations/ distributed process installations subjected to wide temperature changes create conditions for condensation on de-energised electrical equipment. A build-up of dust on insulated surfaces subjected to moist damp conditions, can create an additional fire hazard. Under these conditions relatively low levels of leakage current - less than 80mA travelling across an insulated surface can ignite combustible material and fluids containing simple contaminates such as detergents. Scintillations forming on the insulation surface create conductive tracks which result in a cascade effect and increased leakage current and resultant fire hazard. See video “How do RCDs prevent fire” http://www.doepke. co.uk/ If the electrical specification for the installation does not cover the detection of safe levels of earth leakage current there is an increased risk of an electrical fire, especially if equipment is mounted out of sight and or subject to infrequent maintenance. Where conventional protective bonding cannot be relied on to achieve the required level of electrical safety,


PECM Issue 13

and RCD protection is required under the regulations, only Type B RCDs can be used with 3 phase VSDs: see GAMBICA Installation Guide 4th Edition - Page28. 4.2.3 and manufactures installation instructions.

If the electrical specification for the installation does not cover the detection of safe levels of earth leakage current there is an increased risk of an electrical fire BS7671 Compatibility of Electrical Equipment Installing equipment containing 3 phase VSD and EMC filters (see Fig 1.) requires a detailed assessment of the leakage current associated with the equipment. BS7671 Regulation 331.1 gives some guidance on the

assessment of characteristics of the equipment that impact on the safety of the installation – referred to as “harmful effects”. This includes amongst other safety issues; earth leakage currents, high protective conductor current present under normal operation, d.c. feedback and high-frequency oscillations. Operational Leakage currents and residual currents associated with VSD installations Drive installations produce operational leakage currents across a wide frequency spectrum see Fig 2: Under normal operating conditions the leakage currents flowing in the protective conductor should not cause unnecessary operation of the RCD. Comparing the operational characteristics of the drive installation against the RCD characteristic will identify any weakness in the proposed design based on the protection level required i.e. <30mA personal protection. >30mA <300mA fire protection. Fixed Leakage Current: The EMC filter - internal or external to the VSD produces a fixed leakage current to

earth, with frequency components between 100Hz <1kHz plus leakage currents in the resonant frequency range of the filter.

If the switching frequency of the inverter is in the resonant frequency range of the external EMC filter (poor design specification), extremely high leakage currents can flow. Variable Leakage Currents: The length of cable between the inverter and motor has a significant effect on the operational leakage current, and should be kept as short as possibletake note of the VSD manufactures recommendations. If the switching frequency of the inverter is in the resonant frequency range of the external EMC filter (poor design specification), extremely high leakage currents can flow. Changing the

switching frequency of the inverter may not elevate the problem as it will still be a multiple of the filter resonant frequency. From this it can be seen that the resultant leakage current seen by the RCD will be complex; vectorial sum of the capacitive, inductive and resistive elements of the leakage currents plus the various frequency components. Transient Leakage Currents: These occur during switch-on / switchoff and as result can cause the RCD to trip if the transients exceed the defined tripping characteristics of the selected RCD. Type B RCCBs have a higher resistance to inrush residual currants with a maximum duration of 10ms <3KA. RCD protection to meet existing Regulations When there is a requirement to include RCD protection to meet existing regulations, inverter manufactures recommend the use of Type B RCDs for 3 phase VSDs. Doepke offer a free 64 page Technical Application Guide covering the selection of RCDs for use with 3 phase VSD installations and measures for reducing associated

Remote pumping stations/ distributed process installations subjected to wide temperature changes create conditions for condensation on de-energised electrical equipment. A build-up of dust on insulated surfaces subjected to moist damp conditions, can create an additional fire hazard. leakage currents. http://www.doepke.co.uk/rcd/ rcdB.html Chaz Andrews â&#x20AC;&#x201C; Technical Manager Doepke UK Ltd. Email: sales@doepke.co.uk Web: www.doepke.co.uk Issue 13 PECM


Electrical & Electronics Fibox enclosures: a rugged, non-corrosive alternative to steel Two ranges of enclosures were showcased on the Fibox stand at Southern Manufacturing 2015, together with examples of 15 established families, which encompass over 1500 size options in total. ARCA is a range of wall or pole-mounted, hinged door cabinets that offer a viable alternative to sheet steel enclosures. They are non-corrosive, UV stabilised and lighter than its steel counterpart, but suitable for harsh environments. Euronord lll is designed to fulfil a multitude of applications in the industrial electronics industry for an aesthetically pleasing housing. lt has, says the company, a comprehensive list of features and benefits. Also shown was MNX, the popular range of small to medium sized enclosures which offers more than 300 different size configurations. See the enclosure options available at www.fibox.co.uk.

Tel: 01642 604400


Three in one – the new true RMS DMM, AC/DC current clamp and insulation tester from Martindale Electric Martindale Electric, known for providing innovative and time-saving electrical measurement solutions for electricians and service professionals, introduces a unique clamp meter in their range of multimeters and clamp meters that also has an insulation tester built-in. The CMi210 is a high-spec insulation clamp meter, providing a true RMS measurement of AC current up to 1500A and AC voltage up to 750V as well as insulation tests to 6G Ohms with 5 test voltages from 50V to 1000V. The CMi210 is ideally suited to anyone carrying out general testing and maintenance in service and installation organisations. The new design replaces three instruments in a single handheld design saving money, space and weight in a tool kit.

Tel: 01923 441717


Ready to tackle increasingly demanding PCB assembly projects

All functions on board – our innovative light curtains

Speedboard Assembly Services has enhanced its Printed Circuit Board (PCB) assembly capabilities, following its investment in an IBL BLC 509 Vapour Phase oven; where Vapour Phase affords much better control and stability over the entire soldering process, compared to traditional reflow soldering, regardless of board characteristics.

A multitude of complex systems need to be integrated in a production line in order to guarantee the safety of staff. Light curtains play an important role when it comes to protecting humans against moving parts of machines. However, a light curtain alone will not be sufficient. In addition, emergency stop switches and safety door contacts need to be integrated and wired. A safe connection of controllers, motors, and pneumatic equipment make additional safety components necessary. A smart and innovative solution to this problem can be found in Panasonic’s light curtain SF4C.

Neil Owen (left), Speedboard’s Managing Director, comments: “High complexity, and by extension high value, boards demand the use of alternative production techniques in order to maintain consistently high quality. Following our investment in Vapour Phase, we are able to tackle increasingly challenging projects for customers operating in sectors such as Industrial, Defence, Medical, Communications and Security, where stringent standards are demanding consistency and quality throughout the entire manufacturing process.”

Tel: 01753 746700 Email: sales@speedboard.co.uk www.speedboard.co.uk

SRK series extended by new double level terminals

Email: Info.pewuk@eu.panasonic.com www.panasonic-electric-works.co.uk


Manufacturers of Transformers.

CONTA-CLIP has extended its SRK series of screw connection terminal blocks, adding approximately 40 new double level models for nominal wire cross sections between 2.5 mm² and 10 mm². The new SKRD double level terminal blocks are available as standard models with two potentials and 2 x 2 connections, with four connections on one potential, or as a protective earth terminal with a snap-on PE foot contact. The new products are compatible to the existing SRK accessory range. CONTA-CLIP will announce further SKRD types later in 2014, such as models with integrated electronics for switching status signaling and models with surge arresters.

Email: quade@conta-clip.de

Emergency stop switches or safety door switches can be connected directly and without need for a safety PLC to the light curtain. The additional contacts needed for monitoring the power relays can also be connected directly to the light curtain.


Some points why you may consider us 1) High Quality at Competitive Prices. 2) Transit time to your door approximately 1 Week. 3) We are in the EU so no customs documents. 4) Been Established for over 30 Years.

Are You Certain Of The Fill Material In Your Melt Pressure/Temperature Sensors? We are extremely proud to be launching the new and improved 5000 Series Melt Pressure/Temperature Transducers/Transmitters, incorporating the new Terwin Traffic Light System - taking the uncertainty out of the identification of sensor fill materials. This System is extremely simple but unique to the Terwin 5000 series. The sensor housing is now colour coded to identify the fill material within the unit. A red housing indicates Mercury fill, amber housing indicates NaK fill and green housing indicates Oil fill. As simple to understand as the instructions given at traffic lights – STOP / PROCEED WITH CAUTION / GO. No more valuable time spent scouring machines, part numbers, data sheets and websites for fill information, which can now be identified with ease, even from a distance. When you purchase a Terwin sensor, you will always know what you are using!

Email: info@terwin.com


PECM issue 13


5) Family Owned Business. 6) Work to ISO 9001. 7) Very Flexible manufacturing to customers specs.

Also soon starting manufacture of Toroidal Transformers. DEECO LTD.

Kw8, Corradino Industrial Estate, Paola. PLA 3000 MALTA Tel : 00356 21824019 / 21824572 Fax : 00356 21674774 www.deeco.com.mt

Condensation the creeping danger umidity - condensation - corrosion: This chain of adverse conditions often adds up to cause failure in sensitive electrical and electronic components. The use of modern electric enclosure heaters is an effective and economic countermeasure that addresses these frequently neglected causes of defect and avoids damage or even breakdowns.


Operational reliability and longevity are attributes every customer expects from a panel or enclosure. For some electronic components, the service life is directly related to the ambient temperature. This requires the interior temperature of enclosures to be lowered and unwanted excess heat to be removed. However the danger arising from condensation in enclosures is often disregarded, even when the resulting defect characteristics are usually very dramatic. Short circuits cause damage in individual units that must then be replaced. Condensation - a rarely recognized cause of faults or even complete breakdowns of an entire control system. Condensation is thus a source of faults that must be taken seriously. The biggest risk in practice occurs when relatively high humidity and temperature fluctuations coincide in an encapsulated enclosure. There’s something in the air Humidity arises when the sun extracts water from waterways and plants by evaporation. This share of water vapor in the atmospheric air is referred to as “absolute” humidity (in g/m³). How much water can be stored in the air depends on a variety of factors, such as temperature or air pressure. The higher the air temperature, the more invisible water parts can be absorbed by and stored in the air. The ratio of “absolute” humidity to the maximum possible humidity is referred as “relative” humidity (in %). At 100% RH, the air is saturated and the so-called dew point is reached. No further water vapor can be stored in the air. The excess water vapor share is dumped into the environment as condensation.


PECM Issue 13

Tel: 01372 747250 • www.stego.co.uk

Dew - refreshing for nature, devastating for technology At constant absolute humidity (water quantity in g/m³) and falling temperature, the air becomes saturated and can no longer hold the water vapor: the dew point is reached and fine water droplets are deposited. This is when the danger of component failure in enclosures begins. Corrosion even without condensation The formation of condensation only starts when a relative humidity of 100% is reached. But even values lower than that can present a danger for enclosures. Corrosion can already occur at much lower values. This is the result of various long-term studies. The empirical limit thus determined is at around 65% RH. From this threshold on, one has to expect corrosion in panels & enclosures, even without condensation being formed. Optimal conditions can only be achieved by constant temperature. Condensation and corrosion are not the only factors that significantly reduce the lifetime of the components - so does mechanical stress brought about by continuous temperature fluctuation. The “life insurance” for panels & enclosures: electric enclosure heaters The state-of-the-art solutions are electric enclosure heaters that have been developed specifically to avoid condensation and temperatures that are too low or fluctuate too much. The air in the enclosure is heated to the point where it can hold the entire water vapor and condensation is avoided. Without a heater, the relative humidity increases and condensation occurs on components. Conclusion: Enclosure heaters are a reliable protection against condensation and temperatures that fluctuate or are too low. When comparing the cost caused by failures to the purchase price of enclosure heaters and controllers, the latter represent little additional cost that nevertheless makes a big difference.

ETF012 Hygrotherm

CSF028 fan-assisted heater

CSF060 heater

Thermal Management Solutions by STEGO Anti-Condensation Heaters Filter Fans - IP55 Lamps, LED Lighting Thermostats + Hygrostats Accessories for Enclosures


STEGO UK Ltd Unit 12, First Quarter Business Park, Blenheim Road, Epsom, Surrey KT19 9QN Tel. +44 (0)1372 747250, Fax +44 (0)1372 729854 www.stego.co.uk info@stego.co.uk

Electrical & Electronics

Connect 2 Expertise



Get the right solution Proven, reliable connectors and cable assemblies are here www.fischerconnectors.com/uk

Fischer Connectors Ltd. Havant / Hampshire Freephone 0800 432 0301 sales@fischerconnectors.co.uk

Use the DCDC63125F-SU-ADJ step up voltage converter as a battery charger, a lamp regulator, or a LED driver. The Voltage of a 3000 watt fuel cell can be stabilized. The voltage of the fuel cell must be less than the output voltage. It is great for charging batteries. It is great for LED drivers. The output voltage is adjustable with a multiturn pot. For more information go to http://www.zahninc.com


PECM issue 13

® Current Limiting Protector




Â&#x2021;6&$'$$GDSWDEOH Â&#x2021;&RVW(IIHFWLYH G&W System Protection Division gwelec.com ISO 9001:2008 certified ISO 14001:2004 certified

Electrical & Electronics

New innovations in Stainless Steel Enclosures providing high protection for harsh environments

innovative enclosure solutions for industrial & electronic applications

www.eta-enclosures.co.uk New Fluke 805 FC Vibration Meter is the latest addition to Fluke Connect – the world’s largest wireless system of test and measurement tools Fluke has introduced the handheld Fluke® 805 FC Vibration Meter, a portable multifunction vibration screening tool that provides quantifiable information on the bearings and overall health of motors and other rotating equipment, and shares that data in real time via Fluke Connect™. The Fluke 805 FC is ideal for frontline mechanical troubleshooting teams that need reliable and repeatable measurements of rotating equipment to make imperative go/no-go maintenance decisions.

For over fifty years, Kimball Electronics has produced electronic assemblies for the automotive, industrial, medical, and public safety markets.

Vibration screening is a critical part of motor maintenance, and trending measurement data over time provides invaluable insight into long-term motor health. The Fluke 805 FC automatically saves vibration data wirelessly to Fluke Connect cloud storage so authorised team members can view all of the measurement data for each asset with the Fluke Connect app on their mobile devices before they leave the inspection site. Using EquipmentLog™, technicians and managers can get all their measurement data in one place to get the complete asset story.


Kimball specializes in durable electronics; assemblies that are required to perform in harsh and demanding environments requiring very high reliability for very long periods of time. Kimball operates six facilities in 5 countries: Mexico, China, Thailand, Poland, and two operations in the United States. Kimball Electronics provides services such as design, prototyping, subassembly, and complete system integration. At Kimball Electronics, client designs are transformed into final assemblies by a very experienced team executing world-class manufacturing processes. Visit www.kimballelectronics.com to learn more!

The value of using Briton EMS EXCELLENCE I N E L E C T RO N I C M A N U FA C T U R I N G S E RV I C E S

1. Complete turnkey electronics manufacturing services – including design – supported by in-house engineering, PCB / SMT assembly, materials procurement, full testing and shipping.

We provide . SMT & Through Hole PCB Assembly

2. Devolving manufacturing to Briton EMS improves your companyÊs cash flow – and your ROI.

. Complete Product Build

. Low/Medium Volume Manufacturing

. BGA/µBGA Placement & Inspection

3. Electronic products manufactured in low and medium volumes in the UK.

. Test Solutions/JTAG/AOI . Global Procurement

. Lead Free Services

4. Option to manufacture higher volumes in our offshore facilities in Indonesia.

. Engineering and Design Support To meet your

Quality, Flexibility & Delivery targets

Call our sales department today

01234 266300 www.britonems.co.uk


PECM issue 13


Briton EMS Ltd 4 Shuttleworth Rd Elms Industrial Estate Bedford " MK41 0EP

[e]: sales@britonems.co.uk info@britonems.co.uk

A project you'd like to discuss? E-mail sales@britonems.co.uk info@britonems.co.uk or call 01234 266 300.


Momentum Gathers for Facilities Management 2015 acilities Management 2015, which is returning to the NEC, Birmingham on 24 - 26 March, is boasting an expanded showfloor, underlining its position as the leading UK event for the facilities industry outside of London.


Facilities Management 2015 will be co-located with three other complementary shows including a brand new show – Cleaning 2015

Co-Locations Facilities Management 2015 will be co-located with three other complementary shows including a brand new show – Cleaning 2015, which will focus specifically on the buyers and suppliers from within the cleaning sector, giving them a dedicated show for their needs. Its second co-location is Maintec – the leading UK event for the maintenance, plant and asset management industry – a neat fit as many FM visitors also have a wider maintenance remit. The Health & Safety Event, which is run by a leader in the health and safety sector, Western Business Exhibitions Exhibition Hall Exhibitors at Facilities Management 2015 include all the major names such as Ice Road Gritters, Scot Young Research, WD40 and Cooleraid. These will be joined by an exciting array of new exhibitors including NBC Bird & Pest Solutions, Kemper UK, Williamson-Dickie Europe Ltd and


PECM Issue 13

Asckey Data Services. Access Control Technology, which designs and manufactures electronic access control and door entry products, will use the show to introduce ACTviquest, which is an integrated access control and video management solution - all-in-one compact box. It is capable of recording up to 8 channels and managing up to 100 doors with ACTenterprise Lite, and will suit most small to medium sized applications allowing approximately 12 days recording. CPA Engineered Solutions Ltd’s Enershield Air Barrier cleverly creates a ‘virtual door’ by recirculating ambient air and forcing it across an opening to create up to a 90% seal. The seal separates the atmospheres on either side and stops the transfer of temperature, humidity, dust, odours and insects. With just a draught of air creating the barrier, vehicles and pedestrians can pass without obstruction.

Exhibitors at Facilities Management 2015 include all the major names such as Ice Road Gritters, Scot Young Research, WD40 and Cooleraid. These will be joined by an exciting array of new exhibitors including NBC Bird & Pest Solutions, Kemper UK, Williamson-Dickie Europe Ltd and Asckey Data Services.

Manhattan Atrium, the UKâ&#x20AC;&#x2122;s leading supplier of Enterprise Asset Management (EAM) solutions, will be using Facilities Management to display its latest web-based software suite. It enables organisations to optimise their property estate, enhance business performance, manage risk, add value and reduce costs. Show Floor Entertainment Visitors will have plenty of learning opportunities at Facilities Management 2015 too, including a return of The

Visitors will have plenty of learning opportunities at Facilities Management 2015 too, including a return of The Business Exchange. Business Exchange. This will feature a selection of free content-rich practical talks full of the latest research, new innovations and case studies exploring the hottest topics, challenges and trends. Running in conjunction with The Business Exchange will be FM Matters where experts from some of the biggest names in industry will share their knowledge and experience. If you are interested in exhibiting, please contact Chris Collins on +44 (0)20 8843 8825, chris.collins@easyFairs.com or visit our website for more information and to register for free entry: www.fm-birmingham.com. Issue 13 PECM


Facilities Management

www.brownmac.com Email: pecm@brownmac.com






PECM issue 13




Short Term Chocolate Preservation By Carl Webb Director of Andrews Chiller Hire ompanies involved in food processing and storage will appreciate the diverse role that air cooled fluid chillers and air handling units contribute in ensuring that their products leave their factory and reach its destination in excellent condition. Planned routine maintenance ensures this equipment can deliver chilled water wherever it is required – whether cooling actual production equipment or lowering temperatures in chilled storage areas or as part of the in-house HVAC system.

chocolate four to six times a week, which rises significantly during holiday periods such as Easter where it is estimated that more than 80 million

Figures published by research group Mintel show that 17% of UK consumers eat

chocolate eggs will be sold. Not just Easter eggs, ninety million chocolate Easter



PECM Issue 13

Figures published by research group Mintel show that 17% of UK consumers eat chocolate four to six times a week

bunnies are also expected to be sold. At these seasonal highs, driven by consumer demand for ‘more’, confectionery manufacturers are under pressure to increase productivity and often require additional low-temperature storage. Good News for Retailers Whilst holiday periods provide good opportunity for retailers to boost sales, often they are unable to take advanced delivery to satisfy demand due to limited on-site storage or company policy of straight from supplier to shop floor. This puts the onus on the manufacturer to hold the additional stock for a short period, often requiring a short term storage solution by way of temporary chilled store. Running a permanent chilled store is expensive therefore food and confectionery producers operate with minimum facilities capable of handling a nominal output. Storage facilities with only ‘part load’ see a rise in operating costs, therefore manufacturers try to maintain a full store, hence they are not able to accommodate


Chocolate shop counter display

increased seasonal demand. One of the most economical short-term solutions is to convert an existing room into a chilled store or rent an additional warehouse which then can be turned into a cold store. The most successful conversions require shortterm hire of a fluid air chiller working through air handling units which recycle air from within the warehouse to the chiller where it is cooled and then returned via the AHU back into the warehouse.

One of the most economical shortterm solutions is to convert an existing room into a chilled store Economical Temporary Chilled Store One company to benefit from an additional temporary storage warehouse was a chocolate producer, particularly essential at this time of the year in the run-up to Easter where confectionary demand increases significantly. This application called upon the skills of Specialist Hire Division of Andrews Sykes to supply and install a totally integrated temporary cooling system. Their engineers calculated that to achieve the required low temperature would require two x 550kW chillers feeding eight 150kW air handling units. The chiller and 2 x 800kVA generators were sited as

Andrews Sykes Hire Limited Chiller Division Unit 54 Gravelly Industrial Park Tyburn Road Birmingham B24 8TQ Tel: +44 (0)1902 328725 E: shdinternalsales@andrews-sykes.com web: www.andrews-sykes.com

Above Right Air handling units

close as possible to the warehouse without restricting customer access and all internal pipework was carefully positioned to avoid disruption to warehouse staff as they went about their daily routine. To provide a totally independent system the hire company also supplied a 6,000 litre bunded fuel tank.


500kW chiller installation

Prior to the warehouse becoming operational the Andrews system went live, warm air drawn from the warehouse into the AHUs, (each capable of delivering up to 20,160m3/h) and circulated over ‘cold’ coils

resulting in a temperature drop as the now much cooler air was blasted back into the warehouse. This created the right storage environment to accept confectionery items from the production floor, the continuous repetitive chilling process ensured that low temperature was maintained throughout the short-term hire. Underperforming temporary chilled storage could result in degradation of the final product, with the retail customer returning a complete batch. To prevent waste it is essential to seek expert advice from specialist hire organisations such as Andrews Chiller Hire. Engineers will carry out a site survey to clearly understand customers’ needs and put forward a highly effective and practical short-term solution. By providing 24/7, 365 day access to specialist engineering staff and with a nationwide network of more than 24 depots Andrews Sykes Specialist Hire Division is always able to provide an extremely prompt response to your enquiry. For confectionary producers the need for additional shortterm chilled storage does not need to be planned in advance. Issue 13 PECM


facilities MANAGEMENT

Discovering innovation at the heart of the facilities industries

REGISTER TODAY! After a hugely successful launch event, Facilities Management 2015 will return for a bigger and better second edition this month â&#x20AC;&#x201C; this is your best opportunity to source new suppliers, network and gain industry knowledge. Register online today for free admission and avoid the queues - www.fm-birmingham.com

Co-located with


Show supporters

Organised by

Fluid Handling

Aquaflow, a division of T-T Pumps Ltd, introduces their range of new liquid turbine flow meters. Acuflux is designed with reliability, durability and practicality in mind to incorporate the required features of a flow meter with manufacturing expertise to produce a flow meter that operates efficiently in demanding media conditions. The Acuflux’s durability is demonstrated in its diverse temperate range, allowing a flow of liquid from -40°C to +85°C and a 40 bar maximum working pressure. Not only is the Acuflux reliable in terms of its robust design of corrosion resistant stainless steel, it is also reliable in terms of its data capture with the readings guaranteed to achieve accuracy within one per cent. Aquaflow, recognising the importance in customer satisfaction, have produced a product with usability in mind. The simple-to-use flow meter incorporates a two line LCD display indicating flow rate, volume and cumulative totals for clear data recording.

Tel: 01630 647111


The new Series 5 YTRON-Z in-line homogeniser After consulting Ytron-Quadro (UK) Limited a YTRON-Z inline emulsifier was booked for long term trials in DFI Leeds. Eric Dunlea from the Dairygold R&D innovation centre in Ireland and Howard Ibbetson, Dairygold Food Ingredients engineering manager, conducted exhaustive trials across the DFI product range. In their own words, “the outcome was extremely positive. Our already high product quality visually improved. Product was smoother and a ‘glossy’ effect was seen across all products. The lower fat variants gained body too which has now delivered what we feel is a “best-in-class” product. Starch is used in some products as a stabiliser, the presence of un-hydrated starch molecules in finished product is clearly not acceptable to our customers. The YTRON-Z gave us another tool to eradicate these occurrences and speed up our process without damaging the functionality of the starch”.

Filter Devices from Helapet The art of filtration OComplete

bespoke filter service OIndividually designed and printed to your specification, whatever the quality OExtensive range of connectors and access to a variety of media

www.filterdevices.co.uk 0800 0328 428

The results were so conclusive that 2 YTRON-Z units were ordered. These will be installed in the two production lines, packing bulk & smaller foodservice size packs.

Email: mixing@ytron-quadro.co.uk


Mixing and Dispersion Specialists

Ytron Y Directed Jet Mixer t Strong axial flow t Full product mixing across tank t No Vortexing – No air entrainment t No Baffles – simplified cleaning t ByPass incorporation of powders t High Shear options

Tel: 01494 792 898 Email: mixing@ytron-quadro.co.uk www.ytron-quadro.co.uk

Issue 13 PECM


How to guarantee accuracy throughout the manufacturing process

WDS agreed to supply the Bloodhound SSC project with vital components free of charge.


or want of a nail the shoe was lost. For want of a shoe the horse was lost. This proverb carries on through rider and message to battle and kingdom. It pre-dates modern manufacturing – probably by a couple of centuries – but exactly the same principle applies to engineering. Chris Putman, Sales and Marketing Director of WDS explains that if you don’t get the small details right, the big picture will never be perfect. Most of us enjoy flying away once in


PECM Issue 13

a while, for a few well-earned weeks in the sun, putting the worries and cares of our engineering world behind us. We can relax on the outward flight knowing that every component of the plane is manufactured and maintained to the strictest tolerances and maintained to the highest standards. At 30,000ft and 600mph, we know we don’t have to worry about cheap parts, quick fixes, or slapdash recordkeeping. This is because the aerospace industry represents the pinnacle of engineering in terms of design, innovation and manufacturing quality.

In today’s world, many component parts need to be manufactured with supreme accuracy. The aerospace industry, Formula 1 and precision engineering are obvious fields that require tolerances equivalent to a hair’s breadth over many metres. But cars, consumer goods, electronic devices, medical equipment and many other products are now made to tolerances almost as demanding. This requires workholding, fixturing and location parts that conform to high tolerances. Production of these parts must be accurate and repeatable – and

Engineers at WDS Component Parts in Leeds, have perfected a procedure for guaranteeing that their clients can produce accurate parts, time and time again. often produced at bewildering speeds. In addition to these technical requirements, there are frequently commercial pressures for low cost, reduced lead times, changed orders and design variants. Then there may be tightening quality requirements for say, improving traceability or reducing defects. Engineers at WDS Component Parts in Leeds, have perfected a procedure for guaranteeing that their clients can produce accurate parts, time and time again. In the first stage they work with customers through the specification stages to produce technical drawings of fixtures etc. These are cast in iron, then machined and finished to an accuracy of 5µm to the metre using ISO9001 registered tooling. Prior to delivery, the parts are tested in-house using properly calibrated measuring equipment and supplied with a certificate of conformity. Cast iron has some key advantages: it minimises size distortion caused by fluctuating temperatures and is a deadening

material, which cuts vibration during machining. Workholding parts – such as cubes, end-plates and risers – are not only high value; they are also extremely cumbersome to manoeuvre and require a fair amount of storage space. Where production cells are responsible

WDS engineers are able to work with customers to create matrix designs that can hold many different parts. for different part runs, exchanging the workholding tools can often result in significant downtime during product run change-overs. WDS engineers are able to work with customers to create matrix designs

Workholding parts – such as cubes, end-plates and risers – are not only high value; they are also extremely cumbersome to manoeuvre and require a fair amount of storage space.

www.wdsltd.co.uk that can hold many different parts. This improves the work flow in most environments and keeps productivity high, as they typically only need to be turned through 90deg or 180deg to change from one task to the next.

Made in Britain Around the world British engineering is synonymous with design ingenuity, quality and reliability. It’s a reputation that we, as a nation, are quite rightly proud of, and it’s a tradition that WDS is happy to be a part of. WDS manufactures the majority of its products in-house at its Centre of Engineering Excellence in Leeds and its 30-year relationship with the aerospace industry sets the standards by which it measures every job. Issue 13 PECM


Husky 3300 Pumps â&#x201E;˘

The Husky 3300, 3 inch (76,2 mm), air-operated double diaphragm pump features a four bolt joint design, which provides even sealing pressure for leak-free operation and a three-piece manifold for increased installation flexibility. Available in aluminum, polypropylene and stainless steel.

t Flow rates up to 300 gpm (1,135 lpm) t t t Modular stall-resistant air valve design t t Heavy-duty construction t t Easy maintenance

Graco offers a complete line of double diaphragm pumps for all type of applications.

1/4 inch (6,3 mm)

3/8 in (9,52 mm)

1/2 inch (12,7 mm)

1 inch (25,4 mm)

1-1/2 inch (38,1 mm) 2 inch (50,8 mm)

Go to our website to find out more information about Gracoâ&#x20AC;&#x2122;s Husky line: graco.eu/husky01

New Innovation from Colex International Limited

NeuVend SI Tap Tail

NeuVend SI


80% of Colex product is bespoke, so they have a wealth of experience in designing and manufacturing hose to meet your specific requirements.

olex International Ltd. is a UK company with over 20 years’ experience in the manufacture of high quality hoses and tubes. With an excellent reputation for forward thinking, innovation & new product development, Colex has added a number of new lines to their portfolio to meet the ever increasing demands of the market. Protectaflex is the next generation dual containment hose system, offering all the benefits of existing products but in a smaller, lighter and more manageable format. The durable PU outer is UV stable and offers excellent clarity for visual inspection. Inner hoses are available in reinforced PVC, Vendhose and NeuVend™. NeuVend SI™ is a triple layer hose with added antimicrobial protection. It has been designed for critical applications where there is an enhanced risk to human health from microbial organisms within


the potable water supply system.

these Tap Tails to exactly suit your requirement.

NeuVend SI ™ is suitable for use in all potable water supply applications especially where the additional Biomaster Antimicrobial Protection properties are critical, such as, hospitals, dental clinics, nursing and care homes, HVAC, aviation & leisure.

Antimicrobial Silicone Tube offers all of the benefits of standard silicone, with added antimicrobial protection. Specifically engineered for applications where bacteria control is required, antimicrobial silicone provides prolonged and effective protection against bacteria such as MRSA and E.coli.

NeuVend SI™ Lined Flexible Tap Tails are comprised of NeuVend SI™ Liner overbraided with stainless steel and fixed on both ends with the required fitting. The NeuVend SI™ liner itself is manufactured from a blend of polyolefin based materials lined with smooth polyethylene internal surface all containing a Biomaster antimicrobial additive. The NeuVend SI™ liner combined with stainless steel over braiding results in a Tap Tail that has excellent flexural and working pressure properties. Available in a variety of lengths with a number of different fittings, Colex can make

In addition Colex also manufactures a range of stock products including, nylon, PVC and polyurethane hoses & tubes plus a range of PTFE and Silicone. 80% of Colex product is bespoke, so they have a wealth of experience in designing and manufacturing hose to meet your specific requirements. Please visit www.colexint.com for more information about all of Colex Internationals products and services or email sales@colexint.co.uk to enquire about products.

Issue 13 PECM



are industry leaders in barrier safety

The Heart & Soul of Health & Safety A-SAFE’s new iFlex range takes barrier protection in the workplace to the next level here’s a whole lotta love in Health & Safety. Hidden within the practicalities and the necessities, the endless streams of guidance and advice, the sometimes painful, paper-dry legalese and documentation, there’s a love for people, for things, for doing business the right way.


Health & Safety in the workplace isn’t some enforced bureaucratic nightmare made real; it’s a modern, forward-thinking philosophy based around sound, long-term investments and practices that protect what really matters in business: people. From this, all the other important business considerations follow-on: customer relationships, innovation, long-term protection of hardware and structures, logistics and, ultimately, profitability. Consider further, then, the people and things we love: would anyone who truly loves someone or something ever give them a knowingly substandard product? A knocked-off necklace with fake jewels, say, or a fitted kitchen with dodgy parts and workmanship, or, for argument’s sake, a quickfix barrier system that leaves your beloved facility non-compliant with Health & Safety procedures, pays no heed to the general management of traffic and pedestrians and is so unfit for purpose it gets ripped up or needs replacing in double-quick time, leaving your employees, hardware and critical structures in further jeopardy and your


PECM Issue 13

bank balance reeling like it’s been paid a visit by a modern day Dick Turpin. Well, you’d be surprised… In the world of industry, love for your facility means giving it the best chance to grow, flourish and be productive. Health & Safety procedures cover all three of these factors and the barriers you place in and around your workplace should be among your first Health & Safety considerations. A-SAFE are industry leaders in barrier safety, inventors and manufacturers of the world’s first fixed polymer safety barrier system and experts in managing the safety of personnel, vehicles and critical structures in the workplace. The company’s scientific approach to barrier safety, including constant innovation and investment in research and development, ensures they have always been world-leaders in their field. Factories, facilities, warehouses, car parks and airports across the world reap longterm cost and safety benefits from installing A-SAFE’s impact-absorbent, maintenance-free, high-strength barriers. Even better, in 2015 A-SAFE will take barrier system protection to a whole new level. The company’s iFlex range will offer a plethora of never before seen innovations, all independently tested, all raising the Health & Safety bar, all offering longer-term cost savings and larger returns in

investment for those companies with an intelligent Health & Safety brief. Food and Drink facilities can benefit from hygiene-compliant, wipe-clean, non-corrosive barriers with no ingress points where water, dirt or debris can collect. Major advancements in modularity will mean longer, stronger barrier rails that can be replaced with maximum efficiency, massively reducing facility downtime, manpower hours and maintenance costs, as well as providing streamlined options for upgrades. Multi-directional capabilities will allow barriers to better fit into a facility’s overall design and aesthetic and a practical, ergonomic design will mean installation is smooth, logical and simple. Combine these innovations with a handy multi-tool for added functionality and convenience, options for countersunk bases and spinning collars and A-SAFE’s visually pleasing, cylindrical, seamless exterior and you have a one-stop Health & Safety system that is simply unbeatable. When it comes to showing your love for your facility and your workforce, beware of steel barriers that cannot absorb impacts without ripping up your floors and needing to be replaced, take care to avoid cheap imitators that are untested and unable to properly address the forces your vehicles possess and watch out for short-term solutions that do not deliver the return your investment deserves. Put your heart and soul into your Health & Safety by investing in the best – and let your love life blossom. A-SAFE are the inventors and manufacturers of fixed polymer safety barriers; used around the world to offer unbeatable, moneysaving protection for buildings, personnel and equipment – for more information call 01422 331133, email sales@asafe.com or visit asafe.com.


Health & Safety Bringing flair to work at height JSP has introduced a range of fall protection equipment, including: harnesses; lanyards; restraint systems; lifelines; retractable fall limiters; rescue equipment; full specialist kits; and accessories. The harnesses and lanyards include the Spartan economy range, the Pioneer mid-range and the premium K2 collection, which conforms to the highest standards of technology, comfort, safety and ergonomic design. For day-long wear, JSP’s Pro-Fit harnesses, made from elasticated webbing, offer safety and comfort with their ultra-lightweight aluminium hardware. The Pro-Fit range also includes JSP’s DielectriK insulated harness, made entirely from electrically-insulating polymers and suitable for people working in environments carrying a risk of electrocution.

x x x x x x x x x x x

Tel: 01993 826050


Workwear catalogue

The new U-Power Wear catalogue is packed with details and pictures of the company’s safety clothing. The range includes trousers, dungarees, shorts, jackets, bodywarmers, T- shirts, polo shirts, hoodies, socks, gloves, neckwarmers and hats in a variety of distinctively-branded, co-ordinated lines suitable for both and leisure. New items include the Impact Gear jacket, with features such as tablet PC pockets, laser gauge pockets and double mesh back vents; Supremacy trousers with a multitude of pockets and anti-abrasion fabric on contact areas; the Enjoy fake fur-lined hoody; and the iPlus Biker gloves, with silicone finish on the fingertips for good grip. Detailed information on the company’s style, technology, service, materials, sizes and colours are all provided in the latest catalogue. U-Power’s new Wear collection of Italian-designed work-to-leisure clothing features in the Wear collection catalogue 2014-15 and is available http://www.u-power.it/workwear/pdf/ for download from CATALOGUE in glossy, full-colour, 140-page printed catalogue format.

Email: info.uk@u-power.it


PECM issue 13


Master exhibits solutions for industry Master Abrasives has an established reputation for supply to industry of abrasives, surface finishing and related products, in conjunction with a premium range of tools. Following the recent launch of the new website to focus on their tool servicing offer (www.master-toolservices.co.uk), Master has appointed Andy Wright to the position of Sales Manager for the Master Tool Services department. Andy will continue in the role as Business Development Manager on the abrasives side of the company but will now focus on the development of its tooling offer. He will also be managing the Master stand at the Health & Safety Event this year where Master will be promoting their complete Tool Servicing and solution package. The event takes place at the NEC, Birmingham on 24-6 March and you can find Master there on stand D39. The initial introduction of Master Tool Services was a strategic development of the company’s regular tool maintenance department. “Now, we have invested in facilities, equipment and personnel with a view to taking pneumatic tool maintenance to a new level within the industry, offering solutions for industry alongside our abrasives package” states Managing Director, Paul Batson. He continues: “Our goal is to offer a service second to none in the area of Preventative Maintenance. The principle being to provide a service for companies that assists them in controlling the cost of tool maintenance, it is particularly important where a large number of tools are spread over multiple sites, while actively reducing the risk of excessive and unnecessary vibration levels and associated HAV consequences. This is achieved through a structured and Preventative Maintenance Programme (PMP).”

sales@master-toolservices.co.uk www.master-toolservices.co.uk

Health & Safety

Worldâ&#x20AC;&#x2122;s First 4G ATEX Zone 1 Smartphone Now Shipping! The Smart-Ex 01 is an ultra-rugged smartphone and is the first Zone 1 device to run the latest Android 4.4 Kit Kat operating system. You can now scan an RFID tag, capture inspection data, communicate with colleagues and take a high quality picture of a defect using just one device.


he latest ecom smartphone puts work orders, permits, historical photographs and CMMS data in the palm of your hand. ecom understand the challenges faced in modern day hazardous areas and guarantee that we are able to show you multiple uses for the Smart-Ex 01 that will make your life easier, more efficient and safer. The Smart-Ex 01 is the ideal companion for mobile workers who need to be able to contact people while they are in Zone 1, Zone 2 or other hazardous areas due to its exceptional 4G LTE connectivity. The IP68 rated Smart-Ex 01 has a scratch resistant Gorilla Glass 2 display, which is extremely bright and fully readable in direct sunlight, as well as being usable while wearing gloves. The optional built-in camera (8MP rear and 1MP front) enables users to photograph problems they find while on site and clearly communicate those issues with a control centre. To find out more about the Smart-Ex 01 and the range of applications it can be used for, contact ecom on 01642 465 400 or visit www.ecom-ex.co.uk Issue 13 PECM


IIRSM Authors New Conference Programme at The Health & Safety Event 2015


he Health and Safety Event, a national exhibition and conference organised by Western Business Exhibitions, is giving visitors a sneak peak at its exciting new conference programme independently authored by The International Institute of Risk & Safety

A must in the calendar of any health and safety manager or business director is the seminar entitled ‘Developing a risk management programme’.

Management (IIRSM). The director of Long Latency Health Risks Division at HSE, Kären Clayton will officially open the conference programme that takes place from 24th to 26th March at the NEC in Birmingham. A must in the calendar of any health and safety manager or business director is the seminar entitled ‘Developing a risk management programme’. Delivered by Emma Cundiff, Director at Peritis Limited, a speciality management consultancy and training company, the seminar builds a bridge between Enterprise Risk Management (ERM) and Occupational Safety and Health, which on the surface are two worlds that are diametrically opposed. Emma

believes that the skills used in the two disciplines are similar and therefore the two worlds have synergies that it is advantageous to explore. Alongside Emma’s belief, there is also very real movement in the market whereby those with responsibility for safety and health are having other, aligned responsibilities ‘tagged on’ to their role. Amongst these are ‘the environment’ and increasingly ‘risk management’.

The Health & Safety Event is free to enter and it is highly recommend that visitors register in advance for entry tickets On a more practical footing, there has been a recent focus regarding diesel exhaust risks within the workplace and the potential harm they can cause to a worker’s health. It is believed there are approximately 500,000 people exposed to diesel engine exhaust particulate during the course of their

About the Health & Safety events: The Health & Safety Events series represents a great use of time for visitors from virtually any industry and at any level, not just health and safety professionals. The venues are chosen for ease of access while the educational content addresses the most topical and pressing safety issues. Along with event partners, Arco, DuPont and NQA and title sponsor 3M, the Health & Safety Events series is officially endorsed by the International Institute of Risk & Safety Management (IIRSM) and supported by the British Occupational Hygiene Society (BOHS) and Safety Groups UK. The 2015 series includes 3 events: The Health & Safety Event – NEC Birmingham 24-26th March (Educational Partner – IIRSM) Health & Safety Scotland – SECC Glasgow, 22-23rd April Health & Safety North – Bolton Arena, 7-8th October You can register online at www.healthandsafetyevents.co.uk or by calling the event hotline on: 0870 4866816.

work in Britain, whether a professional who works around diesel engines or drives a diesel car. However, although the exhaust emissions disperse into the surrounding air and sometimes are not easily detected, this doesn’t necessarily mean that there is no risk to the worker; low levels of diesel engine exhaust can still increase the risk for cancer and other serious diseases. Duncan Spencer the Safety Manager of John Lewis Partnership hopes to raise awareness of this hot topic by exploring what this could potentially mean for companies in his seminar entitled ‘Diesel Exhaust Risks’. Additionally, Dr. Gayle Brewer, Senior

Lecturer in Psychology at the University of Central Lancashire, will deliver a seminar entitled ‘An Introduction to Psychosocial Risks’. Dr. Brewer’s seminar will look at psychosocial risks (stress, bullying and harassment) that are slowly becoming recognised as key occupational health challenges. With her seminar Gayle aims to help organisations understand and put in place different types of interventions in order to tackle these issues. The full seminar programme for the three day event can be viewed online at www.healthandsafetyevents.co.uk. The Health & Safety Event is free to enter and it is highly recommend that

visitors register in advance for entry tickets, especially for seminar places as these are extremely popular. The event is taking place at the same time and in the same location as Maintec, Facilities Management 2015 and Cleaning 2015. This co-location of events ensures that any visitor will maximise the time they spend attending the NEC. To register online visit www.healthandsafetyevents.co.uk or call the event hotline on: 0870 4866816.

Issue 13 PECM



.. KluberConsult – Saving Energy and reducing CO2 with synthetic gear oil Insulation manufacturer finds high energy savings • >7% power consumption reduction • Potential savings of 100,000 kWh per year across the site • Reduced wear- reducing parts replacement and inventory • Reduced oil consumption and disposal For high energy users, reducing energy consumption has a major impact upon their business. For considerable time Klüber Lubrication has been extoling the virtues of synthetic gear oils and the energy savings that can be achieved using this advanced lubricant technology. Recently a major insulation materials manufacturer has seen this is action. As a high energy user, the priority of reduction in energy consumption couldn’t be more important. All aspects of their process were under review and as their lubrication partner, Klüber Lubrication proposed reviewing their gearbox lubricants. In consultation with the site maintenance team, an SEW SA67 bevel


PECM issue 13

helical gearbox on the product conveyor, from the Cooling Zone to Packaging was selected as representative for trial with Klübersynth GEM 4-220N synthetic hydrocarbon gear oil. An energy monitor was fitted to record the power consumption during typical production. The mineral oil lubricant was then drained and replaced with Klübersynth GEM 4-220N. The power consumption was then recorded during production. Overall, during mixed production conditions, a reduction of 7.2% power consumption was achieved. This resulted in a potential annual saving of 300 kWh on this gearbox, purely due to the better lubricating properties of the Klübersynth GEM 4-220N providing higher efficiency in addition to superior wear reduction properties. Across the site, on approximately 200 assorted gearboxes, the potential for

savings is 100,000 kWh per annum. Oil drain intervals are also extended 3-fold due to the extended life of the Klübersynth GEM 4 range and their improved resistance to oxidation. Add that to the associated reduction of maintenance costs and waste disposal; and additional significant savings are achieved. The gearboxes will benefit from extended life due to the better anti-wear properties of Klübersynth GEM 4-220N, thereby helping to reduce spares inventory. Matching all this to the reduced energy consumption measured in reduced CO2 emissions and this insulation manufacturer is making significant headway on their costs reduction programme. Tel: 01422 205115 sales@uk.klueber.com www.klueber.com




SpeedMarker SpeedMarker 1300 1300


Specially designed to mark large Specially designed to mark large bulky items and high volume bulky items and high volume small parts, the SpeedMarker small parts, the SpeedMarker 1300 can process parts up to 1300 can process parts up to 1250mm wide. 1250mm wide.

2015 2015

With the ability to communicate with With the ability to communicate with your own software or database, plus your own software or database, plus the option to automatically generate the option to automatically generate data matrix codes and barcodes, the data matrix codes and barcodes, the SpeedMarker can legibly mark as small SpeedMarker can legibly mark as small as 1-point font on metal and plastic as 1-point font on metal and plastic with ease. Integrate our SpeedMarker with ease. Integrate our SpeedMarker series of galvos into your own series of galvos into your own production system for the utmost in production system for the utmost in flexibility. flexibility.

Book Book your your customised customised demonstration demonstration at at our our South South East East Showroom Showroom now â&#x20AC;&#x201C; 0191 417 4505 now â&#x20AC;&#x201C; 0191 417 4505


into one machine. into one machine.

Process: Process: Wood, Wood, glass, glass, acrylic, acrylic, plastics, plastics, metal metal and and many many more. more. We We also also supply supply a a range range of of materials materials including: including: Trotec Trotec Laserable Laserable multi multi layered layered laminates, laminates, acrylic, acrylic, anodised anodised aluminium and stainless steel. aluminium and stainless steel. Quote PECM to qualify for your 'special offer' (including free Quote PECM to qualify for your 'special offer' (including free TroCare, accessories or consumables*) when confirming your TroCare, accessories or consumables*) when confirming your order with a deposit. order with a deposit. *Special offer dependent upon model purchased. *Special offer dependent upon model purchased.

www.troteclaser.co.uk www.troteclaser.co.uk

www.trotec-marking.co.uk www.trotec-marking.co.uk

Individual Valve actuation air supplies connected to local valve control manifold


he general trends in the automation of food processing have been heading towards more precise control and more information being gathered at device level. It is important for process engineers to appreciate which control structure would be most appropriate for their particular application. Process control infrastructure has seen many advances in terms of design, efficiency and reliability, where better control has also paved the way for continuous processes, reduced waste, improved hygiene and greater efficiency. In addition, the amount of information available from local devices improves the feedback for control loops and provides better information for increasingly sophisticated plant visualisation, management and reporting software. However, integrating this technology into an existing application can be a daunting prospect and one that may require expert help. Automated process valves, depending on their size and design can either be â&#x20AC;&#x2DC;pilotedâ&#x20AC;&#x2122; i.e. a pressurised air supply


PECM Issue 13

Intelligent Valves connected to sensors in a local control loop

is used to actuate the valve, or, an external actuator, such as a solenoid, is used. These items are usually connected to a PLC or other electronic controller, one which uses a software program or routine in order to keep the sequence and operation of the process valves in synchronisation with the desired pressure, flow and mixing required of the fluid being controlled.

Intelligent Valves

connected by a fieldbus control network


with individual pneumatic pilot air supplies

If a compressed air supply is available, then piloting the valves may be the right option and there are some innovative solutions on the market to connect large numbers of pneumatic control air lines to a control valve manifold block in a hygienic environment. This centralised system can provide an ideal solution for smaller applications or those with reduced automation requirements. However, as the scale of production increases so does the complexity and quantity of control wiring and compressed air lines all of

The company also provides smaller localised controllers such as the multiCELL device which require space, time and skill to be installed correctly. The alternative is the use of intelligent control valves that only require a common supply of compressed air and a fieldbus connection. When connecting larger numbers of process valves, which are often required in high densities for continuous process applications â&#x20AC;&#x201C; typically supplying fluids such as ingredients or for CIP processes in food processing applications - then a distributed control approach may be more suitable. Using fieldbus protocols such as ASi, Profibus and DeviceNet

allows individual valves to be connected using just one or two cables to link back to a local controller, or up a level to a factory wide bus network. The relative costs of a separate local enclosure, rack mounted plc, I/O, cabling, power supply, HMI etc. can also effectively be replaced with just one small control unit that can be mounted either on or very near to the process valve. This is made possible by using smaller proprietary controls and / or intelligent valves with their own onboard control loops and parameters. Deciding on which approach is the most suitable requires the decision makers to have all of the available information and this will usually require an in-depth knowledge of the process as well as competent advice on the advantages and disadvantages of each design. Consideration about the ease of commissioning and maintenance as well as the availability of competent fieldbus engineers is also essential. BĂźrkert Fluid Control Systems has been at the forefront of developing the technology required to make these significant steps in process control design possible. The ELEMENT range of intelligent control valves for example has been specifically designed for hygienic applications with many features that will benefit the food processing industry. The company also provides smaller localised controllers such as the multiCELL device which can be used to monitor and process feedback from several valves and sensors before communicating up to a PLC or wider factory automation platform. These are all supported by a number of experienced designers and engineers, all on hand to provide expert advice in designing and installing a new system. BĂźrkert has solutions for all options, with no bias towards one or the other, just a commitment to delivering the best value and long term reliability. www.burkert.co.uk Issue 13 PECM


Machining & Machinery

Manufacturers of High Quality Anti Vibration Products

E: sales@fibet.co.uk T: 01282 878200


PECM issue 13

www.fibet.co.uk F:01282 878201

Machining & Machinery

International success for UK manufacturer of plastic tanks The blend of skill, knowledge and technical capacity at Barkston Ltd has placed the UK manufacturer as a supplier of choice in Asia. The Leeds based company is using polypropylene and pvc to make more commercially sustainable tanks. The lightweight plastic materials used have wide acceptance for use in corrosive applications because they are more cost effective, eliminating the need for additional maintenance such as re-coating to guard against corrosion. Modifications and repairs can easily be made with no advanced preparation needed on the material with little down time and usually no need to remove the equipment from service.

Tel: 0113 249 2200


Brighton Sheet Metal Brighton Sheet Metal is a privately owned company, established in 1911 and incorporated in 1953. The company moved to purpose built premises in 1958 and in 1997 took over and refurbished derelict premises and linked them to expand and develop assembly and powder paint facilities. This effectively doubled the manufacturing space to the present 3,500 sq metres. Over the years, BSM has established itself as one of the leading UK specialists in sub-contract precision sheet metal products, supplying a wide range of products to Blue-chip and internationally renowned customers. The company aims to provide a total service from design concept to prototype development, through to volume production with finishing, assembly and bespoke packaging facilities. A variety of other facilities e.g. silk screening, plating, machining and extrusions are available through a network of approved sub-contractors.

www.brightonsheetmetal.co.uk Issue 13 PECM



There is more on offer than ever before at Maintec 2015, which is returning to the NEC, Birmingham on 24 – 26 March.

Maintec 2015 Gathers Pace T

here is more on offer than ever before at Maintec 2015, which is returning to the NEC, Birmingham on 24 – 26 March. The leading UK event for the maintenance, plant and asset management industry, celebrating its 40th edition has a packed hall full of industry leading exhibitors, content rich seminars and the latest innovations. Complementary CoLocations Building on last year, which saw Maintec’s floor plan and visitor base expand massively, Easyfairs have confirmed that it will again run alongside Facilities

Enclosures from the smallest to the largest. ENCLOSURES




Exhibitors at Maintec 2015 include all the major names and show regulars such as Hörmann UK, Pruftechnik, Thermaflue, KeyTracker and AV Technology on domestic and industrial electric systems. The Cable Detection EZiTEX t100 Signal Transmitter and the FLIR E8 Thermal Imaging Camera will also be exhibited.

Management - the UK’s only event for the facilities industry outside London. The Health & Safety Event will also return for its second year. Finally rounding off the clever colocations will be Easyfairs’ new show, Cleaning 2015, which is focused on buyers and suppliers from within the cleaning industry. Industry Leading Exhibitors Exhibitors at Maintec 2015 include all the major names and show regulars such as Hörmann UK, Pruftechnik, Thermaflue, KeyTracker and AV Technology, many of whom will be using the show to launch new products to the market or unveil their very latest upgrades.


Visitors will have plenty of learning opportunities at Maintec 2015 too, including a return of The Business Exchange

For all those looking for the latest in CMMS systems, the Ashcom Technology stand is a must see. The company will be showcasing its MaintiMizer BlackBox, which is an all-in-one CMMS/ EAM solution created for businesses with small or non-


existent IT departments. It contains everything needed to be successful wrapped up in a self-contained network appliance. Also on display

There will also be a return for The Business Strategy Forum, which will include sessions from expert speakers and major industry names. will be its flagship product, the MaintiMizer Web Edition and its Software as a Service, MaintiMizer.com. Acutest will be displaying its HT MacroTest G3 Multifunction Meter, an innovative instrument capable of carrying out safety tests

The quick connect specialist, CEJN, will be exhibiting its MultiFLOW Air & Fluid Gun, which effectively cleans surfaces with air or water, using an unparalleled blowing force. Also on display will be CEJN’s coupling series eSafe and its full range of hose and cable reels. Show Floor Entertainment Visitors will have plenty of learning opportunities at Maintec 2015 too, including a return of The Business Exchange, a selection of free content-rich practical talks full of the latest research, new innovations and case studies exploring the hottest topics, challenges and trends. There will also be a return for The Business Strategy Forum, which will include sessions from expert speakers and major industry names. Plus there will be additional showfloor entertainment in the form of show favourite, The Lions’ Lair. For further information about Maintec 2015 and to register for free entry, please visit www.maintecuk.com

SOFTWARE & SERVICES www.rittal.co.uk

Maintec Preview Our DATA LOG can tell you! MEASURE

In need of Penstock Valves? Pollution Containment? Drain Closure Devices? ASOV’s, or ROSOV’s?




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£ The FlapstopperTM (pictured) pollution containment device will isolate a drain within 5 seconds. It can be powered by a small solar panel, or by mains. The valve can be integrated to any number of probes for automation (i.e. pH), or connected to some of our wireless remote operation devices. Operating on a wide variety of sites, we aim to retro-fit systems with as little impact on your site as possible, meaning no major civils work or site closures. Environmental Innovations Ltd is a UK specialist designer and manufacturer of pollution and spill containment systems. Many of our customers seek to comply with the most up to date legislation and literature surrounding major spills, firewater risks and COMAH regulations. We have worked with them to create cost effect retro-fit solutions to enable their business to mitigate the risks associated with an incident.


PECM issue 13

+44 (0) 1279 600 440 sales@environmental-innovations.biz The Innovation Farm, Sawbridgeworth Road, Little Hallingbury, Bishops Stortford, Hertfordshire CM22 7QU


“Have you looked at your sites Major Spill and Firewater risks?”


6513546 5765165765123579854325957


6559432324687 9845213546879 6542103546875 6120324687651 2032546842103 484132



01925 817803

How much money is that old compressor wasting?

Maintec Preview






The best of both worlds with the Advanced Panel Meter (APM)


odern Digital panel meters are replacing analogue meters in many applications as they allow the user to take an accurate reading at a glance, even from a distance. However, analogue meters are extremely good at showing what the reading is in relation to any set limits – high and low for example. Trumeter have taken the best of both worlds with the Advanced Panel Meter (APM) range of products, combining the speed, accuracy and flexibility of a digital meter with the instant visual representation of an analogue meter. A new Process Meter model has been launched into the range, which features an accuracy of 0.1%, with user selectable voltage and current inputs for use with many industrial sensors. User configurable nonlinearisation of up to 20 points means the Process Meter can be used with non-linear sensors too. The meter also features two independent outputs

which can be configured as either digital or analogue, for easy integration with PLCs and other systems. The APM has been specifically designed for engineers requiring a more effective and easy way of monitoring and displaying data. The 40 segment curved bar graph display has a programmable scale and the large 4 digit readout provides precision. The high contrast LCD screen offers flexibility and ease of viewing thanks to its adjustable screen brightness, large display and wide viewing angles. The APM is capable of displaying information in both digital and bar graph format, giving the user an immediate visual indication of the measured parameter, while the separate starburst display area allows annunciators, custom messages and alarm information to be viewed. Other features include an in-built visual alarm display that can be programmed to flash and change the

backlight colour at set limits, giving a visual alarm when a set point is reached. Two independent alarm set points can be created based on specific requirements, and once the meter detects values within these critical ranges it can change or flash the backlight and switch the outputs. The APM was successfully launched in Autumn last year in volt, amp, and frequency meter variants, and has proved to be a winner thanks to its “easy to use, easy to read” functions. Trumeter plans to expand the product range and introduce more variants this year, built on the same innovative technology. Please contact your regional Trumeter sales office for further information: Europe: +44 161 705 4317 The Americas: +1 954 725 6699 Asia Pacific: +604 5015700 Issue 13 PECM


Keeping the pressure up on mine safety


The Trimax S range of pumps from RMI have been used across the world in many of the largest mining operations


here are few industries as potentially dangerous as underground mining where safety systems must be built and maintained to the highest standards. Market pressures demand that the productivity and efficiency of mines continue to increase, which puts increasing pressures on technology to improve safety equipment. Modern longwall mining techniques require a roof support system that maintains a safe working area while moving with the shearer and allowing a controlled collapse of the roof. A coal mine presents a number of challenges for the designers of mining equipment, and a long list of standards that must be met. The potential for

explosive gases means that all mines have an extensive network of gas monitors to warn of any potential risk to life. As a further precaution, any equipment designed to operate in the mine must be certified to work in potentially explosive atmospheres. In addition, the reliability of any safety related equipment must be proven beyond doubt. Within the mining industry, safety is the highest priority, meaning the selection of equipment for use within a mining environment has to a rigorous process, with sustained testing being completed before operational approval is given. Most countries operate a scheme whereby all safety critical equipment undergoes

design scrutiny as well as on-site testing before it can be specified for operation within the industry. One such example is the UK Coal Acceptance scheme. The testing period can last for a whole year, during which the equipment undergoes continuous monitoring to ensure that the performance levels remain within necessary tolerances. The certification process is extremely vigorous and only the best equipment is awarded a UK Coal Acceptance Certificate at the end. The roof support system consists of a series of individual shield units which use hydraulic rams to hold the overhead shield plates in place. All of the units are connected together and



RMI Pressure Systems is a global leader in high pressure pumping systems and has spent over 100 years delivering innovative and practical solutions to customers around the world


Modern longwall mining techniques require a roof support system that maintains a safe working area while moving with the shearer and allowing a controlled collapse of the roof

powered by a high pressure hydraulic pump which provides the power to hold thousands of tonnes of rock in place while the coal face is mined. RMI Pressure Systems is a global leader in high pressure pumping systems and has spent over 100 years delivering innovative and practical solutions to customers around the world. With particular expertise within the mining industry, both above and below ground, many of RMI’s most popular products include certifications and approvals from some of the world’s leading mining organisations. The Trimax S range of pumps from RMI have been used across the world in many of the largest mining operations

and are recognised as one of the most reliable and efficient pumping systems available. Constructed from the highest quality materials, and manufactured to exacting tolerances, the S range is capable of producing 517 l/min at pressures up to 600 Bar. RMI also has a policy of continuous development of energy efficient products, which has led to the introduction of the ODIN (On Demand Intelligence) control system. This system uses a range of data supplied from equipment used in the process of continuous longwall mining and uses it to calculate the changes in demand for hydraulic fluid before they occur. In this way ODIN can modulate the pump speed and change the flow

and pressure characteristics to meet demand in the most responsive way possible. Mike Sherman, RMI Marketing Manager, comments “As one of the world’s leading manufacturers of high pressure, high flow pumping systems, RMI has been helping to maintain mine safety for many years. With the majority of applications in remote areas, with limited access and where unplanned downtime is very expensive, reliability is an essential quality required of our equipment. We have an enviable reputation for designing efficient and reliable equipment, which has been used across the world in the longwall mining industry for many years.”

Measurement & Monitoring Precision inertial MEMS sensors offer ultra-high resolution First Sensor presents a new technology platform to fabricate high precision MEMS inertial sensors for the detection of inclination, acceleration and vibration. The capacitive sensors are based on single crystal silicon and utilize the latest micromachining technology. The devices achieve large signal-to-noise ratios and excellent stability over temperature which allows them to detect smallest changes in acceleration or inclination. Due to high aspect ratio microstructures (HARMS) the sensors feature ultra-low cross axis sensitivities. Further, the patented highly flexible AIM (Air gap Insulated Microstructures) technology minimizes parasitic capacitances.

Tel: +44 1788 560426 • Fax: +44 1788 561228 Email: FSM@first-sensor.com • www.first-sensor.com

OMEGA Introduces Handheld Wireless Bluetooth® Transmitter The OMEGA UWBT Series of Bluetooth® transmitters combine the accuracy of an industrial sensor/transmitter with the convenience of smartphones and tablets. It measures different sensor inputs such as thermocouple, RTD, relative humidity, and pH and transmits the data to your smart phone or tablet via wireless Bluetooth communication from the free UWBT app running on an iOS or Android™ smart phone/tablet. The free app has many features including the ability to be configured in 9 different languages, can be paired with multiple transmitters simultaneously, monitors and logs sensor data on your smart phone or tablet, and displays sensor data in digital, graph, or gauge format. This CE compliant product has the capability to download logged data to your smart phone or tablet and email the data to an email address or to the Cloud, the UWBT logs up to 10 samples per second and logs data to the handheld transmitter with date/time stamping or directly to your smartphone/ tablet and works with mobile devices and computers with USB communications.

Capacitive level switch sensor PFKS for the supervision of liquid levels in the pharmaceutical beverage and food industry The new level switch PFKS with capacitive measuring principle has been designed by Müller Industrie-Elektronik GmbH as a Low Cost version for the supervision of liquid levels in containers and tubing for the pharmaceutical, beverage and food industry. With the hygienic process connection, the embodiment in stainless steel and the M12 device connection, diverse areas of application are given in the food processing, in breweries, for pharmaceutical production as well as in the biotechnology and medicine technology, in particular for the EHEDG correspondent use in aqueous liquids and paste-like media as for example milk, beer, soft drinks, syrup, concentrates or CiP liquids. The capacitive measuring principle of the PFKS is insensible compared with foam generation and adhesion. Even with high-viscous and adherent media the new level switch sensor PFKS works extremely reliable. www.mueller-ie.com/en/level-measuring-technology.html

OMEGA Introduces high accuracy industrial wet/wet differential pressure transducer The OMEGA PX509HL Series industrial differential pressure transducers are rugged shock and vibration rated with high accuracy and are specifically designed to provide long life in demanding industrial areas (ruggedized Containment Pressures up to 10,000 psi). The compensated overload range minimizes errors induced by large line pressures. Features include welded stainless steel construction, user accessible potentiometers for zero and span, and demountable electrical terminations or a fixed conduit fitting without trim pots. They are temperature compensated over a broad range providing excellent thermal properties and high long term stability. A precision micromachined silicon sensor is at the core and provides a very stable reading with exceptional high accuracy of 0.08% and a broad compensated range of -20 to 85°C on most ranges.

Tel: 0800 488 488 Email: sales@omega.co.uk www.omega.co.uk/pptst/UWBT.html

Tel: 0800 488 488 Email: sales@omega.co.uk www.omega.co.uk/pptst/PX509HL.html

The EE300Ex Humidity & Temperature Transmitter Conforms to International Standards for Intrinsically Safe Applications

Handheld infrared thermometer Raynger® 3i Plus for high-temperature applications

The intrinsically safe EE300Ex humidity & temperature transmitter from E+E Elektronik conforms to the European ATEX Directive and now also to the international IECEx and the FM classification specifically relevant to the USA and Canada. This makes the device suitable for worldwide usage in explosion hazard areas. The EE300Ex was developed for use in explosion hazard environments and can be mounted directly in both gas and dust hazard areas of zone 0 / Div1. Precise humidity and temperature measurements from 0…100 %rel. hum. and -40…180 °C (- 40...356 °F) are also possible in applications under pressure up to 300 bar (4351 psi). Just as with humidity measurement in air, the EE300Ex can also be used for moisture measurement in oils.

Raytek presents a new handheld thermometer series for flexible temperature monitoring in high-temperature industrial applications from 400 to 3,000 °C, for instance in steel production and processing, the chemical and petrochemical industry, as well as heat treatment and power plants. Raynger® 3i Plus 1M and 2M models measure infrared radiation in the shortwave spectrum (1 µm and 1.6 µm) and provide high precision (+/- 0.5%, 1 °C). Thanks to the superior resolution of 250:1, critical plant parts and products can be reliably monitored from longer distances. For exact aiming, the measurement spot is highlighted with two laser beams. Moreover, even red hot objects can now be easily targeted by means of a new “Red Dot” scope sighting function (patent pending). Additionally, the use of a “Red Nose” heat-resistant warning detector and alarm reduces the risk of the sensor overheating, minimizing repair costs while averting costly accidents and ensuring operator safety.

Tel: info@epluse.at

Email: jschwelm@raytek.de


ProLine P 44000 from Knick: Pt100 transmitter for high voltage applications


Complete HACCP validation: Food Tracker for cook and chill processes

The output signal is galvanically isolated from the input signal and the voltage supply. The isolation is designed for working voltages of up to 6 kV AC/DC. The test voltage during routine testing is 15 kV AC.

Food Tracker systems from Datapaq ensure highly efficient process monitoring and HACCP documentation at the click of a key. In addition to complete temperature profiles and extensive alarm and reporting functions, they offer multiple simultaneous food lethality calculations (F0/ Pu value, D-value, chill rate Critical Control Point) and an optimization function that predicts the effect of parameter changes on the process without repeated trial runs. A state-of-the-art 6 or 8-channel data logger from the MultiPaq21 series guarantees high accuracy, high resolution, and large memory without data loss. Designed for efficient operation, it manages eight consecutive measurement runs before data download to a computer. A start/stop button and an alternative time or temperature trigger provide true ease of use.

Email: knick@knick.de

Email: stephan.wilke@fluke.com

When temperatures are to be measured using Pt100 resistance thermometers in high-voltage environments, standard temperature transmitters are often unsuitable due to their insufficient insulation. Resistance thermometers can be insulated against high voltage. In practice, however, the available installation space is often too small. Moreover, the insulation is weakened by thermal and mechanical aging. Instead, high-voltage resistant galvanic isolation ensures maximum safety. ProLine P 44000 from Knick is a high-end Pt100 transmitter for monitoring the winding temperature of electric motors, generators, transformers, or the like.


PECM issue 13



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ˆ ˆ ˆ ˆ ˆ ˆ ˆ

Take a Closer Look

Measurement & Monitoring Portability key to success of oil in water analyser Quantitech first launched the InfraCal 2, a portable oil in water analyser, in 2013 and the company’s Dr Andrew Hobson says: “There has been a heavy demand for this instrument in the oil sector because of the new functionality that now comes as standard. The InfraCal 2 can now be operated from an internal battery and also provides lower detection limits. However, the original InfraCal was not able to store multiple calibrations or to log readings, so the latest instrument can be more independent, making it better suited to remote operation. We are therefore hoping that it will also become popular in a wider range of other manufacturing and processing industries, including wastewater and fracking.”

Sensors that Learn Take the Guess Work out of Maintenance In the chemical and petrochemical industries, plant safety and process reliability often rely on analytical instruments operating correctly. Maintaining process analytical instruments and keeping them in good condition can be cumbersome and costly. Download METTLER TOLEDO’s latest white paper and discover how a new process analytical measurement system based on sensors that learn can help plants reduce costs and enable better process control decisions. See for yourself how sensors are performing and when they need to be calibrated, serviced or replaced. Sensors that Learn™ is just one element of METTLER TOLEDO’s Intelligent Sensor Management (ISM®) digital technology platform.

Tel: 01908 227722


Download the whitepaper at www.mt.com/uk-sensors-wp

New RUGGED 4-20mA Panel Indicator

■ Stainless Steel & Toughened Glass ■ High Impact IP66 Front ■ Suitable for Ex e, Ex n or Ex p Equipment ■ Ex ia Model for Zone 1, 2, 21 or 22 ■ Ex nA Model for Zone 2 or 22 (Isolator or Barrier Not Required) ■ General Purpose Model also Available


Hitchin, Herts. SG5 2DA, UK sales@beka.co.uk Tel +44 (0)1462 438301


PECM issue 13

Leaders in temperature measurement

LABCAL PRO Precision Digital Thermometer

L300 8 Zone Temperature Alarm / On-Off Controller

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L60 Thermocouple / Fine Wire Welder

Pt100/Pt1000 elements Temperature transmitters Digital Thermometers Thermocouple welders Hand held instrumentation Thermal calibration

View our videos Temperature Sensor Manufacture Thermocouple Connector Manufacture Thermocouple connectors and cables

Thermocouple Cables E-Commerce Facility

IP67 Sensor assemblies with terminal heads

Industrial and Scientific sensors

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Sensors for specialist applications

Thermocouples for plastics machinery

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Buy on-line www.labfacility.com info@labfacility.com  www.labfacility.com Bognor Regis tel: +44 (0)1243 871280 . Sheffield tel: +44 (0)1909 569446

Measurement & Monitoring

Highly effective vibration and thermal imaging Founded in 2005 by Stuart Collins, Vibration Monitoring Services Ltd (VMS) is a leading specialist in the fields of vibration analysis, thermography and demolition/piling vibration monitoring. Based in Kent, with more than 25 years specialist experience VMS can understand your requirements having forged numerous partnerships with clients in the building maintenance, pharmaceutical and heavy industry sectors, amongst others. Using our services and expertise, companies are able to identify potential faults and remedy them, planning repairs within scheduled shutdowns, thereby extending the life of the system and reducing the chances of loss of production and downtime.

Longer reach New longer point level probes from ifm electronic

ot so long ago ifm electronic launched the groundbreaking LMT point level sensor which has been a big hit ever since, so now that there are new versions even more users can benefit from the LMT’s ability to ignore tricky deposits and even foam.


While the first three versions of the LMT were short probes designed for minimal intrusion, the new LMT units will reach further into a vesse1 to detect levels of all media, from liquid and viscous fluids to bulk materials. Greater reach means probes that are 153 mm or 253 mm long, increasing installation options through insulated sidewalls, or at an angle.


PECM issue 13

New versions with ¾” or 1” threads, 28mm and 38mm long respectively, have also been added to the range. With the latest IO-Link technology built-in, the LMT can also be simply adjusted to virtually any medium. Each of the two switching outputs can be set independently of each other so it is also possible to differentiate between two different media. The parameters can be set with IO-Link and USB interface accessory E30396. With no moving parts and a smooth surface (the surface characteristics of the PEEK tip of the sensor is Ra < 0.8 µ) it is virtually impossible for residues to stick to it or clog the sensor. Even with viscous and sticky media such as ketchup the LMT point level sensor operates reliably. Using high quality materials such as 316L stainless steel and PEEK the sensor meets all requirements of hygienic areas. Flush sealing is ensured by pressing the PEEK tip onto the sealing edge of the adapter. This avoids dead bands and contamination. Approvals such as EHEDG and 3A certify food conformity. The LMT operates on a DC supply of 18 to 36V and with its IP rating up to 69K and ambient temperature range

covering 25 degrees below freezing up to 80 degrees it is ideally suited to food environments. The connection uses an industry-standard M12 connector to take the PNP signals back to the panel. ifm is committed to working closely with its customers to develop products which precisely match their needs, and the company provides expert, readily accessible technical support to help users maximise the benefits they gain from ifm products. For further information, contact Gemma Anderson, ifm electronic Ltd. Telephone: 020 8213-0000 Email: gemma.anderson@ifm.com

Measurement & Monitoring

Vibration Monitoring Services Limited :MFVEXMSRERH8LIVQEP-QEKMRK7YVZI]W



8IP01795 877177SV07840 791587 )QEMPvmservicesltd@btinternet.com www.vibrationmonitoringservices.co.uk

The worldwide number 1 supplier of power transmission products

Know your moisture content in gases and compressed air

Torque Measurement to 1600Nm

Excessive moisture in gases and compressed air can create all kinds of problems in hundreds of applications right across the spectrum.


Whether you are using bottled gases or producing your own, the need to be able to see how pure the point of use gas is, replies on accurate, reliable and repeatable “dewpoint” instrumentation. This can be done by hand-held or portable dewpoint meters for spot checking, or by continuous online monitoring.



6Robust ‘Industrial’ Design 6Economic Torque Measurement 6Simple Installation and Set-Up 6Bearing Free Compact Design 6Direct PC Connection 6Vibration and Temperature Resistant

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01535 663900 ® sales@mayr.co.uk www.mayr.co.uk Torque Limiters

Safety Brakes

Shaft Couplings

For those producing their own gases or air typically fit instrumentation immediately after the dryer(s) and at the point of use, important when large distances are involved, thus ensuring a consistent pure gas flow. Here at Alpha Moisture Systems, we manufacture and calibrate a large range of standard, advanced and bespoke “dewpoint” instruments to measure moisture content in gases and compressed air for the simplest to complex applications. To learn more on how we can help and advise you, call our friendly Technical Sales Team on +44 (0) 1274 733 100, or visit our website www.dew-point.com

Issue 13 PECM


Measurement & Monitoring

Do you want real-time reaction or processing monitoring information?

No more waiting for your off-line chemical analysis giving you a more efficient and cheaper work-flow. The new Microsaic 4000 MiDÂŽ and MiDasâ&#x201E;˘ offers mass detection which can be easily integrated into your process line to give you compound identification in realtime. Our products also connect to other everyday laboratory applications, including liquid chromatography and direct analysis. For a greater understanding of the capabilities and details please contact us at info@microsaic.com, tel: 01483 751 576, visit our website www.microsaic.com.


PECM issue 13

New ThermoBarScan offers instant feedback on temperature measurements


thermometer manufacturers, TME, are excited to launch a new Barcode scanning logging thermometer, the MM7100 ThermoBarScan, representing the next generation in handheld temperature measurement. Unique capabilities Using high accuracy temperature measurement combined with its own integral Barcode reader, this truly innovative thermometer can record not only the temperature, time and date of each measurement but also scans user-set barcodes to identify every product or test point. Up to 1000

separate measurements can be stored on the instrument at any one time before downloading to PC, easily achieved using free open-source software, adding up to a surprisingly cost-effective solution. Versatility The MM7100 is compatible with all standard thermocouple temperature sensors and probes, and customers can choose from Bluetooth or USB interface. Flexibility The user is offered the choice of programming alarm limits for individual targets/locations, global alarms for all temperature test points, or even specially designed legionellasafe alarm limits. The user can also choose their own remedial action recommendations, which display when an alarm limit is exceeded. In-line with customer requests, the MM7100 also features the ability to log a temperature without scanning a barcode.

Up to 1000 separate measurements can be stored on the instrument at any one time before downloading to PC, easily achieved using free opensource software, adding up to a surprisingly cost-effective solution.

High level information Added-value features provide detailed information to support HACCP and ensure due diligence.

• A large screen displaying instant feedback on each temperature measurement • Scrolling buttons on the instrument allow users to examine previous measurements • On-screen information about the product or test point location

In-line with customer requests, the MM7100 also features the ability to log a temperature without scanning a barcode. Affordable The new MM7100 is surprisingly affordable, at just £425, it is competitively priced, and, what’s more, is even compatible with TME’s unbeatable Thermometer for Life guarantee: to repair/replace any thermometer you damage for no more than £55. TME – When temperature matters. For more details on TME’s extensive range of thermometers and temperature sensors visit www.tmelectronics.co.uk for online purchasing or contact the Sales Team on 01903 700651 sales@tmelectronics.co.uk Issue 13 PECM


Focused on the Essentials! A new high frequency bulk solids radar level sensor from VEGA reaches yet further into the most challenging process application areas.


adar level sensors are a proven a success story for bulk solids level, in some industries they have superseded measuring devices like electromechanical and ultrasonic in many sectors. Their immunity to pressure, temperature, in-flight dust, good focussing and no loss of echo even during pneumatic filling, have seen the areas of application extended. Although users are increasingly adopting this microwave technology, it is still recognised that a level sensor which truly covers all applications has not yet been realised. Now, with a higher frequency and performance capability, the new VEGAPULS 69 radar designed for bulk solids comes a big step closer to this ideal. This new level device operates with a frequency of 79 GHz, enabling a much tighter focusing of the transmission signal, this means it easily avoids interference from internal structures inside vessels. With latest generation microwave components, even the tiniest reflection signals can be measured. This means previously difficult to measure products with very poor reflective properties, such as high purity plastic powders or wood chips, can now be measured with confidence. VEGAPULS 69 also offers versatility over a much wider application range. With measuring capability from one or two metres...right up to 120 m, and an accuracy of ±5 mm, it still has enough performance reserves for unusual assignments, such as deep mine shafts or for fast response distance measurement on conveyor car systems. Focused on measurement reliability The ‘beam angle’ of the radiated radar energy and therefore the focusing, depends on two factors: the transmission frequency and the active antenna area. This means at a higher frequency, much better focusing is achieved with a smaller antenna size. The VEGAPULS 69 operates


PECM Issue 13

with a transmission frequency of approximately 79 GHz and a 75 mm antenna, which achieves a beam angle of only 4° (compared to 26 GHz at 75mm – which has a beam angle of 10°) Why is this so important? The narrower 79 GHz beam misses internal installations and vessel wall build up, which makes the measurement more accurate and reliable. This ability makes commissioning much easier and faster, with fewer ‘tweaks’ like ‘false signal suppression’, ‘masking’ or ‘mapping’ (depending on manufacturer terminology). This focusing also means less signal is scattered and more signal returned, so any applications which previously returned very small reflections, like plastic pellets with very low dielectric figures, greatly benefit from this focussing. Plastic powders or pellets are usually stored in high, very narrow silos. Circumferential welds, even if they are only a few millimetres wide, can cause repeat interference reflections in silos over tens of metres. In the worst case, there can be one of these welds every half metre, which can interfere with the useful signal. It is always difficult, especially with plastic powders with very low reflective properties, to filter out the right signal. In some cases large parabolic antennas had to be used to achieve the focusing needed to reduce the interference signals. But these large antennas are no always practical. Another application which benefits particularly from this narrow beam angle is measurement in segmented hoppers or mixing silos in the cement and building materials industry. These multi-compartment silos often have corrugated reinforced plates as the partitions. In comparison with the signal reflected from the product level, these plates can cause very heavy interference, which can be ignored with complex evaluation algorithms, but not always successfully. Another option is using guided wave radars or capacitive based systems, but the problems of

roof loading, cable wear from the stones, changing materials and cable fixing at the bottom, is far from ideal. Food based bulk solid products vary greatly and range from abrasive grains, very fine adhesive powders to dusty by-products, these are measurements you need to rely on. A non contact measurement is preferred (i.e. with no cables for cross contamination, wear, roof loading or breakage), and a radar level is the perfect answer for intelligent foodstuff management. In large facilities the products are usually stored in high, slim silo blocks to concentrate a high volume and store the widest variety possible into a compact area. Increasingly these higher silos are being used, which brings many measuring principles up to their physical limits. In smaller sites, the whole plant can be dependent on a supply from only one or two silos. A reliable level measurement in all these different applications is essential for production and logistics planning, as well as optimising replenishment by the appropriate route planning. One device, VEGAPULS 69, works reliably on all these applications from a few meters up to 120m. The right measurement data avoids unnecessary costs and deliveries. Dynamic performance The user also benefits from the dynamic echo tracking with the VEGAPULS 69. This dynamic range i.e. the difference between the largest and the smallest signal, in radar sensors makes a statement about the real capability of a sensor and the applications it can be used in. The greater these dynamics, the wider the range of application of the sensors. Because of the very large 120 dB dynamic range of the new VEGAPULS 69, even the smallest reflections can be measured. This achieves excellent certainty and reliability for media with good reflection properties such as coal, ore and rocks, but even media with poorer reflection

properties such as plastic powders, fly ash or dry sawdust can be measured confidently by the new technology. With the possibility of measuring ever smaller reflection signals, even polystyrene pellets or extremely light fumed silica applications are possible. This universal application capability offers great advantages especially in applications in which very different media are stored. For example, in the grain processing industry, the silos often fill with different products from wheat, corn or bran, as required. Because of the high dynamics of VEGAPULS 69 the sensor now covers a very wide area of application. Versatility in performance The measuring range is also a sign of the performance capability. Thanks to the good focusing and the high dynamic range, the VEGAPULS 69 can reliably measure poorly reflecting bulk solids, even at a distance of 120m. Longer ranges are common in quarrying and mining, where the higher focusing also plays a role because the rock walls have a rough surface and there are fewer interference signals. The system is designed so that the sensor also operates with the same performance over the smaller measuring ranges. This comes as a benefit to users of conveyor belts, for example, in which distance measurements need to be made under very harsh conditions. A fast measurement is also necessary because the level on the belts changes very quickly. The cycle time of the new VEGAPULS 69 is less than one second with an accuracy of ±5 mm. So even applications in crushers, where very fast moving stone levels need to be monitored, sometimes from far above to avoid damage, are ideal for VEGAPULS 69. Equipment features The new VEGAPULS 69 is available in two versions, a simple version with a light plastic antenna of PP and an integrated lens antenna. (The encapsulated antennas are insensitive to deposits and ensure trouble-free operation even under harsh conditions) The flanged version has an integrated swivel holder made of high quality stainless steel, which can be used to align the sensor in a range of ±10°. On this version an purge air connection, which ensures efficient cleaning across the antenna face in extreme applications, is provided as standard. This is ideal, for example, in the measurement of very dusty wood based products or some foodstuffs. Inspired by the spirit level Apps on smartphones, VEGA engineers came up with something special. They have developed an App to set the inclination for the measuring instrument. If it is possible to get the camera to look through the mounting nozzle down into the silo (using the light/flash if needed) pointed at the outlet, it will automatically calculate the angle you need from the picture, or you can calculate the angles from input of dimensions. Then, after installing the sensor, align it precisely by placing the smartphone on the top and the app will tell you when it is in the perfect position! Proven already! All though new to the market, the radar level measuring instruments have been installed in various test applications over the last year. These so-called ‘zero series’ have been in use worldwide in many different ‘real life’ applications with many successful outcomes. Most importantly in this period, parameters and echo curves were monitored, to optimise the sensor algorithms and perfect their performance. This means VEGAPULS 69 is launched with an already proven track record in the field. More detail about some of these tests will be published soon. Download the VEGA App from your smartphone App store. If you would like to make a test of your own or further details contact VEGA Controls: info.uk@vega.com

Bulk solid level it’s time to focus VEGAPULS 69: The best just got better VEGA have utilised the latest high frequency radar technology to create a non-contact level sensor focused and sensitive enough to measure the most difficult of bulk solids products in the most challenging environments. ƒ All applications: from short ranges up to 120m ƒ Excellent focussing: simplifies set up ƒ Encapsulated antenna: reduces build up For an application demo: info.uk@vega.com www.vega.com/vegapuls69

Issue 13 PECM


Testers’ testers

The MFT1730 multifunction tester is the full-time testers’ tester of choice. Why? „

Dual display- measuring earth loop and PFC simultaneously to speed up testing


Dual non-trip loop testing – 3-wire and 2-wire, for where there’s no neutral, with no lead null required


Dual convenience of on-board results storage and rechargeable batteries


Adapted to any task, domestic or industrial even has a built-in earth stake tester

See why MFT1730 is the testers’ tester today by scanning the QR code with your smart phone Call 01304 502 101 or go to www.megger.com for full details.

Measurement & Monitoring

T-T add more products to their portfolio of WRAS approved products When dealing with clean water applications it is undeniably becoming more important to gain WRAS approval. A Cheshire based company, T-T Pumps Ltd., has long been combining their knowledge and expertise of this sector to manufacture products that reach these high standards to gain the WRAS approval, which users can rely on. Recently T-T’s CDL/ CDLF range of electrically driven stainless steel vertical multi-stage pumps have gained WRAS approval. These pumps are designed to transfer clean and nonabrasive liquids over a wide range of discharge flow rates and pressures. The CDL/ CDLF range is a multifunctional product that can be used in a diverse range of applications from domestic water pressurisation to commercial and industrial systems; the user can be rest assured that for potable water supply a WRAS approval has been issued.

Tel: 01630 647200


Aquaflow, the specialist valve division of Cheshire based T-T Pumps Ltd., are pleased to announce the introduction of a range of stainless steel pressure reducing valves (PRV). The valve will automatically reduce and stabilise downstream pressures regardless of upstream pressure and flow rate fluctuations, due to its responsive directly-acting spring. The downstream and upstream pressure balance, obtained by the intermediate chamber and guided piston, guarantees a high accuracy and long lasting performance. By means of the innovative self-cleaning piston technology, the pressure regulator stands out for its higher reliability when compared to pilot operated control valves that are vulnerable to fine particles. The hydrodynamic profile of the valve body, with its large downstream chamber, ensures high resistance against cavitation effects and vibrations in the event of high pressure ratio conditions.

Tel: 01630 647111


Sensors for rail applications Re-Sol was formed in 2003 to provide reliable fuel flow measurement solutions and services that redefine value in the automotive test sector with an eye towards future technologies. The company focuses on delivering reliable test hardware, software, calibration services and documentation to address an automotive industry need for valuedriven solutions. New fuel flow technologies are under constant development and cannot be effectively tested on equipment meant for lesser technologies. Re-Sol meets this need through custom solutions with proven technology that maximizes usability, flexibility, and ease of maintenance. Re-Sol operates from a modern facility in Auburn Hills, Michigan, USA.

Tel: +1 248 270 7777 www.re-sol.com

Email: Info@re-sol.com

At this year’s InnoTrans exhibition, FSG reports it focused on measuring technology and sensors for rail vehicles. FSG says its units have already proven themselves in many applications, e.g. in Berlin’s underground and rapid transit trains. Amongst other things, the company exhibited rotary encoders featuring a potentiometric, inductive, magnetic, or optoelectronic measuring system. They are said to be especially suited for use as driving/brake control switches to regulate speed, for positioning and measuring in overhead contact lines, and for load measuring or suspension control in undercarriages. The rotation angle output can be analog or digital. Available as single or dual axis systems, tilt angle sensors from FSG are for instance used for level control in undercarriages or in track construction.

Tel: +49 30 / 629 1214

www.fernsteuergeraete.de Issue 13 PECM


Preventive Maintenance The key to protect your plant against electrical machine breakdowns


he inspection and diagnosis of electrical rotating machine performance are key tools in ensuring the continuous operation and performance of production equipment. Electrical machines play a significant role in all industrial applications. Ensuring their output, their optimal availability and their durability, as well as their energy efficiency are basic requirements of industry. An in-depth knowledge of electrical machines, their applications, their operating environments, besides monitoring of the facilities operation and machine proactive maintenance, are therefore essential elements of a successful operation. Early detection of defects and an efficient diagnosis allow owners to minimize downtimes and maintenance times, and, therefore, to reduce costs related to these operations. Let’s have a closer look at direct current machines, which are wrongly considered by some as more demanding as regards their maintenance. It is true that electrical brush machines comprise “wear” parts (carbon brushes, brush-holders), but this apparent inconvenience may, in fact, turn out to be an asset. The carbon brush is a sliding mechanical contact, which transmits electrical current between the rotating part of a machine and its fixed external circuit and, in the case of direct current machines, ensures commutation without sparking. Carbon brushes are guided and maintained in permanent contact with the commutator or the rings by the brush-holders. Carbon brushes and brush-holders


PECM Issue 13

must be checked regularly and changed as required, but if monitoring is regular and preventive, maintenance proves to be inexpensive, easy and schedulable. On the other hand, a simple inspection of the commutator (or slip ring) film may enable a diagnosis to be made on the state of “health” of your rotating electrical machine before serious problems occur. On direct current machines, breakdowns are easily identifiable and defects can often be seen with the naked eye. “Operators or technicians will, for instance, notice sparks or burn marks on the commutator, or increased brush wear. Most often, this diagnosis does not require any specific knowledge of motors. Thereby, maintenance operations may be scheduled according to the development and importance of these indicators”, notes Stéphane Boulanger, Technical Manager of the Motor Maintenance Service Division in collaboration with Roy Douglas, Technical Manager of Mersen USA.

Carbon brushes and brush-holders must be checked regularly and changed as required The global operation of the machines is affected by many kinds of defects: electrical, mechanical, thermal and environmental. When the machine does not perform satisfactorily, several factors must be taken into account for an efficient basic diagnosis:

Example of commutator with presence of significant ridges and flat spots

• Study of the machine, application and its operating cycle, functional analysis of the carbon brush (also called “motor brush”), design of the brush and brush-holder, film analysis. • Mechanical diagnosis of the commutator / rings with surface roughness measurements, control of out of round and brush-holder inspection (visual analysis of their condition, checking of carbon brush movement in holders and the pressure applied to them). The use of measurement instruments such as the roughness meter (surface condition measurement device), CL-Profiler & ComPro2000TM (Mersen solution to measure profiles of commutators and rings), or dynamometer (carbon brush pressure measurement device) are all necessary to obtain relevant results. In the presence of vibration, specific attention must be paid to the bearings, balancing, and machine fixing and shaft alignment. To ensure smooth operation of the machine, an electrical assessment by an expert is required when the following situations arise: - commutator appearance defect (wear, deformation, electrical marking) - significant vibration accompanied by sparking and shunt connection failure - shunt discolouration from overheating - poor current distribution (selective action) - “flash-over” on the commutator (more serious) Depending on failure, there are two

Commutator radial chart before machining (As measured with a CL-Profiler)

possible solutions: â&#x20AC;˘ Basic electrical diagnosis through visual observation of the commutation or sparking on the application in operating conditions, followed by checking and adjustment of the neutral line (i.e., the area where sparking is minimal). â&#x20AC;˘ Specific electrical diagnosis consisting of measurements and control of the integrity of the insulation: o insulation resistance o flash tests (dielectric tests until insulator breakage) o polarization index (test to establish the pollution level or moisture uptake of the winding insulation at surface level) electrical discharge tests (test to establish the intrinsic quality of the insulation) o winding continuity test (ohmic resistance measurement of a circuit to establish the resistance value or check the absence of conductor open or short circuits) o measurement and analysis of leakage currents


Commutator radial chart after machining (As measured with a CL-Profiler)

damage to commutators (deformation, electrical marking, grooving), that must be, in this case, corrected by in-situ machining or grinding, mica undercutting, bar bevelling.

Electrical machines must often operate in difficult environments These measurements and analyses require the services of professional teams specialised in motor technical maintenance. Performing an electrical expert assessment requires the use of specific equipment and, therefore, the services of specialists in the sliding contact and electrical rotating machines field. In-situ solutions are to be preferred, since they allow machining without disassembling the machine and, therefore, significantly reduce machine downtime. For instance, the machining of a commutator, with equipment especially developed by Mersen, takes


a few hours, against more than one day with manual stone machining. The maintenance of direct current machines is often entrusted to external service providers, this does not help the internal teams to master this technology and corresponding diagnosis techniques. Producers of electrical machines, of solutions for electrical machines, and companies in charge of their own maintenance may call on Mersen to train and accompany their users. For instance, Mersen offers training courses on its site or at the customerâ&#x20AC;&#x2122;s site to allow trainees to learn how to make the diagnosis on the operation of carbon brushes in electrical machines and how to perform a predictive and preventative maintenance. Email: infos.amiens@mersen.com http://www.mersen.com/en/ products/electrical-solutions-formotors-and-generators.html

The control of electrical machine power supplies is sometimes also required. Electrical machines must often operate in difficult environments: pollution (oil, dust, acids), or else in hot or cold, wet or dry atmospheres, with absent or insufficient ventilation. The presence of pollutants may cause more significant wear of the carbon brushes and/or the commutator/ rings. Certain signs may be detected and addressed to prevent failures. Oxidation and discolouration of shunts, brush-holders or commutator is a sign, for instance, of an acid attack. In this case, a specific environmental study must be considered. Electrical, mechanical or environmental failures may cause mechanical

Commutator dynamic profile by ComPro2000TM Issue 13 PECM


Process Technologies

Tel: 0208 339 7370 462 Ewell Road, Surbiton, Surrey KT6 7EL, England

Fax: 0208 339 7371

Email: sales@blackfast.com Web:


Mydax’s New CryoDax Chillers Are Meeting the Cooling Challenges of New Emerging Markets By Brandon Hall As the world shifts away from fossil fuels and towards renewable sources of energy, new technologies are fueling new markets. Since 1986 Mydax has offered process temperature control solutions for OEM and one of a kind custom chiller applications. With the ability to provide extreme temperature stabilities of ±0.05°C for critical applications, even with high cooling power requirements up to 70kW, Mydax is bringing laboratory precision to the industrial market. Mydax also offers the CryoDax series of chiller systems for the most demanding requirements with fluid temperature ranges of -70°C to +150°C with cooling capacities from 2kW up to 15kW @ -50°C available. Please call or visit Mydax online for more information.

Mydax Inc. 12260 Shale Ridge Ln. Auburn, Ca. 95602 USA 00-1-530-888-6662 www.mydax.com


PECM issue 13

One such source of energy is hydrogen. Powering fuel cells to generate electricity, hydrogen is an environment friendly alternative to other means of electric generation since its byproduct is pure water. An exciting application for this technology is hydrogen powered fuel cells in the automotive industry. Hydrogen powered cars enjoy a longer range and lack the long recharge times of their battery powered counterparts. South Korea has become an incubator for hydrogen powered cars with government sponsored initiatives in research and infrastructure, and with Hyundai commencing manufacturing on its hydrogen powered Tucson crossover at their Ulsan, South Korea plant in 2015. Mydax is taking an active role in this emerging market by providing a cooling solution for hydrogen refueling stations. One of the challenges faced when pumping compressed, pure hydrogen into a vessel onboard an automobile is cooling the hydrogen to temperatures cold enough to attain the proper working pressure. The capabilities of the Mydax CryoDax60 chiller, the largest of Mydax’s new CryoDax line of chillers, aligned perfectly with these requirements and specifications. Utilizing two 30 horsepower compressors in a parallel configuration, the CryoDax60 is able to cool a recirculating loop of silicone oil down to -60°C, while providing 22.7 kW of cooling at -40°C. Like all Mydax chillers, CryoDax chiller systems incorporate fully welded, powder coated steel frames for durability, as well as stainless steel reservoirs and brazed plate heat exchangers for leak free performance. Reliable operation is also ensured with prejudice component selection and rigorous testing procedures. Standard features also include the Opdax Controller which utilizes a high resolution 5.7” color touchscreen display for ease of use by the operator. In order to serve customers in Europe, Mydax’s CryoDax chiller systems are also manufactured in compliance with European Safety Directives with CE marking available. For more information on Mydax CryoDax chillers or any other custom cooling solution, visit www.Mydax.com or call +1-530-888-6662.


The right coating can make it as good as new, if not better


t is said we live in a throw-away age, where it is easier to buy a replacement than try to fix something. This may be alright for things like mobile phones and iPods, but it is another matter when you consider large pieces of capital equipment worth thousands, or even hundreds of thousands of pounds. This is where industrial coatings from Repair Protection and Maintenance come in, by protecting equipment from corrosion and erosion in the first place, or reclaiming it to make it as good as, or even better than, new if a problem does occur. The cost of corrosion in the UK is around 4% of GDP, but these are costs that can be cut when it is realised that not everything that has suffered from corrosion damage necessarily has to be discarded. It is no-longer the case that a corroded tank or vessel, pipe, pump casing or other equipment needs to be replaced; even those with severe pitting or even holed. One way of achieving this is rebuilding corroded

or damaged areas with appropriate heavy duty coating material and lining the vessel to protect it and extend its life.


Blasting and relining a large neutralisation tank.

Lining is an effective alternative solution to replacement in terms of costs, time and environmental impact. For example, there is no necessity to dispose of contaminated equipment, to dig anything up or knock anything down.

Large tanks can also have their life extended, for example fuel storage tanks. The bottom of the tank and walls, up to around 300mm above the floor, can suffer from corrosion, mainly due to the water content in fuel. The environmental fall-out and subsequent costs, should a leak occur, are immense. A cost effective solution is to line these areas with a suitable coating and, if required, reinforced with a laminate system to strengthen the floor.

The effective use of coatings can be employed when a change of service conditions would be advantageous. The same methodology can also be employed to extend the life of new plant and equipment and older equipment can be updated to comply with new legislation. The effective use of coatings

can be employed when a change of service conditions would be advantageous. Redundant tanks used, for example, for fuels or chemicals can, through the use of coatings, be changed to water storage tanks.


Repair of a corroded vessel, before and after

An additional bonus is that a longer warranty period can often be obtained for something that has been repaired and lined than the manufacturer will offer on brand new equipment. A typical manufacturerâ&#x20AC;&#x2122;s warranty will be two to three years at most, while we can offer up to 10 years, depending on the environment and proposed use.

Issue 13 PECM


Process Technologies Save energy & save money! Air Dryer Technology is an independent specialist company providing service and after sales support on all types and makes of compressed air/gas dryer, filtration and condensate management systems. The main activity is providing technical support and comprehensive packages for on-site servicing of compressed air/gas treatment equipment and desiccant air drying plant. Air Dryer Technology also provides consultancy and equipment upgrades to increase efficiency and reduce energy costs. Retrofitting a dryer control system provides significant benefits by operating to actual site conditions, rather than original design specification. It will also restore customer confidence in equipment operation and performance. Installing a dewpoint control system to a compressed air desiccant dryer will save energy, considerably reduce operating costs, and provide efficient dewpoint control. Features and benefits include; Controls Compressed Air Monitor Dewpoint Extends Service Time Extend Cycle Time Constant Dryer Knowledge Retrofit Design Record Performance Data Installation Service/Technical Support

Tel: 0161 788 7900

Save Money Reduce risk Maximise desiccant life Reduce switching valve wear Increase confidence No equipment modifications required Predict dryer failure Peace of mind


Old, Tired, Troublesome Valves? Leaking shaft seals? Worn our valve? Product discharge problems? We offer a free of charge assessment of any rotary valve or diverter valve to help diagnose the fault. With DMN’s unrivalled knowledge and experience of rotary and diverter valves we are sure to have the solution to keep you process in operation.

DMN UK Ltd. T +44 1249 818 400 dmn@dmnuk.com

www.dmnwestinghouse.uk 104

PECM issue 13

Call for a free on-site survey!


• • • • • • • •

Process Technologies



CEV58 MULTI-TURN ENCODER WITH INDUSTRIAL ETHERNET 58MM INDUSTRY STANDARD WITH DIRECT INDUSTRIAL ETHERNET CONNECTION: - Compact 58 mm housing - PROFINET, EtherCAT, Ethernet/IP, SERCOS3 - 15 bit resolution per turn, 4096 turns absolute - 3 x M12 connectors - IP 65 - 30 years of encoder innovation

For more details Call 01371 876187 email info@tr-electronic.co.uk or visit www.tr-electronic.co.uk


Issue 13 PECM


Process Technologies


All CERTUSS Steam Generators are type tested according to European Pressure Equipment Guideline DGRL 97/23/EG. CERTUSS offer seven construction groups within their range of fossil fuel Generators with outputs ranging from 80kg/hr to 2000kg/hr and operating pressures of up to 32 Bar G. To accompany the Generator, CERTUSS also offer their CVE Package Plant Module, where all of the associated ancillary items are pre-piped, pre-wired and factory tested.


CERTUSS (UK) Limited Unit 45 Gravelly Industrial Park Tyburn Road Birmingham B24 8TG

Fuel types offered are Gas, Light Oil, LPG and Bio Fuel, with combination burners offered on all units from 500kg/hr upwards. Also available are a range of Electrical Steam Generators from 6kW to 120kW. CERTUSS also offer a new â&#x20AC;&#x153;TC Modelâ&#x20AC;? with touch screen control and full modulation from 50-100% firing. The TC offers output ranges from 5002000kg/hr and is compatible with many BMS interface provisions such as Profibus and Modbus etc. TC Model Generator and Package Plant shown below.

Tel: 0121 327 5362 Fax: 0121 328 2934 sales@certuss.co.uk www.certuss.co.uk

Tel: 0121 327 5362


S&S Plastics Ltd based in Kirkby-in-Ashfield wants to encourage more young people into manufacturing. Plastics manufacturing has an enormous presence in the East Midlands but a dwindling amount of youth interest has created a gap between the older and younger workforces. By working with local authorities S&S Plastics have opened their doors to introduce GSCE students to world of engineering.


S&S Plastics also have two apprenticeship schemes in our Toolroom department, Jack Gent who is doing Apprenticeship Level 2 in Performing Engineering Operations and Howard Harbour who is carrying out a HNC in Manufacturing Engineering both who are already showing to be valuable members of the team.




www.environmental-innovations.biz - 01279 600 440 ¡ 3

+44 (0) 1279 600 440 sales@environmental-innovations.biz | www.enviromental-innovations.biz The Innovation Farm | Sawbridgeworth Road | Little Hallingbury | Bishops Stortford | Hertfordshire | CM22 7QU


Issue 13 PECM


Southern Manufacturing MIE Solutions UK Limited are pleased to offer MIETrak Pro the industry specific MRP/ERP Software.

With over 23 years experience in the Sheet Metal, Engineering and Fabrication industry and with a Worldwide presence, we understand our existing and potential new Clients needs within these industries. MIETrak PRO can offer you a cost effective complete solution including: t t t t t t t t t t t t t

RFQ / Quotation / Estimating Sales Order Processing Works Order / Router Design Purchasing Scheduling Shop Floor Data Capture Stock Control Time Clock / HR Costing / Reporting Shipping / Invoicing / Accounts Integration Quality Control Preventative Maintenance And much more.........................

To discuss your requirements or for further information call 01527 576444 or visit



PECM issue 13

The quick brown fox jumps over the lazy dog. The quick brown fox jumps over the lazy dog. The quick brown fox jumps over the lazy dog.

Southern Manufacturing 2015 sets new attendance record Southern Manufacturing & Electronics 2015 achieved unprecedented attendance figures and set new records for exhibitor rebooking, say organisers European Trade & Exhibition Services. arly indications are that over 8,300 visitors attended the event over the three days, an increase of around 20% on last year’s figure. The 2015 show was notable for its move to a three-day format for the first time in its 20 year history, and for the large number of international companies taking part in the show. Visitors to the event witnessed an incredible line-up of the UK’s top engineering firms, electronic component suppliers and subcontractors, plus live demonstrations from many of the world’s leading machinery manufacturers and firms from as far afield as Taiwan, Japan and the USA. European companies were also well represented, with firms travelling from Spain, Italy, Germany, Switzerland, the Netherlands, Latvia and Slovakia to attend.


Many exhibitors expressed satisfaction at both the quantity and quality of visitors to the show, which traditionally attracts a high percentage of design


PECM Issue 13

engineers and senior decision makers due to its convenient location in Farnborough, close to the M3 and M4 corridors. Kevin Nicholl, general manager UK, Ireland and South Africa for TTI Inc., said the show was, “…a good place to meet new customers and for customers to meet field engineers face-to-face, which is important.” Matt Wood, product manager for Amada UK, commented; “A lot of good enquiries today. We‘ve seen customers we know and new customers – a good mix.” Midas sales and marketing director, Paul Banham, said, “We are pleased with the number of new customers we’ve met this year. . . including real, live engineers, which is encouraging.” Leading machinery manufacturer, Matsuura, commented on its blog: “With more enquiries received from new potential customers than at any other UK show in recent years, we trust that Southern Manufacturing 2015 will prove to be our most successful to date.”

Visitors were similarly upbeat, with some taking to social media to comment on the scale of the event and the diversity of firms taking part. Twitter user @mikethebee commented, “An amazing venue packed with more stands than you can imagine in 3 days”. @SentinelManLtd tweeted, “Great atmosphere here in Farnborough at the Southern Manufacturing show today”, while @ PWCircuitsLtd said “Walking round #southmanf today. Can’t believe how much bigger and busier it is this year, good job @Industry_co_uk !” Bookings for Southern Manufacturing & Electronics 2016 are already well ahead of previous years. To find out about exhibiting at this unique event, simply visit www.industrysouth.co.uk or call 01784 880 890. Visitors can follow all the latest news from the show’s exhibitors on its blog page at http://blog.industrysouth. co.uk or by following @industry_co_uk on Twitter

Introducing the new AMD FireProâ&#x201E;˘ W9100

The new AMD FireProâ&#x201E;˘ W9100 professional graphics card is designed for the most demanding workflows and delivers the ultimate 4K experience in next-generation workstations. Professional graphics cards such as AMD FirePro are a good choice for design engineers as they are tested, optimised and certified to work with all leading CAD/CAM/CAE applications.

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Elmtec is a UK distributor for AMD FirePro professional graphics graphics, contact us today for more information and where to buy.

AM FireProâ&#x201E;˘ AMD W9100 W9

W: www.elmtec.co.uk

E: marketing@elmtec.co.uk

Software & Systems GSM Graphic Arts GSM Graphic Arts manufactures a full range of durable plastic and metal barcode labels to suit your particular unique identification label requirements including:• Roll-form labels offer an economical option for high volume usage in low risk applications such as Logistics and Stock Control. • Anodised aluminium barcodes provide a hard wearing, solvent resistant finish in which the unique code is printed and sealed within the grain of the material - these are used in Asset Management, Logistics and Warehousing applications. • Undersurface Printed Plastics, where the barcode is printed on the rear of the material producing a very durable finish, ideal in applications where a hard wearing flexible label or tag is required. Ideal for Marketing and Warehousing applications. • Etched Stainless Steel is used in very high temperature applications or in harsh environments. All barcode labels can be supplied with self-adhesive or fixing holes to suit your specification. The latest digital printing technology enables GSM to print full colour logos within the barcode labels to offer the complete labelling solution. For further information on the comprehensive range of barcode labels and tags produced by GSM Graphic Arts visit our website www.gsmgraphicarts.co.uk or call us now on +44(0)1845 522184.

Strong, Simple, Reliable Poor production yields caused by micro contamination is an issue which effects many industries. Any process such as printing, laminating or converting will require high levels of particle control directly prior to critical applications. Contact cleaning technology products manufactured by KSM Superclean Ltd are designed to solve this problem. At the heart of the system is an assembly of SuperBlueTM elastomer rollers, which pick up dry, unattached particles to the sub micron level from your critical materials. Once lifted from the substrate the contamination is then transferred to an adhesive roll to trap and permanently remove it from your environment. The rolling action of the system means that there is no scratching of substrates and careful formulation of the elastomer rubber and adhesive roll means that there is also no danger of transfer of adhesive to the critical surfaces. Whether you are processing rigid or thin film material in small panels, sheets or roll to roll, KSM Superclean have a machine design to fit your application. Visit www.ksmsuperclean.com today and see what systems are available to solve your micro contamination problems.

REQUEST YOUR COPY OF OUR NEW COLORFABB CATALOGUE TODAY! COLORFABB 3D Printing Spools available in 1.75mm, 3mm & XL sizes Wide range of colours available All 1.75mm and 3mm Spools only £25 | All XL Spools only £50


*Cutwel reserves the right to remove any offer at any time. Please see website for full terms and conditions.

Please follow us on twitter @ Cutwel3D 01924 869610


PECM issue 13



FOR ALL YOUR MAGNETIC REQUIREMENTS IN SENSING AND SWITCHING STICK WITH MAGDEV LTD Let us help you or your design team to decide which permanent magnet material to use for your reed switch and hall effect applications. Contact one of our technical team by phone, fax or email for unbiased design assistance or our sales department for access to our large stock of hundreds of sizes in all material grades. We can satisfy your requirements, whether for prototype pre -productions or production quantities: also, in many instances, we are able to supply special sizes or assemblies where no suitable standards exist

Let MagDev help you choose the appropriate reference magnet for your reed switch and Hall Effect applications. Contact one of our technical team by phone, fax or email for assistance with matching the correct grade of magnet best suited to the working environment of your device. Many of the required grades & profiles will be available from our large stock of permanent magnets, if your required material is a non standard size MagDev can cut from our stock of bars & rods or provide a quotation to supply the magnets from our manufacturing partners.

MagDev is part of the Delta Magnet group of companies, based in Swindon UK, and comprises a major test facility, in-house machining plant and over 12,000 sq ft of warehouse space with low cost manufacturing facilities in India. We supply permanent magnet components and assemblies from a variety of materials including Neodymium, Sintered Ferrite and Alnico and a full range of soft magnetic components including cores in a choice of shapes and sizes manufactured from a range of materials including manganese zinc, nickel zinc, sendust, iron powder and cobalt based amorphous. MagDev is BS EN ISO 9001:2008 accredited; we provide application specific solutions for permanent magnet assemblies, as well as assisting with the design and supply of high frequency and high power chokes and transformers for various applications.

MagDev Ltd, Unit 23, Ash Industrial Estate, Kembrey Park, Swindon, Wiltshire 5FMFQIPOFt'BYt&NBJM4BMFT!NBHEFWDPVLt8FCTJUFXXXNBHEFWDPVL



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The UK’s first exhibition dedicated to the UK’s water, electricity and gas utilities Utility WeekTM Live incorporating IWEX is a new exhibition and conference providing those working in the water, gas and electricity utilities with all the learning, information and contacts needed to meet the challenges of running a modern utilities company. The event will focus upon the strategy behind the business of utilities, the implications of the policy and regulatory framework plus the technology and innovation to operate efficiently and cost-effectively.

Key benefits of visiting: Comprehensive exhibition of the latest technologies and solutions Free learning with CPD workshops & seminars Networking events High-level Keynote Conference

Exhibition Topic Trails Leading speakers from across the utilities sector New Exhibitors Zone National Drilling & Tapping competition

Pre-register free at

utilityweeklive.co.uk To book your stand or request further information, please contact the sales team:

Rachael Lyon – water sector +44 (0) 1342 332097 rachael.lyon@fav-house.com

Nicky Shaw – energy sector +44 (0) 1342 332070 nicky.shaw@fav-house.com

Gold Sponsors:

Brought to you by the publishers and organisers of:


Supported by:

Organised by:

Co-located with:

Do Business Better at Sustainability Live Sustainability Live – incorporating NEMEX and Energy Recovery – is the UK’s leading exhibition for innovative energy management and sustainability and returns to the NEC Birmingham from 21 to 23 April 2015.


ith more than 160 participating organisations, including 100 expert speakers across four conference theatres, plus the latest technologies and solutions from all the leading suppliers, this year’s show is a must attend event for all engineering professionals, both those in senior strategic roles and their operational teams. Strategic level thinking New in 2015, the Sustainability Live Conference is a three-day, premium ticketed conference bringing together the business and policy leaders who are finding new ways of building resilience into organisational models, and reaping the benefits. The conference will address the strategic needs of senior level delegates and places are strictly limited for qualifying personnel. Confirmed speakers include experts from leading brands and institutions, including Sainsbury’s, Carlsberg, M&S, B&Q and the University of Cambridge, as well as forecasting and innovation expert Professor James Woudhuysen and BBC business and economics journalist Simon Jack.

to help sustainability professionals operate more efficiently – and gain CPD hours. These sessions will offer practical advice about implementing sustainability and energy management initiatives. Focusing on People, Policy, Processes and Best Practice the Energy Efficiency Theatre 1 will tackle a range of upcoming industry challenges and opportunities, including ‘Strategies for effective energy management’ and ‘Changing behaviour by changing capability’. The programme for Energy Efficiency Theatre 2, which highlights developments in Technology, Tools and Kit, includes sessions covering sustainable transport strategies and taking the first steps towards onsite generation. Finally, the Energy Recovery Theatre will offer a packed programme, focusing on the latest technologies for driving on-site energy generation. Sessions include the ‘Green your fleet: how do we step up a gear on biofuels? a panel debate examining the opportunities and challenges in converting waste to vehicle fuel.

Practical workshops and seminars

On the show floor

Running alongside the Sustainability Live Conference is a three-day programme of practical, free CPD workshops and seminars designed

Operational teams can also make the most of this year’s exhibition, which features the latest innovations in energy and resource management,


PECM Issue 13

alongside the industry leading energy recovery technologies and services. Companies confirmed to date include the Society of Environmental Engineers, construction and engineering specialist AECOM, voltage optimisation system Powerstar and KRR Prostream. Other confirmed exhibitors include battery manufacturer Tadiran, transformer manufacturer Wilson Power Supplies and energy saving lighting specialists Danlers, Dalkia, and PA Energy. With so many products and innovations to see in 2015, four new Topic Trails will help visitors maximise their time at the exhibition. The Topic Trails for 2015 include ESOS, Energy-efficient buildings, Energy generation and Smarter systems. Finally the Innovation Zone is another exciting new show feature in 2015. Showcasing 16 emerging technologies in the trial stages of development, it’s the ideal chance to learn about the latest emerging technologies and what benefits they could offer businesses in the future. For more information or to book your place at Sustainability Live, register free now at sustainabilitylive.com. For more information about participating, please contact the sales team: T: +44 (0) 1342 332097 E: sustainabilitylive@fav-house.com.

Utility WeekTM Live incorporating IWEX

The Utility Week™ Live Keynote will be one of the key highlights of the new event.

Conveniently co-located with Sustainability Live is a brand new event, Utility WeekTM Live incorporating IWEX. The UK’s first exhibition dedicated to the UK’s water, electricity and gas utilities, this is a must attend event for engineering professionals. Designed to aid organisations and utility companies approach longstanding challenges with fresh ideas and concepts, Utility WeekTM Live incorporating IWEX gathers more than 180 participating organisations and global industry providers to showcase their products and services. Utility WeekTM Live Keynote Curated by Utility Week™ and tackling the big issues faced by senior level utility executives, the Utility WeekTM Live Keynote will be one of the key highlights of the new event.

The three-day paid Keynote will take an “outside-in” approach, drawing on other sectors’ experience in managing key issues such as change, resilient infrastructure and customer trust. Designed for strategic level, senior executives from UK’s water, electricity and gas utilities, delegates will be exposed to innovative ideas, new areas for research and new contacts that can be leveraged in the workplace. Speakers include Lord Deben, chairman of the UK’s independent Committee on Climate Change and Tim Yeo MP and chair of the Energy and Climate Change select committee. Technical seminar programme Complementing the Utility Week™ Live Keynote is a three-day programme of free CPD technical seminars, focusing on learning from product experts and technical staff to help operational teams deal with the hard-hitting issues they face. The case study based sessions offer

engineering professionals real-life learning opportunities and innovative ideas to address a variety of concerns. The Energy Theatre will cover regulation and policy, with sessions including ‘A guide to Electricity Market Reform’ which covers the latest policy developments, their objectives, implementation and impacts. Also, the panel session ‘Whole system approach to decarbonisation of energy’ will examine current thinking on whole system approaches and potential solutions to this long-term challenge. The Pan Utility Theatre will explore common issues that straddle water, gas and electricity; with sessions including ‘Fracking’, a panel debate which asks what role shale gas is likely to play in the future of the UK energy mix. Also the seminar ‘BIM for Utilities’, will explore how BIM fits into the delivery of engineering, designing, constructing and managing assets and explains its relevance and value for modern utilities. Finally The Water Theatre will address a wide range of industry issues and legislative changes, including TOTEX, the opening of the water market, PR14 abstraction and upstream reform. Sessions include ‘Towards Universal Metering’, which will explore whether universal metering is desirable, and considers the benefits of new and emerging technologies, including smart meters. For utilities staff working at an operational level, other show features not to be missed include the four Topic Trails and the free exhibition. Exhibition In its inaugural year, the event is forecast to welcome more than 150 exhibitors showcasing the latest equipment, software, technology and services to the utilities industries.

This includes a huge range of product experts and technical staff from across the utilities industry. Exhibitors confirmed to date include Bonut Engineering, ABB Group, Albion Community Power LC, Draeger, Steelway, plus plenty more. Register for free now at utilityweeklive.com. For more information about participating, please contact the sales team: T: +44 (0) 1342 332097 E: utilityweeklive@fav-house.com.

With so many products and innovations to see in 2015, four new Topic Trails will help visitors maximise their time at the exhibition. The Topic Trails for 2015 include ESOS, Energy-efficient buildings, Energy generation and Smarter systems.

A Fibrelite composite cover is used at an Antarctic waste treatment system

Composites Reach the Antarctic Fortunately, our composite covers are available in a range of sizes and load ratings, and we can also make them to customer specifications as we did for this project. Designed to be a ‘fit-and-forget’ product, they are maintenancefree, lightweight, durable and very strong as a matter of course.


PECM Issue 13


ibrelite’s design and technical team were recently called upon to help an engineering team constructing a specialist waste water treatment system for a facility in the Antarctic. This specialist system is essential for treating all black and grey waste water generated on the base before it can be safely discharged into the sea.

This specialist system is essential for treating all black and grey waste water generated on the base before it can be safely discharged into the sea. David Holmes, Fibrelite’s Technical Director, explained: “The lead designer on this project came to us very early on with his brief which was very stringent: not only did the specifications require customdesigned access, other requirements included easy access to internal workings as well as needing to be chemically inert, corrosion-resistant and able to withstand extremely low temperatures.

“In addition, the rigorous rules requiring any base on Antarctica to leave little environmental impact meant that those working on the site would need to lift the covers regularly to ensure the system was working efficiently, so operator safety was also a critical requirement. “Fortunately, our composite covers are available in a range of sizes and load ratings, and we can also make them to customer specifications as we did for this project. Designed to be a ‘fit-and-forget’ product, they are maintenance-free, lightweight, durable and very strong as a matter of course. “And specialist lifting handles are all that is required for operators to remove the covers as and when required.”


Storage, Handling & Distribution C3412 – The new generation “Compact Crane” With unique infinite outrigger positioning technology, the versatile C3412 can be set up and operated in the most demanding of confined spaces. Hybrid technology allows it to operate internally or externally around production lines or construction sites.

Stowed: Only 2m high, 1m wide and 2.9m long Reach: 21m

This compact crane has a maximum lifting capacity of more than 4 TON!!!

Reedyk compact cranes dealer for the UK and Ireland www.promaxaccess.com • sales@promaxaccess.com

AB Systems appointed UK distributor for Avian Granulator Materials handling and process cooling specialist AB Systems has added a new range of high quality, cost effective granulators, shredders and pulverisers to its extensive product portfolio. The move follows the appointment of AB Systems as the UK distributor for world-leading manufacturer, Avian Granulator. Offering outstanding performance and efficiency, Avian Granulator products are proven to reduce energy consumption by up to 40%, meaning AB Systems is best placed to help manufacturers reach even the most ambitious energy, environmental, and cost saving targets.

Email: info@ab-ltd.co.uk


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TONE Scaffolding Services innovates by using Bradshaw… TONE Scaffolding Services has recently taken delivery of two tow tractors and 4 bespoke industrial platform trailers from Bradshaw. The vehicles have been put in to Paddington Station to tow large amounts of scaffolding around the site, to locations where the workers need it during the station’s restoration project, which includes refurbishing the platforms, repairing existing structures supporting London Street, building new bridges and walkways together with the installation of new mechanical and electrical systems. Due to the access restrictions at the station and the large volume and length of the load, TONE Scaffolding required a vehicle with both the maneuverability and towing capacity. The T700 tow tractor, together with bespoke 4 wheel interlinked steering trailers, enables for large volumes and lengths to maneuver through tight areas, with 2 or more trailers capable of being linked in series, enabling a larger load to be carried at any one time. The three-wheel T700 tow tractor from Bradshaw can pull up to 7,000KG, with key features of the electric vehicle including hydraulic drum brakes to all three wheels, electronic regenerative braking under deceleration, dynamic speed sensing to prevent over-speeding in all driving conditions, automatic hill hold and automatically applied transmission parking brake.

For further information on Bradshaw’s range of vehicles visit www.bradshawelectricvehicles.co.uk


PECM issue 13


Profile Technology

Conveyor Technology

Linear Motion

Factory Equipment

Flexible modular solutions from mk! Compatible standard modules from mk simplify your production and maximise efficiency. Technology from mk provides the ideal solution for plant and special machinery engineering. mk Profile Systems Limited a company of the mk Technology Group Unit 2· Wolds Farm Business Park Kinoulton Lane· Kinoulton· Nottinghamshire, NG12 3EQ Phone +44 (0)1949 823751· Fax +44 (0)1949 81270 www.mkprofiles.co.uk · info@mkprofiles.co.uk

Storage, Handling & Distribution

Better Control of Plastic Lamination in Less Space with Heraeus Infra-Red


fast response, medium wave infra-red system from Heraeus Noblelight of Neston, Wirral, has allowed Weatherfast Ltd of Great Barr to achieve better control over the PVC Membrane laminating of steel sheets/coil used in the gutter industry, while requiring much less space than the convection oven which was used previously. The controllability has also provided an improvement in quality. Weatherfast is a privately owned company, which offers a wide range of waterproofing products both for the new build & refurb sector. Weatherfast gutter systems are laminated with a walkable PVC tread pattern and this is achieved by feeding a coil of PVC through to a set of pinch rollers, where it is pressed onto a continuous coil/sheet of steel, which is simultaneously introduced into the rollers. Previously, the steel had been laminated by passing the steel through a convection oven. This took up a great deal of floor space and, in the event of unanticipated line stoppage, the steel sheet still in the oven could be overheated and often unsuitable for lamination. To solve this problem, Weatherfast installed a 67.7 kW fast response infra-red system, featuring six emitters from Heraeus, which can be shut down very quickly to prevent damage to the

steel. Moreover, unlike the convection system, heat up time is also rapid and miniature circuit breakers on the rear of the compact infra red module allow individual emitters to be switched off or on to match the line speed and required temperature of the process. â&#x20AC;&#x153;We now have more effective control over our lamination process,â&#x20AC;? comments Weatherfasts works manager, Keith White, â&#x20AC;&#x153;And the whole installation is much more energy-efficient and has freed up a lot of valuable floor space.â&#x20AC;? Heraeus specialises in the production and application of high quality energy sources covering the electro-magnetic spectrum from ultraviolet to infra-red. It has over 40 years experience in infra-red technology and offers the expertise, products and systems to provide efficient and effective solutions to drying, heating and curing problems throughout industry. www.heraeus-infraredsolutions.co.uk

Get the most from your material handling equipment...

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PECM issue 13

Our training courses help deliver:

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Storage, Handling & Distribution CORR-EX VCI Corrosion Control Film Packaging EnSolv precision vapour degreasing solvent is an increasingly popular â&#x20AC;&#x153;drop inâ&#x20AC;? replacement for the carcinogen trichloroethylene. Vapour degreasing is the most widely used, quickest, most efficient and cost effective cleaning process which relies on the difference between the parts for cleaning being at ambient temperature and the vapour formed by boiling EnSolv, a stabilised n-propyl bromide formulation, being at a much higher temperature (gradient typically 20 to 73C). More accurately referred to as Condensation cleaning it is the change of state from vapour to liquid on the cooler metal surface which dissolves the oils and removes other surface contaminants. Cleaning products and processes such as EnSolv are increasingly sophisticated, formulated to remove every trace of cutting oils and fluids from machined parts and from steel sheet fabrications. The Corr-eX Division of EnviroTech Surface Technologies now supply storage bags and films in a range of sizes, manufactured from polythene or PPE film impregnated with volatile corrosion control agents which are safe on the parts, for operators to handle and have no impact on the environment. Vaporisation of the volatile chemicals form a protective molecular envelope around the parts while dispersing the condensed moisture. When sealed into a package with the parts immediately after cleaning and inspection the volatile corrosion inhibitors (VCIs) leaves clean, dry and corrosion free metals parts that are ready for immediate handling and use requiring no further cleaning. For further information please visit www.corrosion-protect.com



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Issue 13 PECM


A trading division of BID Group Ltd, KLIMATE is one of the UK’s leading high-speed door manufacturers. With over 20 years experience in maintaining high-speed door products, KLIMATE is recognised as a UK leading specialist in maintaining all makes of high-speed doors. (www.klimate.co.uk).


ased in Blackburn, Lancashire industrial capital sits Big Bear Confectionery. Although still functional and operational the decision was made to invest in making the manufacturing process faster and more efficient while at the same time reducing cross contamination between products. Part of this project was to create a one way system through the process room with the aid of 2 of Klimate’s high speed doors. As all of the doors made by Klimate are bespoke Big Bear stated that they would like to be able

to see outside of the room at all times so the doors were constructed with the top half completely transparent thus allowing for people entering and leaving the room to see if it is safe to do so. Having previously had 2 high speed doors installed by Klimate, Mark Walsh from Big Bear was well aware of the quality of both the product and the workmanship of the engineers. “We have two larger doors already on loading bays and are more than happy with the doors and more importantly

“We have two larger doors already on loading bays and are more than happy with the doors and more importantly the response times should we ever need an engineer to attend site”

the response times should we ever need an engineer to attend site” The room where these two doors are situated has been completely transformed from what it was to what it is now – a modern, clean, and efficient food production area. The decision has already been taken to have a similar sized door installed across the corridor from these on a room which currently houses nuts. This door could be interlocked with the production facility to prevent any possibility of cross contamination.

Klimate High Speed Doors on new Production Room

✓ ✓ ✓ ✓ ✓ ✓

We manufacture the widest range of computer controlled storage and retrieval systems for bar, tube, profile, sheet and other materials. Systems may be interlinked with saws, including ours, other machine tools, robotic sorting systems, MRP and ERP systems, and more. If you are running out of space in your warehouse or factory, KASTO has the perfect solution for you.

WEPBA 17-125 Quick


he WEPBA 17-125 Quick is the world’s first compact 1700 watt 5” industrial quality angle grinder with dead-man’s paddle switch, 2 second disc brake and Metabo Auto-balancing technology.

This German built compact angle grinder distinguishes itself with its ergonomic perfection and smallest grip circumference in its power class. The WEPBA 17-125 is best suited for ultimate work progress particularly in intensive industrial shift operation. The World’s first compact 1700 watts grinder boasts a new Patented Metabo Marathon Motor with increased armature diameter for increased torque, more copper in reduced space providing more power in a reduced motor circumference, increased airflow and winding protection for improved cooling and higher overload capacity, a new dust


PECM Issue 13

protection concept and long life carbon brushes for increased service life. Other main features include Dead-man’s paddle switch and 2 second brake for maximum operator safety, Autobalancer for up to 50% less hand arm vibration and up to 50% increase in accessory life. TC electronics for constant speed under load, soft start, restart protection and overload protection. Metabo S-automatic safety clutch for antikickback protection for operator and machine safety, “Quick” guard change for tool-free adjustment for when switching between grinding and cutting applications and improved “M-Quick” disc change for tool-free changing of accessories. Metabo UK Ltd Tel: 02380 732000 Email: marketing@metabo.co.uk




Metabo UK Southampton (02380) 732000 metabo.co.uk

Valves for non Hygienic Application A Case Study


This valve system was put through a one year in-service test and was a success. It resulted in greater service life than the current system and it was all done at a competitive price; much to the delight of the paint manufacturer.

he Dixon range of valves is not restricted to hygienic applications. Dixon also offers industrial actuated valves for use within many process industries. In some cases a hygienic valve can be used in a multitude of applications not first thought. Sometimes the best solution to a process problem can be found outside of its traditional industry supply base. Dixon Hygienic have offered solutions to numerous industries. In one instance a paint manufacturer required a solution for moving paint which was accumulating in the void behind the ball on its nonencapsulated SVF ball valves. On being presented with the problem Dixon Hygienic investigated and found that the titanium dioxide additive within the paint was causing premature failure of the standard ball valves being used. The paint manufacturer had made the decision to remove ball valves from the production line completely until Dixon came up with the solution that the existing valve supplier had overlooked.

Not being dissuaded by the fact that this was not a traditional hygienic valve application, Not being dissuaded by the fact that this was not a traditional hygienic valve application, Dixon Hygienic developed a successful solution.

Analysing the current industrial ball valve being used, it was determined that the best solution would include an encapsulated ball valve. This would minimise titanium dioxide paint migration between the ball and valve body. Dixon concluded that a seal with higher abrasion resistance would be beneficial due to the nature of the titanium. Additionally the size of the actuator was increased to produce more torque. This ensured valve rotation if the process fluid began to solidify. After a complete study of the application and the unique additives present in the media, Dixon Hygienic offered a complete solution consisting of: 1. Supplying an encapsulated ball valve to minimise internal voids. 2. Using 15% fibreglass reinforced PTFE seats and seals for abrasion resistance and increased cycle life. 3. Utilising a larger actuator to overcome resistant forces inherent to solidifying paint. This valve system was put through a one year in-service test and was a success. It resulted in greater service life than the current system and it was all done at a competitive price; much to the delight of the paint manufacturer. Therefore in most cases a solution is readily available, if not within existing expertise, it may be from another industry. But it all starts with detailed analysis and by aligning Dixon Group with solution partners that can provide different industry perspectives. Contact Gill Platt @ Dixon Group Europe Ltd T: +44 (0) 1772 323529 E: marketing@dixoneurope.co.uk

“The Right Connection ” for all Industries ®

Dixon, a world leader since 1916, supplying Hose and Coupling solutions.

Tel: +44 (0)1772 323529 Email: sales@dixoneurope.co.uk Visit www.dixoneurope.co.uk for our global service locations

Waste Management


PECM issue 13

Level probes - extended Several new variants of ifm's popular LMT point level sensors have been added to the range. Longer probes, up to 250 mm, are particularly useful in overfill applications. Internal timer functions can be set using standard IO-Link accessories.

www.ifm.com / uk/ lmt ifm Telephone 020 8213 2222

Profile for MH Media Global

PECM - Issue 13 2015  

PECM - Issue 13 2015