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Global Success Through Innovation

Process Engineering Control & Manufacturing Issue 14 ÂŁ3.95

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

Control & 37 Automation

Electrical & Electronics

23 Air, Gas & Odour Control

Facilities 66 Management

Health & Safety 76


Machining & Machinery 85 KASTO / Advanced Manufacturing Show NEC / 2nd - 4th June / Stand A17

Measurement Process 99 & Monitoring 88 Technologies

Storage, Handling & Equipment 114

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

Connect onnect with u us


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 14 Contents Tel: 01227 392575

Email: elizabeth@pecm.co.uk

Tel: 01227 392575

Email: justine@pecm.co.uk

Tel: 01843 830249

Email: benjamin@pecm.co.uk

Tel: 01843 830249

Email: sophie@pecm.co.uk

Tel: 01843 830249

Email: josh@jdholmes.co.uk

Tel: 01227 392571

Email: jamie@pecm.co.uk

Tel: 01843 830249

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.

Editors Choice News & Events Air, Gas & Odour Control Cleaning Control & Automation Drives & Controls Electrical & Electronics Facilities Management Flow Measurement & Control Fluid Handling Health & Safety Hydraulics & Pneumatics Lubricants Machining & Machinery Measurement & Monitoring PDM Preview Process Technologies Product News Software & Systems Storage, Handling & Distribution Subcon Preview Valves & Flow Control

7 16 23 30 37 56 58 66 69 72 76 83 84 85 88 96 99 108 110 114 121 127


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 14 PECM


Bürkert rotary ball valve and flash steam generator

The specification of the valves in this instance is very important in order to achieve high reliability over an extended operating life with frequent and arduous operating cycles.

Super efficient new autoclave uses compact .. Burkert process valves to meet cost and performance targets he latest Logiclave™ type vertical closing autoclave from ESTS claims to reduce running and maintenance costs by up to £60,000 over an average 10 year operating period. The secret to achieving this figure is low maintenance, high reliability and low energy consumption. This is


largely made possible by the use of an innovative flash steam generator and a combination of Bürkert Type 2000 angle seat steam valves and rotary ball valves. ESTS has been manufacturing commercial autoclaves for over 10 years and has a large choice of models

available. Most are employed to sterilise items such as porous loads, fabrics, utensils, glassware, fluids and plastics for both laboratory and medical use. The latest model however is billed as a ‘game changer’ by the designers due to its ability to deliver a substantial reduction in overall energy usage and operating costs. The latest and largest of the compact vertical closing, rectangular chamber machines; the Logiclave™ LAB300 has just been launched with the company’s revolutionary flash steam generator on board. The unit comprises fourteen Bürkert valves, some of which have been adapted to reduce inventory and purchase costs as well as withstand the high temperatures associated with repeated steam sterilisation. The LAB300 uses pulsed vacuum / pressure cycles to replace the air in the chamber with steam in order to achieve sterilising conditions. When the cycle starts the first of the Bürkert valves, a stainless steel bodied Type 2000 pneumatically operated angle seat valve, opens as an exhaust and then closes when the machine reaches a vacuum set point of 100 millibar within the chamber. When it reaches this level, steam is injected via another Bürkert angle seat steam valve. The specification of the valves in this instance is very important in order to achieve high reliability over an extended operating life with frequent and arduous operating cycles. The steam supply valve is a high temperature unit that has been specified by process valve supplier Control Stream to include PPS material to ensure a longer seal life in the actuator.

Bürkert Type 2000 steam valve on ESTS autoclave


PECM Issue 14

Colin Hartop ESTS points out Bürkert Type 2000 steam valve

The valve body selection was also important to provide a compact solution; the bodies of Bürkert’s latest generation of angle seat valves are considerably smaller than other older designs and helped to ensure a compact, but reliable final product. A number of the angle seat valves were also supplied with a male thread which is a specification developed for Control Steam as a first for this application. This reduced inventory purchase costs for the machine builder by reducing the number of joints and connectors required to construct the piping circuit. Essentially a benefit just to the OEM, it does however add to the overall cost competitiveness of the machine.

In order to guarantee savings in the total cost of ownership, the valves that control the fluid and steam in and out of the heater have been adapted to cope with the high temperatures. There are two actuated ball valves being used – one to control water flow into the header tank and another to drain the flash steam generator of any residual fluid; this has an extension piece to keep the heat transfer to a minimum to protect the actuator which inherently has a lower temperature protection rating than an angle seat valve. The lack of a conventionally heated pressure vessel boiler in the machine is a crucial aspect in the reduced

maintenance cost calculations, as they are subject to comprehensive legal service and inspection procedures. The physical cost of these checks amounts to over £1,000 on a bi-annual basis, plus the cost of two days of operational downtime. Experience also shows that immersed elements either in chamber or when fitted to conventional electrically heated steam boilers are prone to failure with typical costs associated with replacement at well over £1,000.

Bürkert Type 2000 angle seat steam exhaust valve

The flash steam generator in the LAB300 is used to create steam ondemand. This is far more efficient than a more conventional pressure vessel boiler arrangement that heats a volume of water to produce steam and then maintains it throughout the day, constantly using energy to battle insulation losses. The ESTS exclusive design employs ceramic heating elements cast into a solid aluminium heater matrix. The unit attains operational temperature in a matter of seconds and converts water into steam on an on-demand basis, rather than maintaining a pressure vessel reservoir. An average usage cycle consumes just 10kWh which ESTS estimates will provide a 50% reduction in energy costs.

Issue 14 PECM


Colin Hartop, one the team responsible for the design of the Logiclave™ comments, ‘If you combine the cost reduction in servicing with the reduced energy costs and reduced downtime - just in terms of scheduled maintenance - there is a huge potential saving in the total cost of ownership between a Logiclave™ and a conventional autoclave of similar capacity. Our estimates put it conservatively at around £60,000 over a typical 10 year operating life. ‘The Logiclave™ also reaches operating temperatures considerably quicker than a conventional autoclave, which has to heat an entire vessel full of fluid before it produces steam. You then have to leave it on, which is inefficient, or keep starting it up again which increases costs and extends cycle times considerably.’ ‘We are only able to deliver these figures because we use quality valve products from a supplier that can be flexible about our needs, which is why we chose Control Stream as our preferred supplier and we standardised on Burkert valves. The precision of operation is critical to achieving total life cost savings with this machine so performance is equally as important as durability.’ www.autoclave.uk.com

Ball Valve and actuator controlling water into autoclave

Colin Hartop sets ESTS Logiclave300L autoclave


PECM Issue 14

Editors Choice

Advanced CNC Machine Monitoring with CNC Applications CNC Applications provide professional services and products to CNC machine tool users. These include CNC Training, CADCAM software and shop floor CNC data collection systems. Based in Warwickshire the company was founded in 2012 by Ben Groves after his many years working in the industry for companies such as the Engineering Technology Group and Fanuc GE. The company has grown and gained a reputation for delivering a professional service and implementing solutions to help manufactures drive efficiency and cut costs. CNC Applications flagship product is a CNC Machine Monitoring system called FactoryWiz. Working alongside our clients we are helping them identify untapped production capacity in their CNC machines. Increasing our customer’s productivity by just 5%, which is normally very achievable, the return on investment is enormous; pay back can be as little as just 2 months!

x x x x x

We have customers who tell us the system paid for itself during their trial. We have another customer who is saving £3m a year in one cell alone! FactoryWiz Monitoring is a powerful, modern CNC Machine Tool monitoring and data collection package that allows you to see your whole factory on one screen (PC / Tablet / Smart Phone), in real time and live interactive graphs showing OEE, Part Quality, Performance and Utilisation. Look back at past events and performance with Historical PDF reporting (automatically emailed to you). For more information call Ben Groves on 0121 2883366 or go to www.cncapplications.co.uk

FactoryWiz Monitoring allows you to see your whole factory on one screen, Live. • Live interactive graphs showing OEE, Part Quality, Performance and Utilisation. • Interactive Timeline of events. • Historical reporting (automatically emailed to you). • Access data using web browser (PC / Tablet / Smart phone). • Emailed notifications. In-depth real time information: • Machine Status (Running / Feed Hold / Idle / Alarm / Setup) • Part ID / Active NC Program • Part Count • Feed / Rapid / Spindle Overrides • Tool Number • Alarm Number and Text • Live OEE

x For more information call us on 0121 2883366 or join us at www.cncapplications.co.uk x Issue 14 PECM 7 x

Specialist in sensors and transmitters F

or over 25 years OMNI Sensors and Transmitters Ltd has acted as UK Distributor for the Austrian manufacturer E+E Elektronik GmbH. E+E has developed and produced sensors and transmitters for the measurement of relative humidity, moisture in oil, dewpoint, air velocity, CO2, flow and temperature. Dataloggers, hand-held transmitters and calibrators complete the comprehensive product portfolio of the Austrian sensor specialist. Over 95% of E+E products are exported around the globe, with their main applications in industrial measurement technology, heating, ventilation and air conditioning technology and in the automobile sector. Specific examples include drying systems, process controls, building air conditioning systems, climate controls for traffic infrastructure and vehicles, engine management and agricultural processes. Above average measurement accuracy, outstanding long-term stability and the highest possible manufacturing quality are the

Over 95% of E+E products are exported around the globe, with their main applications in industrial measurement technology, heating, ventilation and air conditioning technology and in the automobile sector.

key features of all E+E devices. With a turnover of around 35 million Euros, E+E Elektronik employs over 250 people. Current production innovations With the EE160 transmitter, E+E Elektronik offers the ideal solution for precise and cost-effective measurement of relative air humidity and temperature in the HVAC sector. The housing with protection rating IP65 offers maximum protection against contamination and condensation. EE160 transmitters are available in wall-mounted or duct-mounted designs and with current, voltage, BACnet or Modbus RTU outputs. Typical applications include building air conditioning and ventilation control, or humidity and temperature monitoring in storage rooms. Thermal flowmeters from E+E Elektronik record the mass flow of compressed air and industrial gases, independently of pressure and temperature. Different versions (EE771, EE772, EE776) permit the use for pipe diameters from DN15

The housing with protection rating IP65 offers maximum protection against contamination and condensation.

to DN700 and an operating pressure of up to 40 bar. Simple and rapid mounting - with replaceable valves with no power interruptions at all necessary - facilitates installation into existing systems as well. For example, consumption of compressed air, nitrogen, helium, CO2 or oxygen can be measured. EE871 Probe for CO2. is designed for use in harsh, demanding OEM applications. A multiple point CO2 and temperature adjustment procedure leads to excellent CO2 measurement accuracy over the entire temperature working range, ideal for use in agriculture or outdoors for instance. EE871 incorporates the dual wavelength NDIR CO2 sensor, which compensates for ageing effects. The measured data range of up to 10000ppm is available on Modbus or E2 digital interface. For further information Omni Sensors and Transmitters Ltd 01926 614263 www.sensorsandtransmitters.com sales@sensorsandtransmitters.com

Omni Sensors and Transmitters Ltd is pleased to announce the EE300EX transmitter – for the Safe measurement of humidity and temperature in areas of explosion hazard. The new EE300Ex humidity / temperature transmitter manufactured by E+E Elektronik has been specially developed for challenging industrial applications. The device conforms to the ATEX Directives for intrinsically safe equipment, and can be used in both gas and dust explosion hazard areas.

Ingenious: The separation of the connection area and measurement unit, the EE300Ex can be installed quickly and easily.

With an easy-to-clean, elegant stainless steel housing, the humidity¬ transmitter is ideal for use in the pharmaceutical and chemicals industry. The EE300Ex can be mounted directly in the explosion hazard area of zones 0 / 20. The tried and trusted E+E humidity probe provides long-term stability as well as precise and reliable measurements in the 0…100% rel. hum. and -40…180°C and from 0.01…300bar under pressure. The 2-part housing concept (separation of the connection area and measurement unit) simplifies more than the installation of the humidity transmitter. It also permits the rapid replacement of the measurement unit - such as for calibration - without time-consuming re-cabling. The EE300Ex offers a high level of flexibility thanks to various versions. As a compact version for wall mounting or with an up to 10m remote measurement sensing probe, the humidity transmitter is ideal for a wide range of applications. The current values can be read off the device directly using the optional display.

Safe: The EE300Ex humidity/ temperature transmitter can be mounted directly in explosion hazard areas.

Just as with humidity measurement in air, the EE300Ex can also be used for moisture measurement in oils. The humidity content of an oil can be issued as absolute in [ppm] or relative as water content [aw]. Typical applications are found in systems for cleaning/drying oil or on oil platforms for online monitoring of lubrication and gear oils. The EE300Ex is designed using 2-conductor technology. The measured values are issued on 2 analogue outputs with 4…20mA. The power can be supplied via any intrinsically safe power supply device. In addition to the measured values for humidity and temperature, the dewpoint, frost point, absolute humidity, mixing ratio and other computational functions can also be issued. The configuration adapter can be used to carry out custom modifications of the transmitter and to adjust the humidity and temperature outputs quickly and easily.

Flexible: Thanks to various versions the EE300Ex offers a high level of flexibility.

In addition to the applications given above, the EE300Ex is ideal for use in power stations, grain mills or explosion hazard storage rooms.

sales@sensorsandtransmitters.com 01926 614263offer Issue 14 PECM


Editors Choice Benefit from improved efficiencies in process applications with HBM training

HBM paces ahead with its new compact force transducer

Following on from a successful series of training and workshops, HBM – a market leader in the field of test and measurement – has announced the dates for its next training course, which will take place on the 21-22nd May 2015.

As precise measurements of especially small forces in a given measuring environment often place high requirements on force transducers, HBM - a market leader in the field of test and measurement - has responded to these demands by developing the new CFT-25kN force transducer with a nominal force of 25kN.

Suitable for all personnel working in a field where fast weighing and high accuracy is demanded, ‘Fundamentals of dynamic weighing and strain gauge load cells’ is a two day seminar designed to improve efficiencies in your process application. Located at the Woodland Grange Conference Centre, Warwickshire and presented by Dr. Henrik Brutlach, this HBM seminar is aimed specifically at technical orientated users, technicians and engineers from the field of mechanical engineering or similar, especially users of strain gauge based load cells in dynamic weighing processes. All seminar materials required for the course are included.

Featuring a compact design, without compromising on accuracy, the new CFT-25kN is only 3% the size of other transducers on the market using similar sensors, which is particularly suitable for use when space is constrained. Manufactured to the highest quality using Gallium Phosphate, the CFT-25kN produces twice as high an output signal for the same measurement load in comparison to Quartz, which is the standard material on the market. This makes it possible to measure extremely small forces reliably.

To register or for further information on this training course, contact HBM United Kingdom Ltd on 0208 515 6000 or via email: info@uk.hbm.com or visit the HBM website at www.hbm.com/en/menu/seminars/seminar-calendar/

For further product information and the complete technical documentation available for download visit www.hbm.com/paceline. Alternatively please contact HBM United Kingdom Ltd on 0208 515 6000 or via email: info@uk.hbm.com

Vortec’s Hazardous Location Enclosure Coolers Receive ATEX Certification

Terex cements relationship with CEMEX

Industrial facilities with hazardous locations, which require ATEX Certification, gained new safe cooling options as Vortec’s line of Hazardous Location Enclosure Coolers received official ATEX Certification. “The ATEX Certification means that industrial facilities can now save thousands of dollars while cooling electrical, electronic and control system enclosures in ATEX Zones 2 and 22. Previously, industrial facility managers had to spend thousands of dollars to modify traditional Freon air conditioning units for hazardous locations or purchase expensive ATEX Certified air conditioners,” said Vortec Engineering Manager Steve Broerman.

Terex Material Handling’s Demag Service team has completed a major refurbishment and upgrade of a Demag crane system at the CEMEX cement production facility in Rugby. The plant is CEMEX’s largest UK operation, working 24/7 and outputting over 5,000 t of cement per day.

The newly ATEX Certified ATEX Vortex A/C models 7415, 7425, 7435 and 7470 draw on Vortec’s fifty plus years of air technology expertise and in-depth knowledge of industrial needs to fill the need for safe enclosure cooling in hazardous locations. These Vortec models offer 900, 1500, 2500 or 5,000 BTU/hour cooling capacity to suit the differing needs of each facility.

CEMEX’s Operations & Technology team recognised that heat and dust in the arduous working environment had been causing system faults. In addition, some of the crane system’s components, including the Siemens S5 PLC, were no longer supported by manufacturers. The Demag crane’s existing controller was updated with a state-ofthe-art Siemens’ S7 PLC, facilitating fully automatic control via an interface with the CEMEX master control room. The refurbishment programme also transferred the control systems to a bespoke 8 x 2 m cabin, which had been prefabricated in Germany and delivered to site as a plug-and-go package. The air conditioned cabin has an air seal, minimising the ingress of dust, to protect against damage to the control equipment. The cabin, which is located near the roof of the store also improves safety as technicians are no longer required to operate the system from the crane bridge.

Email: sales@vortec.com

Email: bnb-help@terex.com


Royal HaskoningDHV recognised for asset management expertise with ISO55001 certification Lloyd’s Register has recognised Royal HaskoningDHV for its approach to asset management at Chemelot Industrial Park making them one of the world’s first engineering consultancies to receive ISO55001 certification. ISO55001 is the new international standard for asset management. The standard supersedes PAS55 and goes a step further by incorporating the financial impact of asset management decisions. Royal HaskoningDHV’s innovative managing agent role separates the owner, manager and service provider roles associated with asset management, resulting in greater transparency, fewer conflict of interest situations, and higher service levels. For more information on Royal HaskoningDHV’s approach to asset management, visit royalhaskoningdhv-tailoredassetoptimisation.com

Aluminium Shapes celebrates thirty years extruding in steel town, Corby Aluminium Shapes www.alishapes.co.uk, one of only two UK owned aluminium extrusion companies, is marking 30 years in business with a raft of new business wins and investment in growth. Extruding over 5 million metres of aluminium a year from it’s base in ‘steel town’ Corby, key markets include retail, medical, building automotive and hi tech enclosures. The company specialises in making the impossible possible in extrusion terms, and has produced sections for bomb resistant window systems, tile trim, child safety rails, super fast hard drives, lighting surrounds and domestic appliances amongst many other end uses. Building a name for itself in the UK and Europe for the rapid turnaround of new tooling and samples with the added benefit of in house cutting edge CNC , Aluminium Shapes produces sections from as low as 28g up to 6kg per metre. Aluminium Shapes will be exhibiting at LuxLive http://www.luxlive.co.uk/ 18-19 November, 2015 at London’s ExCel.


PECM Issue 14


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

Quality products and excellent service,

Strong performance. We provide a full range of rugged & reliable measurement sensors, instrumentation, pumps, drive couplings and hydraulic components to suit the needs of even the most demanding of industrial applications.

Derbyshire and Sons are a family run, precision engineering company known nationally for quality service at competitive prices. Trading for over 35 years, Our commitment to premium quality & service is demonstrated by our full ISO9001 accreditation.

qFlow metering and Instrumentation qGear & Piston Pumps qMagnetic Couplings qHydraulic System Components qProcess Measurement Sensors

In addition to general precision machining, our areas of expertise include the production of flanges, screwed stainless steel pipe fittings, block tees for the Petrochemical / Turbine & Automobile Industries as well as one off bespoke work to your own requirements. Our services are extensive and include:Turning – Conventional methods and also CNC Turning up to 6ft in Diameter. Advanced CNC turning - 5 Axis including power tooling; specialising in exotics metals. Boring, Milling & Drilling – Conventional and CNC. Boring up to 1 Ton. Tel:- 0151 423 1478 Or email sales@derbyshiresengineering.co.uk for more information. Or why not visit our website:www.derbyshiresengineering.co.uk

Specialist suppliers to Large Industry

UK Flowtechnik

Contact us today on 0800 433 4770 or Email: sales@ukflowtechnik.com Discover more at www.ukflowtechnik.com Issue 14 PECM


Unmanned aerial vehicle surveys will need the best in big data management PHOTO


Today’s UAVs are small, simple and cheap to operate, and can carry multiple types of surveying equipment. They allow survey data to be collected in a continuous stream throughout the flight and instantly uploaded to a server for immediate analysis.

battlefield monitoring, filming, crowd control, traffic management, assessing the condition of buildings, metrological forecasting, geological surveys, flood management, etc. The big data solutions developed for agriculture will transfer directly into these fields.


nmanned aerial vehicles (UAVs) are making surveying of landscapes, buildings, etc. so much easier and more cost-effective that it is inevitable that there will be an explosion in this activity. This will create massive amounts of data that will need to be managed and stored efficiently, as Steinar Sande, CEO of Raima, a leading provider of high-performance, always-on database management systems, explores. The vast North American prairies have been producing grain crops in global volumes for many decades. They helped feed America and Canada as they grew, and generate large amounts of foreign revenues from the export markets. From the 1960s onward, aerial and even satellite photography of the fields have helped drive efficiency into planting, irrigation and harvesting. However, such surveys were difficult and expensive to execute and the results were often crude. Not surprisingly then, the advent of the modern UAV has moved agricultural surveying onto an entirely new plane. Today’s UAVs are small, simple and cheap to operate, and can carry multiple types of surveying equipment. They allow survey data to be collected in a continuous stream throughout the flight and instantly uploaded to a server for immediate analysis. Where previously aerial surveys were occasional and crude, now they can be


PECM Issue 14

frequent and detailed! Farmers are now talking about moving into an era of ‘precision agriculture’, which luckily ties in with economists’ predictions that worldwide population growth over the next two generations will mean that food production will have to at least double. UAV surveys will play an important role in ensuring the necessary increase in productivity. As well as conventional cameras, the survey UAVs can carry specialist equipment such as ultraviolet, infrared and thermal imaging cameras, hyperspectral sensors and lidar scanners. (Hyperspectral sensors provide ‘big picture’ or wide-view information to typically 10mm resolution. Lidar is a cross between lasers and radar which automatically focuses on planted areas and scans them with up to 500,000 laser pulses per second to collect ultra-high resolution data.) These data streams will have to be accurately married with GPS (global positioning systems) and other information for complete analysis. It is inevitable that farmers will want their surveys to provide instant information, so the survey data will have to upload instantly to the cloud, be processed, then downloaded - to both mobile devices in the field and to a central computer in the farm office. Transferable technology Many other industries are also adopting UAVs for security surveillance,

Much of the hardware necessary for this sort of blanket surveying is already available at near-commodity prices. But for precision agriculture and other professional uses, data quality and post-processing are critical, and this is a specialist role for dedicated data services providers. With its RDM (Raima Database Manager) embedded data management technology, Raima already has a proven track record in big data applications across many industries. Its solutions offer specialised capabilities that enable intuitive management and manipulation of real-time information. RDM is optimised for embedded, real-time, in memory and mobile applications, delivering flexible and reliable solutions for collecting and storing large volumes of data. It provides intuitive and efficient methods for managing and navigating through information quickly. The product has a highly modular structure, so that only the components that you really need are included in your embedded application. As well as multiple APIs, RDM includes developer tools to help you manage databases on an embedded platform, and these tools can also be built into your application if desired. There is no doubt that in future, data – and the information and knowledge that can be drawn from that data – will be one of the greatest assets available to farmers. Raima’s RDM data management technology offers agriculture the tools needed to achieve greater productivity and to be better able to react to changing market requirements.

Editors Choice

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

Pera Technology is one of Europe’s leading new product development (NPD) contractors We support businesses of all sizes in creating innovative new products that enable you to build a competitive advantage. We bring innovation to life by bringing hardwon, real-world industry experience to your own market knowledge. When it comes to understanding and sourcing funding from National and European funding bodies, Pera Technology has proved itself to be one of Europe’s most successful intermediaries.

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.

We work with you to: conceive ideas create prototypes commercialise products Find out how Pera Technology can help you, call +44 (0)1664 501201 or email enquiries@peratechnology.com

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.

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

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 14 PECM


Editors Choice

IChemE safety publications T

he Institution of Chemical Engineers (IChemE) offers a range of safety publications relevant to the engineering and process industries. Loss Prevention Bulletin (LPB) Our Loss Prevention Bulletin is the leading source of case studies in process safety in the industry and has an archive spanning over 40 years of lessons learnt from accidents. It was first published in response to the disastrous explosion at Flixborough in 1974 when a need was established for the process industries to be able to share information on accidents in the hope that a lesson shared is a lesson learnt. LPB is offered on an individual subscription basis, or as a site licence allowing multiple users at one

organisation to have access to this vital resource. Visit www.icheme.org/lpb for more information. Safety books

We offer a wealth of safety books. We have just launched a new edition of one of our best selling books, HAZOP Guide to Best Practice, Third edition. The new edition brings additional experience to help you deliver optimum safety and efficiency of performance. www.icheme.org/hazopguide We also market the BP Process Safety Series which is a collection of 17 books produced by us, in collaboration with BP. It demonstrates both organisations’ ongoing commitment to process safety and best practice through the dissemination of lessons learnt from recurring accidents. It is intended

to help the reader understand safe operating practices and procedures within processing plants. Now available electronically, the series comprises titles such as Hazards of Water, Hazards of Electricity, Confined Space Entry, Safe Furnace and Boiler Firing, and many more. For the full list visit our online shop. The series is available to buy individually, as a full set, or as a company-wide annual licence. For the full collection of our safety books visit www.icheme.org/shop For enquiries contact sales@icheme.org

Loss Prevention Bulletin dies in process The leading source of case stu ar archive of lessons safety with access to a 40 ye aluable resource for learnt from accidents. An inv ety. anybody concerned with saf Company wide licences available to this valuable resource

www.icheme.org/lpb sales@icheme.org 0951_14


PECM Issue 14


Editors Choice

RUD Chains Ltd Offshore Lifting Capabilities up to 200 tonne RUD Chains Ltd, part of the RUD Group, is one of the world’s largest manufacturers of round steel chains, producing top quality chain components and systems for over 140 years.


manufactures a range of lifting and lashing applications that guarantee ultimate safety when lifting and moving heavy loads. Offering over 500 different tested and certified lifting/lashing points for bolting and welding. Their products have been increasing popular across the offshore industry, due to their heavy lift capabilities of up to 200 tonne, and their robust resistance to corrosion. The WBPG 85-200 tonne hoist ring, is one of RUD’s most popular offshore products at the moment, perfect for many heavy engineering, construction and offshore projects. RUD are known in the industry as a worldwide manufacturer and supplier for a range of hoist chains used across

the offshore industry. RUD hoist chain can be supplied to suit a variety of project sizes from 3 x 9 mm up to 32 x 90 mm. TECDOS, RUD’s conveyor and drive systems, have been setting high standards across the offshore industry due to their distinctive product features. RUD’s highly wear resistant round steel chains that are used in the applications are extremely robust, offers three-dimensional mobility and has an exceptionally high resistance to corrosion due to the vigorous surface coating that is applied to the chain. The TECDOS application can be used across a wide range of maritime projects which involve the use of round steel chain drives. So far TECDOS

has been used to assist opening and closing of flood gates, lifting and lowering containers, moving and swivelling port cranes, launching lifeboats to telescoping crane booms to name a few. RUD Chains offer a wide selection of applications to the offshore sector, providing lifting capabilities from 50 – 200 tonnes, operational to temperatures as low as -45 degrees and much more. RUD Chains Ltd: for all your offshore lifting needs. For more information call 01227 276 611, Email: Katie.crane@rud.co.uk or visit us at www.rud.co.uk

Issue 14 PECM


News & Events Revware, Inc. 3D Modeling, morphological data collection, motion tracking, and guided surgery are easy with Revware’s MicroScribe® 3D digitizers. These ultra-portable measuring machines are available worldwide. Features: • Truly portable (≤ 13 lbs.) • One hand operation • Work sphere diameter up to 66 inches • Collects accurate single point and RPY data, point clouds with laser attachment. • Achieves stated accuracy of up to 0.002 inches without requiring special measuring environment (perfect for work in the field)

Hart launches new Speedor variant Hart Door Systems, the creator of the Speedor high-speed industrial door brand now found on over 6,000 sites across some 20 countries, has launched Speedor Storm which incorporates a unique guide system which delivers exceptional wind resistance up to Class 5, over 90 mph.

Applications: • Reverse engineering for model creation and 3D printing (STL file generation) • Guided surgery, industrial motion tracking, robot teaching • Inbound part inspection • Morphological data collection • Vocational training, basic research

Nick Hart, Hart’s technical director, says the door has been designed for specific applications where large external openings up to 8m, x 8m are vulnerable to wind. “Class 5 matches 12 on the Beaufort Windscale, the highest rating. Two Speedor Storms have been operational in an exposed site in Aberdeen for the last 12 months. This amounted to rigorous testing in a difficult and challenging environment without an issues arising. We achieve this with a reliable and clean in-line drive system complete with integral safety brake. It has variable speed operation and an optional break-away bottom rail with auto reset feature,” explains Mr. Hart.

Contact Information: CJ Meese cj.meese@revware.net www.revware.com

Freephone: 0800 783 0404

Demag V-type crane wins iF Design Award

Reassuring badge

The Demag V-type crane has won the internationally renowned iF (International Forum) Design Award for its outstanding design. The award recognises the innovative construction of the V-type crane girder, which is based on bionic principles. In a similar way to bone structure, the design only uses material where it is necessary. Depending on requirements, the new girder design can be adapted with millimetre accuracy to the height of existing or planned buildings. This versatility facilitates simple implementation in existing production bays and greater freedom for planning new buildings. The distinguished judging panel, comprising members from 20 countries, recognised the crane in the Industry/Skilled Trades’ category. “The award demonstrates that our new Demag V-type crane design truly represents a revolution in the market and that industrial cranes can also achieve new levels of design excellence”, explains Andreas Hambrock, Head of the Universal Cranes business line at Terex Material Handling. “At the same time, the optimised crane girder design makes it more precise, lighter and more durable than other universal cranes.”

Email: bnb-help@terex.com


Automotive sector demand growing for innovative EMI shielding solutions Although EMI and thermal issues have been prevalent in the military and aerospace sectors for many years, the rapid development and evolution of both automotive electronics and vehicle electric drive systems means that Chomerics is witnessing increasing numbers of automotive industry customers seeking innovative solutions to these problems. To discover the underlying reason for this trend, look no further than the increasingly high proliferation of electronic devices in vehicles, which has resulted in greater power consumption and power density. With this in mind, Chomerics can now offer a host of different solutions for common automotive applications that take into account variables such as the fluids, vibration and temperature cycling to which a specific EMI gasket may be subjected. For example, an EMI gasket for use in the passenger cabin may not be suitable for the engine compartment, where elevated temperatures come into play.



JSP says that the distinctive ‘shield’ shape on the front of its industrial safety helmets provides reassurance that they are the genuine article. The shape has evolved over the last 40 years for the purpose of clearly distinguishing the helmet from others in the marketplace. According to JSP, it provides an assurance of quality and durability for procurers, site managers and users. JSP notes that the shield badge of identity has become more important in recent years owing to the increasing proliferation of cheap, illegal, counterfeit helmets in international circulation that do not meet the requirements of British and European Standard EN397. Because each helmet is unique, wearers can use JSP’s online tracing and verification system at www.jspcheck.com to validate the DNA of their helmets by using the individual barcode, which allows it to be tracked.

Tel: 01993 826050


3 Steps to Success The Pristine Approach Musculoskeletal Disorders (MSDs) remain one of the most frequent types of workrelated injury across most industry sectors. Yet, despite efforts to reduce this through legislation and better risk management, it can rarely be eliminated. Even when the risk is significantly reduced, if an item has to be moved manually, a residual risk remains. So why are MSDs still so prevalent? Quite simply, conventional methods of addressing that residual risk aren’t effective. Pristine Condition Ltd has enjoyed unprecedented success at bucking that trend, showing clients how to reduce manual handling injuries and then sustain those results, by addressing the key causes of initiative failure. “Reducing handling injuries is quite simply about changing people’s habits; exchanging a bad one for a good one, which itself has three drivers: • Individuals’ buy-in to the change • Monitoring take-up of the change • Management support to maintain the change The harsh reality is that initiatives fail when any of those three is deficient. For more information on why Pristine Conditions approach has been so successful, visit: www.pristinecondition.com or call Pristine Condition Ltd on +44 (0)1491 414464

AUMA ACE Scheme Drives up the Standard AUMA UK Ltd is introducing the ACE (AUMA Certified Engineering) Technician Certification Scheme to drive up the standards of actuator installation and maintenance within the controls industry. Split into three levels, the training and accreditation programme is targeted at actuator technicians working for both customers and independent controls contractors. The AUMA programme is set at three levels: ACE Technician Level 1 aimed at in-house technicians. ACE Technician Level 2 suitable for on-site installation and service activities and ACE Technician Level 3 which provides the highest level of qualification for those involved in communications protocols and systems integration. Accreditation cards are provided to each qualifying technician so customers can check that personnel are suitably qualified to work on their sites, be safe in the knowledge that relevant tests have been passed and be assured that 12 month refresher training has been completed. For full details of the ACE Certified Technician scheme contact Kerry Harris on 01275 871141 or e-mail kerry.harris@auma.co.uk

Email: mail@auma.co.uk


PECM Issue 14


Lamba Welding Systems is a family-run business with 40 years’ experience in the resistance welding field. We encompass the whole field of resistance welding machinery from bespoke design and build of full lines from grating, temporary fence, mesh, down to precision micro welders for the butt welding of wire. This also includes servicing and repairing standard machines. We strive to provide the best service at a competitive price and maintain stock to ensure minimum downtime. We also have a fully comprehensive tool room to manufacture any bespoke resistance welding components to your specification. Please call 01748 850292 or visit www.lambaweld.co.uk for more information.

News & Events

12 – 14 MA#    



www.railtex.co.uk Supported by:

Register now for your free visit to the UK’s premier rail event Railtex 2015, the UK’s showcase for railway technology, products and systems, will soon be opening its doors, so now is the ideal time to register for your free visit via the show website www.railtex.co.uk

Media Partners:

day will feature a keynote speech from a leading rail industry figure, while a busy programme of industry seminars, updates on major UK rail projects and open discussion forums running throughout the show in the exhibition hall will all be open to everyone. Entry to the event is free for preregistered visitors. Registering ahead of the show avoids payment of a ÂŁ20 entry fee on the door and speeds up access to the exhibition. The website also features full details of all events and activities taking place during Railtex, a complete list of exhibitors, plus a link to the Official Show Preview to help you plan your visit.


ailtex takes place at the National Exhibition Centre in Birmingham from 12 to 14 May. More than 450 companies will be taking part, making this the biggest of these popular exhibitions in over a decade – and an event not to be missed by anyone involved in managing, maintaining or equipping main line or urban rail networks. Busy supporting programme As well as showcasing the latest equipment and services, Railtex offers plenty of opportunities to gain valuable insights into trends in rail industry technology and policy. Each Issue 14 PECM


News & Events New year, new acquisition for waste management group

Mixing Downtime outpaced by Chemineer’s new Express service

Independent waste management company Cleansing Service Group (CSG) A Willacy processing system located in a has confirmed it has acquired part of the refinery tank farm business and assets of Tradebe Refinery Services (TRS) based at Sandycroft, North Wales, and formerly known as Willacy Oil Services.

Chemineer, a leading manufacturer of mixers and agitators for the water and wastewater industries, has launched a new Express Service that is designed to offer customers immediate help in achieving operational performance goals for agitation and mixing processes.

Willacy is a specialist in petrochemical tank cleaning and oily sludge treatment and recovery systems. CSG says it has now acquired the one-acre site and is currently looking at re-establishing the business. CSG managing director Neil Richards said the company will also retain its former Willacy Oil Services trading name.

Bringing a skilled team of field service engineers to help install, maintain, repair and troubleshoot any on-site needs, Chemineer Express will provide a fast turnaround for replacement parts and services. It also includes the carrying out of reliability audits and operator training.

“Willacy have worked on refineries in the UK and around the world and the name is well recognised in the oil industry,” he said.

Irfan Rehman, Chemineer’s Sales Manager, explains: “This timely launch of Chemineer Express will enable us to help our customers optimise their mixing processes and minimise downtime”.

Tel: 0800 048 0622 www.csg.co.uk

Tel: 01332 363 175 Email: chemineeruk@nov.com www.chemineer.com

Email: technicalsales@csg.co.uk

Portwest stylish, comfortable, highquality workwear

Recycled PVC that is 100% water and moisture proof

Portwest is a leading manufacturer of fire resistant & high visibility garments, workwear, safety footwear, work gloves & PPE. Portwest’s market leading range includes FR brands; Bizweld, Bizflame, High Visibility brands; Sealtex and Vest-Port and Steelite footwear.

New from the leading multi metal and plastics distributor Blackburns Metals & Plastics, is Sealwise WCB. A high-quality construction board made from recycled PVC that is 100% water and moisture proof.

All products are manufactured by Portwest, are CE certified in the UK and tested to the highest International standards. Portwest’s product ranges offer an extensive choice of colours, small and big sizes including regular and tall fittings. All products are available from the best UK & Irish safety and industrial distributors. Portwest’s 15,000 m2 UK warehouse guarantees high volume stock levels at all times.


NOF Energy is actively engaging with operators and contractors Overcoming the production and cost challenges of the oil & gas sector will be achieved through smarter technologies and efficiencies delivered by the industry’s supply chain. Through its unique position in the energy sector, business development organisation NOF Energy is actively engaging with operators and contractors to highlight the strengths of a smarter supply chain. Through its online Supply Chain directory at www.nofenergy.co.uk/directory and calendar of industry briefings and networking events, NOF Energy is facilitating new relationships between supply chain companies and the industry to support the use of disruptive technologies and cost efficiencies that meet industry objectives. For more information about NOF Energy contact Paul Livingstone, Business Development Manager +44(0)191 3846464 or email plivingstone@nofenergy.co.uk

The Energy Savings Opportunity Scheme (ESOS) and Pump System Audits The Energy Savings Opportunity Scheme (ESOS) Regulations 2014 came into force on 17 July 2014 and are a mandatory energy assessment and energy saving identification scheme for large undertakings (and their corporate groups). The scheme applies throughout the UK. ESOS Energy Audits have the potential to increase businesses profitability and competitiveness by identifying costeffective savings which, if implemented, will improve energy efficiency. The scheme is estimated to lead to £1.6bn net benefits to the UK, with the majority of these being directly felt by businesses as a result of energy savings.

SEALWISE WCB is a revolutionary, sustainable material that brings innovative qualities including unrivalled peace of mind in the fight against infection and contamination across a wide range of industries. SEALWISE WCB is perfect for hardworking environments and is superior to stainless steel, aluminium composites, laminates, MDF, wood, expensive thermoset resins and cheaper low-quality products. For further information, please contact Blackburn Metals & Plastics at www.blackburmsmetals.com

albin pump ALBIN PUMP is one of the largest manufacturers of hose and peristaltic pumps. Albin Pump designs, manufactures and markets peristaltic hose pumps and air operated floating diaphragm pumps. Our pumps offer the highest level of efficiency and innovative solutions for today’s industry. We offer a complete range of high and low pressure hose pumps with flows from 0-150 m3/h. The advantages of the Albin hose pumps are an increase in lifetime and reduced service and maintenance due to effective and innovative design. We also offer a world patented air driven diaphragm pump which reduces air consumption with up to 50% compared to conventional AODD pumps and reduces pulsations with 70%. To add to this the pump can be installed in any position and provides exceptional lifetime to minimize maintenance.


Manipulation Impossible Valves play an important role when it comes to the safety of process equipment: Unauthorized access or accidental operation can quickly lead to catastrophic results. However, both these scenarios are easily prevented. AS-Schneider, the specialist in the field of industrial valves, provides a range of Anti-Tamper Valve Head Units to allow plant operators to reliably protect their valves against undesired operation.

The scheme’s regulations are published on the government’s legislation website http://www.legislation.gov.uk/uksi/2014/1643/contents/made

The Standard Design of the Anti-Tamper Valve Head Unit is equipped with a bore and matching AT-Key. The valve can only be operated using this special key. The operator can also lock the bore using a padlock in order to prevent the insertion of the AT-Key. This makes it impossible to operate the valve. It can be securely locked in any position – closed, partially open or fully open.

More information about the Energy Savings Opportunity Scheme can be found on the ESOS webpage https://www.gov.uk/energy-savings-opportunity-scheme-esos

Tel: Email: www.as-schneider.com

ESOS is the UK Government’s approach to transposition of Article 8(4) of the EU Energy Efficiency Directive, which requires all large (non-SME) enterprises to undertake energy audits by 5 December 2015 and every 4 years thereafter.


PECM Issue 14

News & Events

Our focus is on the supply of High Grade Carbon and Stainless Steel products with one of the most diverse stock ranges available anywhere in the world running from carbon manganese through to super duplex stainless steels. With Rolls Royce approved quality systems and a 1 hectare specialist proďŹ ling facility we are capable and able to meet any requirement. If excessive drilling or welding is required always consider the proďŹ ling alternative. Founded in 1889, we recently celebrated our 125th year in business and to mark the occasion we have created a timeline showcasing the history of our business.

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

We can accommodate the smallest GRP Production runs from 5 units right the way through to 40,000 plus units. We also offer quality GRP Moulds to improve and increase your production output, all with the expert level of production you would expect from our highly trained team.

Issue 14 PECM


Managing risk plays a key part in the strategy to decrease uncertainty and ensure project estimates track to project performance.

Flexible technology manages E&Cs through market storm By Steven Kratsis, Vice President, Engineering and Construction, EURA, AspenTech


ith the plunge in oil prices, big operators’ oil & gas capital spending is coming under increased scrutiny. Therefore, engineering and construction companies (E&Cs) have a greater need to be more flexible, remain profitable and manage their business through market turbulence. To survive and thrive, contractors need to innovate dynamically across all aspects of their operations and deliver highquality services in line with market forces. So, how can E&Cs weather market storms and address both operational and commercial needs? As the relationship between E&Cs and owner-operators changes, contract conditions need to be more closely aligned to the interests of both parties to ensure project scopes are clear and costs do not overrun. Also, when engineering expertise is tight, the workforce tends to be stretched to achieve more with less resource. Owner-operators consider standardised designs as one option to minimise costs. Therefore, partnering with the right technology vendors with flexible business models can make the difference between


PECM Issue 14

Technology should be seen as a competitive differentiator and not simply a cost of doing business.

lifecycle, while maintaining quality standards.

success and failure during these uncertain times. Simplification and effective execution The dynamics of the market reflect a paradigm shift as old plants are phased out in Europe and Asia, while new plants are built in the Middle East, China, Russia and the US Gulf Coast. This brings great opportunities for E&C companies.

E&Cs compete on a global basis bidding and executing on complex, large-scale projects.

Managing risk plays a key part in the strategy to decrease uncertainty and ensure project estimates track to project performance. Many E&Cs have limited resources. As projects unfold, companies need to do more with less to complete them on time. By improving the bid process, E&Cs can win

contracts with more accurate estimating and project execution performance. Project managers can reduce risk and uncertainty by tracking estimates against performance. By simplifying execution, global teams

Project managers can reduce risk and uncertainty by tracking estimates against performance. can contend with resource shortages. However, this can only be done by partnering with vendors who can reliably help throughout the project

Those E&Cs that can diversify their operations from the oil & gas sector to other markets, like chemicals and mining, will capitalise on delivering high-quality, reliable services to meet client objectives. With the optimism in emerging markets and the positive effect of technological advances, E&Cs see infrastructure development as pivotal to growth. Projects are diverse, ranging from transportation systems, including rail, road, air and shipping networks, through to design and supply of direct fired heaters, complex construction projects for chemicals and refining and project execution expertise to the minerals and metals sector. According to a recent study by PwC, “engineering and construction CEOs see technological advances as the top trend which will transform their business. Many called some aspect of technology the “next big thing” to impact their business, citing everything from new applications for formwork to techniques to better manage and utilise data. Most engineering and construction CEOs are optimistic about their ability to keep up--only 33% are concerned about the speed of technological change, compared to 47% overall”. Competitive differentiator E&Cs compete on a global basis bidding and executing on complex, large-scale projects. By having an integrated software environment, companies can produce optimal plant designs quickly and efficiently, incorporating highly accurate cost estimation technology. In addition, these projects require software that enables significant collaboration internally with the owneroperators. For engineers and project managers, having control over changes to specifications or projects is essential in mitigating risk. Engineering projects need to maintain maximum flexibility early in the project cycle. Issue 14 PECM


Technology should be seen as a competitive differentiator and not simply a cost of doing business. Advances in areas like process optimisation software help E&Cs broaden their global footprint and strengthen their competitiveness in high-growth, emerging markets. Many companies have adopted AspenTech’s aspenONE Engineering software suite to optimise process designs for energy use, capital and operating costs and product yield through the use of activated energy, economics and equipment design during the modelling process. aspenONE Engineering enables E&C companies to bid and perform projects with lower cost and company risk. In addition, partnering with AspenTech brings significant commercial benefits in the form of its business model. With aspenONE® Licensing Model, E&Cs have access to all products in the aspenONE® suite and can use software tools on a ‘check out check in’ basis and track the usage whilst adjusting when and where the software is used based on their changing business requirements. As business priorities evolve, this flexible software model transforms the way companies can conduct business, whether the software is installed on premises or in the cloud, customers have access to the full range of innovative software applications to meet project demands. For example, if an E&C is using Aspen HYSYS to produce engineering models for the oil & gas market, they can switch their tokens to adopt Aspen Plus to produce and optimise process models, including best-in-class physical properties, to support customers in the chemical industries. Common and intuitive user interface with the tools allow engineers to easily switch between applications. Embedded training in the software tools allows quicker learning and interaction to help speed up knowledge when engineering staff may be new to the company or unfamiliar with key project software technology. A leading European E&C recently demonstrated the principle dynamics of diversification by using

Engineering projects need to maintain maximum flexibility early in the project cycle.

AspenTech’s leading aspenONE suite to adapt and support its commercial needs. In 2012, when the oil price reached a high of $125 per barrel for Brent, the focus of engineering tools used was on hydrocarbons. Crude oil prices fell during the second quarter of 2012 as a result of lower oil demand and the global economic slowdown. By the end of 2014, Brent crude oil prices ended at around $58. Reflecting this trend, the large European E&C’s software usage shifted towards a more diverse range of tools to support other industries, including chemicals, metals and mining, heat exchanger engineering projects through to the use of more dynamic simulation software. This proved to be an enormous commercial advantage, using both the AspenTech License Model and the comprehensive software suite of tools to help mitigate risk and adapt to market fluctuations. Innovation and business growth The engineering design and construction industry is rapidly changing against a backdrop of fluctuating oil prices and intense competition. Today, the markets are open to global trade allowing capital investment, skills and technology to move freely across borders and increase business opportunities. Agility is essential to respond quickly to change and being flexible requires organisations to build long-term partnerships with technology vendors to meet demand and support customer needs. Crucially, with the right software tools E&Cs can successfully achieve competitive edge. The biggest capital project opportunities worldwide exist in the midstream and upstream, including gas production, oil production and gas processing. This requires better and more efficient ways of executing projects. As the market continues to show signs of turbulence, flexibility in the engineering of facilities is extremely important. Business is becoming more complex. If E&Cs are to weather the storm in the energy markets, access to a flexible and scalable software model helps E&Cs compete and survive while capitalising on growth opportunities in established and emerging markets alike.


PECM Issue 14

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.

UK AD & Biogas 2014 was the best show I’ve ever been to in the UK Jørgen Fink, Country Manager, Xergi

THE UK’S ONLY DEDICATED ANAEROBIC DIGESTION, BIOGAS AND BIORESOURCES TRADE SHOW Showcasing the latest AD technology and services, and attracting 3,000 visitors from key sectors including farming, food and drink, local authorities, waste management, transport, utilities and more, this is the event for anyone involved in AD.

WHAT’S ON OFFER? sTwo day high-level conference sponsored by s22 seminar sessions sponsored by sR&D Hub sOne-to-one advice clinics sBiomethane vehicle area featuring working examples of vehicles using biomethane technology sUK AD & Biogas Industry Awards 2015 sSite visit (30 June) to Severn Trent Green Power Coleshill providing attendees with an informative insight into a brand new and innovative working AD plant. Book your place now.

“An excellent exhibition with the leading companies involved in AD and biogas in the UK, and also abroad; a great opportunity to learn about the latest trends in the developing science and technology in this field.” Izabela Kasak, Works Technician Process Optimiser, Anglian Water Services

Register for free now at adbioresources.org EXHIBITION SPACE

There is now just 20% of stand space remaining, so make sure to book now to avoid disappointment.

WHY EXHIBIT? sPromote your business, technology and services sReach the most targeted audience directly interested in AD and biogas sEnjoy two full days of networking sShare information and best practice and debate key industry issues sGet a free listing on ADBA’s website and in the event guide If you are interested in exhibiting at UK AD & Biogas 2015 or would like more information, please contact Jamil (E jamil.ahad@adbioresources.org / T 020 3176 4414) or Rachel (E rachel.fenton@adbioresources.org / T 020 3176 5418). Organised by

Sponsored by:


will assess a plant’s individual requirement through analysis of its influent, biomass and effluent

OMEX Trace Element Additives for improved Biogas production and improved Plant

AD & Biogas Plant Operators can ensure their own systems perform to maximum capacity with the use of Nutromex TEA

performance A

s the Government pushes for more take up of Anaerobic Digesters to help achieve its 2020 carbon reduction targets, AD and Biogas Plant Operators can ensure their own systems perform to maximum capacity with the use of Nutromex TEA (Trace Elements Additives) from OMEX.

Many businesses, in particular farm businesses, are increasingly treating waste such as slurries and vegetable off-cuts through Anaerobic Digestion for the production of both biological fertilisers and constantly generated renewable energy in the form of Biogas, which can either be used on site to reduce reliance on costly fossil fuels, or sold as electricity under Government incentive schemes. However, it is rare for Anaerobic Digester Systems to have the complete range of nutritional elements

present for optimal bacterial growth. Shortages of specific micronutrients, which are critical components of enzyme systems in the bacteria, often occur. This can mean that the Digester does not run at full efficiency with a consequential loss of performance and output.

This can mean that the Digester does not run at full efficiency with a consequential loss of performance and output.


also supply a wide range of products to deal with other common issues which occur in the waste water and effluent treatment industry

Nutromex TEA is part of a range of safe-to-use bio available micronutrient supplements created to help plant operators get more from their investment in anaerobic digesters. Omex will assess a plant’s individual requirement through analysis of its influent, biomass and effluent before producing a tailor made micronutrient solution in a form which makes it fully available to the bacteria. As well as specialising in trace element additives, OMEX also supply a wide range of products to deal with other common issues which occur in the waste water and effluent treatment industry such as Sodium and Calcium Nitrate solutions for Odour and Septicity Control, Magnesium Hydroxide Solutions for pH control and solutions to combat filamentous bulking in Biological Wastewater Treatment Facilities. www.omex.com

The introduction of bioavailable micronutrients like Nutromex TEA into the anaerobic process boosts the availability of essential trace elements which can help to improve bacterial performance and increase the methane content of Biogas production – and in the process, increase profits for the plant operator. Issue 14 PECM


Air, Gas & Odour Control

Expert Laboratory services to the AD Industry

Burckhardt Compression is one of the worldwide market leaders in the field of reciprocating compressors and the only manufacturer that covers a complete range of reciprocating compressor technologies. Its customized compressor systems are used in the upstream oil & gas, gas transport and storage, refinery, petrochemical/chemical and industrial gas sectors. Burckhardt Compression’s leading technology, high-quality compressor components and the full range of services help customers to minimize life cycle costs of their reciprocating compressor systems around the world. Since 1844 its highly skilled workforce has crafted superior solutions and set the benchmark in the gas compression industry.

6 Process Optimisation Analysis

6 PAS110 Appointed Laboratory

6 24/48 Hour Turnaround on Key AD Process Parameters

6 Digestate and Soil Analysis for EA Deployment/ADQP


6 Feedstock Suitability Testing

6 Residual Biogas Potential Test

6 ABPR Pathogen Testing

6 Analysis of Trace Element Supplements

Airdri Quest™ and Quazar™ - inclusive washroom provision for process plants

6 Bio-Methane Potential Test

For more information please contact Sean Stevenson 01344 898467 sean.stevenson@nrm.uk.com

Duncan Rose 01344 898467 duncan.rose@nrm.uk.com

www.nrm.uk.com Divisions of Cawood Scientific


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

PAS110 Appointed Testing Laboratory

The Airdri Quest™ and Quazar™ are the latest models in Airdri’s Q range of hand dryers. These models uphold the inclusive qualities identifiable with all Airdri products – reliability, lifespan, design innovation, energy efficiency and low noise output ensuring that Airdri can provide a hand dryer to meet the needs of busy process plants. Designed to comply with the standards set out by both the Quiet Mark and the American Disability Act, the Airdri Quazar™ is an ultra-slim dryer with a stunning design. The stylish, wall-mounted hand dryer comes in a variety of cover finishes – black, white, chrome or brushed stainless steel. Its contemporary design will suit any modern washroom environment, whilst being perfect for facilities limited in space.

Email: sales@airdri.com


Helapet offer high performance filtration and protection for the process industry Gas filtration is an important part of the process industry for both the protection of equipment, and the filtration of samples for environmental monitoring. Helapet 0.2 micron hydrophobic filter devices provide these capabilities using a range of media and connections, allowing a universal fit for large range of applications. Our UK based disc technology provides an effective wide filtration area of 17.35 cm2 while maintaining optimum flow rates. Common applications include the prevention of water and vapour from penetrating through to the downstream side of the filter, thus protecting instruments and equipment from the intrusion of moisture. Using high performance 0.2 um PTFE hydrophobic filter membrane ensures that vessels can be aseptically vented. Helapet provide bespoke VariDisk® design service, including the printing of your own logo onto the device.

For information and free samples visit www.filterdevices.co.uk or email sales@helapet.co.uk


PECM Issue 14

Page Title

Air, Gas & Odour Control

SEEPEX BTEX PUMP FOR HEAVY DUTY BIOGAS APPLICATIONS Designed in response to the demands of the biogas market. The key advantages of the BTEX are: - Conveying capacities from 20 - 80m3/h - Large cross sections and robust components for extreme applications - Liquid addition and mixing within the auger and compression zone for optimum solids content - Foreign object separation via a specially adapted hopper design - Large inspection openings to remove collected foreign objects - Designed for easy maintenance For more information visit seepex.com or contact Lesley Eaton; leaton@seepex.co.uk

SEEPEX UK Ltd. 3 Armtech Row Houndstone Business Park Yeovil, Somerset BA22 8RW

T +44 1935 472376 sales@seepex.co.uk www.seepex.com

SEEPEX to show new addition to their pump ranges at ADBA 2015 S

EEPEX have launched a new addition to their open hopper range of progressive cavity pumps – the BTEX pump for conveying and mixing biogas feedstock. The new design is a response to demand from our customers whose feedstock can contain foreign objects such as stones, pieces of metal or wood. In a BTEX pump these objects are separated out in the hopper/compression zone and can be removed via the large inspection hatches. The pump auger screw has a special pitch to ensure optimum product feed and mixing action. Liquids can be

added to this product feed if needed via flanged inlets in the pump hopper and compression zone. A full liquid addition, mixing and control system is available, encompassing a BTEX pump for high solids, a BN range pump for liquid addition, and a control panel to control the addition rates of the liquid to ensure optimum ds% is achieved. Level controls, dry running protection and pressure monitoring complete the pump protection system.

Also on show at ADBA will be our proven innovation Smart Conveying Technology (SCT), a patented design providing extended service life, reduced maintenance time, easy removal of blockages, and reduced life-cycle costs. The SCT design is installed in many biogas plants globally and provides our customers with the lowest cost in use solution for biogas transfer applications in all stages of the process.

SEEPEX view this robust, easy to maintain, pump as a valuable addition to their range for customers who have feedstock with high solids or with physical contaminants.

Visit us at ADBA 2015, stand D203 or find out more at www.seepex.com

Issue 14 PECM


Boilers & Maintenance

Gas Process Burners Lanemark gas burner systems offer users reliable, high efficiency, process heating solutions. FD Series Packaged Oven/Dryer Burners Specifically designed for process air heating applications in convection ovens and dryers High turndown/short flame lengths providing accurate process temperature control High efficiency gas + air modulation, gas only modulation and simple high/low control options Heat Input Range: 9 kW – 880 kW


D FD-C high turndown oven/ dryer air heating burners.

FD-E low cost high turndown

oven/dryer air heating burners.

FD-C (GA) modulating gas + air process air heating burners.

TX/TRX Series Gas Fired Process Tank Heating Systems High efficiency (80%+) heating of all types of spray and dip process tanks Compact high efficiency small diameter immersion tube heat exchangers occupying minimum tank space Accurate performance modelling using Lanemark TxCalc design software Heat Input Range: 15 kW (1½") – 730 kW (6")


Midco DB Series Air Replacement or “Make-Up� Air Heating Burners Direct fired, high efficiency burner systems, for high volume air heating applications such as paint spray booths, ovens and dryers. Supplied either as Midco burner heads for OEM system integration or as complete packaged systems including modulating gas valve trains and controls Wide range of firing rates to suit alternative temperature rise and air velocity system requirements DbCalc system design software


Midco HMA high efficiency,

TX high efficiency small diameter

high turndown, air replacement or “make-up� air heating burners.

immersion tube tank heating systems.

Lanemark Combustion Engineering Limited Lanemark House, Whitacre Road, Nuneaton, Warwickshire CV11 6BW United Kingdom Tel: +44 (0) 24 7635 2000 Fax: +44 (0) 24 7634 1166 E-mail: info@lanemark.com www.lanemark.com






Byworth’s specialist Boiler Repair and Maintenance Services has    

      visit Why are we so confident? Because our highly trained engineers know their job and carefully stock their vans with over 360 different parts thereby minimising the need for a second visit. If a second visit is required there is still only one call out fee and no extra travel expenses. So to minimise downtime and maximise efficiency with a servicing and maintenance contract it pays to call Byworth.


Servicing contracts to suit individual customer requirements > Routine boiler & burner servicing > Annual & 6 monthly health checks

# # #

Insurance inspection preperation work Ad hoc servicing and repairs First time commissioning

Call our Servicing Department to discuss your requirements:


PECM Issue 14

# # #

Emergency callouts Efficiency checks Equipment Upgrades

Tel: 01535 665225 Email: service@byworth.co.uk Web: www.byworth.co.uk

Keeping bulk solids material on the move with Sonic Soot Blowers By Donald F Cameron, Managing Director Primasonics® and Quattrosonics®


o what are Sonic Soot Blowers? They are pneumatically operated horns that produce low frequency – high energy sound waves. These sound waves are produced when compressed air enters the Wave Generator and forces the only moving part, a titanium diaphragm, to flex. Sonic Soot Blowers are employed wherever ash, dust, powders or granular materials are processed, generated, stored or transported. The Quattrosonic Sonic Soot Blowers were designed as a replacement for the somewhat primitive and abrasive boiler tube cleaning. Steam Soot Blower systems used in Power Industries, however, sharing many of the same qualities as Primasonics Acoustic Cleaner range they are just as effective in Bulk Solids Processing and Transporting industries too. How do they work? Sonic Soot Blowers are extremely simple in their operation, requiring only normal plant compressed air for their initial energy source. Compressed air enters the Wave Generator and forces the only moving part, the ultra-high grade titanium diaphragm to oscillate very rapidly within its specially designed housing. These rapid oscillations create the base tone and the different body sections convert, amplify and distribute this base tone into a range of selected key fundamental frequencies.

Quattro Range is featured in a technical brochure and a video showing them in operation is available on request.

Sonic Soot Blowers produce very rapid sonic sound pressure pulses (up to 350 per second) which produce in turn, a positive (+) ‘push’ followed by a negative (-) ‘pull’ effect which weakens the bond between the particles themselves and the surface to which they are adhered to. This then causes these adherence bonds to break thus dislodging the particles which are then removed either by gravity or in the gas stream. Cleaning Efficiency – because Sonic Soot Blowers use powerful sonic sound waves, these sound waves travel at a speed of 344 metres per second and in a 360° radius. This means that the entire circumference of the tubes and internal structure can be easily reached instead of just the leading edge of the tubes as with a steam soot blower. A periodic ‘sonic sounding’ is all that is required to achieve these goals! Typically 5 - 10 seconds every 6 – 12 minutes. Continuous plant operation is possible because particulate build-up is eliminated. By strategically placing the Sonic Soot Blower they will eliminate the need for operators to enter potentially hazardous and dangerous areas of processing plant to carry out manual cleaning. Primasonics have successfully installed their range of Sonic Soot Blowers within the Solids Handling Industries in; * * * * * * * * * * * * *

Silos Boilers Hoppers Superheaters Filters Economisers Ductwork Air Heaters Fans SCR’s Cyclones ESP’s Air Classifiers

What is required to operate a Sonic Soot Blower? Only two things are needed both of which already exist within all plants, namely standard plant compressed air and an electrical control supply. The compressed air requirements are, firstly a pressure of between 5 & 6 bar (500 – 600 kPa) and secondly a usage of between 18 & 22 litres per second (38 – 42 CFM ) but remember the Sonic Soot Blower will only be


PECM Issue 14

‘sounded’ for a few seconds at periodic intervals. The solenoid valve which is used to turn on and off the Sonic Soot Blower requires an electrical supply, usually either 220 or 110 V AC or 24 V DC. Can Sonic Soot Blowers be easily retrofitted? Indeed they can, in fact most of our sales are to end users or engineering companies who wish to install Sonic Soot Blowers to replace either unreliable or inefficient steam/water soot blowers. Therefore we can usually use the access point left vacant by the removal of the rotary or retractable steam soot blowers where possible or else mount the Sonic Soot Blowers on any available hatches. Installation of Sonic Soot Blowers is quick and easy. Why do Sonic Soot Blowers come in a range of frequencies? Each particular sound frequency has its own individual sound wave pattern (rather like DNA). The higher the sound frequency, the shorter the sound wave and the lower the frequency the longer the sound wave. We have therefore carefully selected five different specific sound frequencies (350 – 230 – 120 – 75 & 60 Hz) for our range of Sonic Soot Blowers because these five different frequencies will provide effective particulate de-bonding over a wide range of applications and plant sizes. The different sound frequencies are achieved by altering the design of the main body of the Sonic Soot Blower. The Quattrosonics Sonic Soot Blower range is featured in a technical brochure and a video showing them in operation is available on request. Also Primasonics will provide a free site survey and report to highlight how their range of Sonic Soot Blowers can eliminate many of the process challenges currently experienced within the Solids Handling Industries. For further information contact Primasonics International Ltd by:Tel: 44 (0) 1768 866648 Email: sound@primasonics.com Web Page: www.primasonics.com



n increased focus on controlling greenhouse gas emissions, coupled with escalating demand for electricity and slow progress on nuclear projects is leading to an expansion of alternative renewable energy sources. Leading the pack at the moment is hydro electricity, the basic principles of which were commercialised in the late 1880’s and now accounts for around 16% of global electricity generation capacity. One of the advantages of Hydro-power is actually the age of its base level technology; as a mature generation method, the equipment is tried and tested and although a large proportion of it is due for refurbishment, it means that refinements in materials and manufacturing techniques can be applied to existing installations. Improved generation efficiency and longevity can now be built-in during routine maintenance, delivering 10% increases in power output from the same source, without re-investing in replacement hardware, surely a massive win-win for the industry. It should be noted that not all repairers offer the same level of service


PECM Issue 14

and expertise, so hydro generator operators need to choose carefully. Installed base The variety of plants is huge, from the smallest Pelton wheel to the largest hydroelectric power station in the world, the 22,500MW Three Gorges Dam in China. However, the principle remains the same, using flowing water to turn a turbine and generate electricity. The key to a successful installation is efficiency and reliability, both of which are benefitting from the latest technological advancements in the sector. In recent years, many hydro projects have begun operating in ways not envisioned during their original design and new installations have been made possible through improvements in technology. Of course, work is still needed to determine how equipment can be improved through new materials technology as well as identifying actions and tools for predicting and preventing failures. Turbine technology As hydropower increases in popularity so the demand for new installations grows. Thanks to


As part of a generator refurbishment, it is essential that inspection and tests be carried out on the stator core and rotor

inherent shortcomings with traditional technology, it may not be suitable to meet these demands in some locations, such as those with large fish populations. Here, development programmes, such as the Alden turbine project, have produced new designs that significantly improve the mortality rate of fish travelling downstream while also improving generating efficiency.

Improved generation efficiency and longevity can now be built-in during routine maintenance Hydro turbine research has also produced a new fish-friendly design criteria for Kaplan and Francis turbines that can be incorporated either into units during rebuild projects or in new hydroelectric facilities. In the USA, the Department of Energy (DOE) has implemented a new hydro programme called “The Advanced Hydropower

Turbine System Programâ€? (AHTS) which aims to develop technology to maximise the use of hydropower while minimising the environmental effects. Refurbishment of existing turbine assemblies can now include the latest materials technology such as the High Velocity Oxygen Fuel (HVOF) coating system, which uses tungsten carbide materials. This and other similar coating and wear protection systems can be used to protect water turbines and draft tubes against erosion from water-born sediment and reduce cavitation effects for Pelton, Kaplan, and Francis turbines. Improving generator eďŹƒciency Advances have been made in the design and construction of the high voltage stator coils used within the generator, which can provide improved efficiency and reliability. The manufacture of high voltage coils is a very precise science; design and construction methods will vary between suppliers, as will the testing procedures, which form the bulk of the proof the client has of the quality of the finished product. Obviously, when repairs are unplanned, speed is crucial in getting the


Improved generation efficiency and longevity can now be built-in during routine maintenance, delivering 10% increases in power output from the same source

equipment back up and running, but this cannot be achieved to the detriment of quality, which has much longer lasting implications. With regard to the testing protocols for these high voltage coils the hydro electric industry works to higher standards than some industrial sectors. For example, Sulzer’s Birmingham Service Centre, where replacement coils are manufactured for use worldwide, subjects its coils to a series of demanding tests both in-house and by external testing experts to ensure that these standards are met and in most cases surpassed in order to deliver a guaranteed product. Maintaining high standards of design and construction has a number of key benefits, most notably reliability and operational efficiency. Employing a process of continual measurement against specification throughout the manufacturing process will ensure correct initial fit as well as continued reliable service. Advances in coil structure & insulation improve longevity In addition to the myriad of small differences in design, construction and materials from one manufacturer to another, there are two distinct insulation methods of coils in generator construction. It is worth focussing on

Epoxy resin is more susceptible to PD activity when compared to mica and so the resin rich coils, which contain less resin than the VPI equivalent, provide better resistance to partial discharge activity.

this aspect of generator repair because it can make a profound difference to the efficiency and performance of a unit, often without having to replace the other major components. Replacement coils or bars will be manufactured either using the heated and individually pressed Resin Rich insulation system or a vacuum pressure impregnated (VPI) resin bath method. While smaller applications might prefer the VPI method, this can become unmanageable for larger installations such as large generators. The design and construction of the resin rich coil provides accurate control

Issue 14 PECM



Resin for the end-windings contains a flexibiliser which provides a small degree of flexibility within the resin, making it less susceptible to the end-winding cracking often seen in larger VPI coils circulating current losses (a process called Roebel transposition), or, by changing winding covers to a non-magnetic material. Improved design software and modern winding equipment also contribute to delivering stator coils with a more efficient and robust construction. Stator core laminations It is not only the stator windings that can influence the efficiency of the generator, the design and construction of the stator core itself also has an influence. As part of a generator refurbishment, it is essential that inspection and tests be carried out on the stator core and rotor. These can highlight any issues with the integrity of the stator core which may have to be replaced before any coils can be installed. Rebuilding the core using new lamination segments which are manufactured from a specific lowerloss grade of magnetic steel can result in a 10% reduction in losses when compared to the material used in the original construction. In addition, the rotor field coils can be stripped and re-insulated with improved, Class F, insulating materials.

of the coil dimensions within the slot, which, combined with good winding practice, minimises any voids between the coil and the slot; resulting in good control of partial discharge (PD) activity within the slot. PD is one of the main failure modes of the insulation in rotating machines, making it a good indicator of normal service life expectancy. The resin rich coil uses a thermosetting epoxy resin infused mica tape for the slot while the resin for the endwindings contains a flexibiliser which provides a small degree of flexibility within the resin, making it less susceptible to the end-winding cracking often seen in larger VPI coils. The flexible end-winding tapes allow the coil to be adjusted slightly during installation in the stator, which ensures a more consistent gap between the coil sides in the end-winding. Epoxy resin is more susceptible to PD activity when compared to mica and so the resin rich coils, which contain


PECM Issue 14

less resin than the VPI equivalent, provide better resistance to partial discharge activity. In most cases the use of modern insulating materials will improve both the dielectric and thermal performance when compared to those used by the OEM during original manufacture.

As part of a generator refurbishment, it is essential that inspection and tests be carried out on the stator core and rotor. Improvement in the control of stray losses can also be achieved by changing the method of stator coil transposition in order to reduce

Sulzer can also redesign, manufacture and fit new AC excitation systems to replace DC systems. The main benefit of this change is to remove the possibility of deposits from carbon brushes contaminating the stator and rotor components; an added benefit is the reduction in brush gear maintenance time giving additional generator uptime. The use of modern materials for both the stator core and the insulation thereby helps to ensure the continued reliable operation of a facility after the generator has been refurbished, but it can also increase the maximum output of the newly repaired generator by over 10%. High voltage testing for Hydro generators Stator coils can be independently tested before being installed, giving the repair centre and the client peace of mind that every coil has passed the numerous tests available. The electrical testing of the completed coil includes the Tan δ, which is a measure of the integrity of the slot wall insulation, where a lower figure indicates a better quality coil. At Sulzer, the figure achieved is always less than half the international standard, with an aim to realise less than one third of the standard.

Further testing can be carried out on sample hydro-generation coils by independent laboratories, including the thermal endurance test, which is carried out at 30kV for 500 hours, a simple enough task for a high quality coil. However, a more arduous test is done at 35kV for 250 hours, however all the coils provided by Sulzer have passed this standard as well. In the majority of cases, the client will specify the test parameters for the coils, which are normally specified to operate at 11kV. As a baseline assessment, coils are subjected to 23.9kV for 400 hours while being heated to normal operating temperature, around 120°C. This test is in accordance with the demanding IEEE standard 1553, which relates specifically to hydro generator coils. Additional coils can be initially subjected to the withstand test, which evaluates the ability of the coils to operate in overvoltage conditions which may be expected during their life. Coils are expected to pass this test which is conducted at 28kV, as well as a further test at 60kV and an end-winding test at 22kV, with no detectable issues with the insulation. While the IEEE standards set out the framework for these tests, the exact test voltages and durations are specified by the client to ensure that the coils meet the requirements of the individual application.

independent repair market. Globally, Sulzer has invested in a number of overspeed balancing pits which can be used as part of each repair project for its clients. Though, due to their rarity, Sulzer has also made these available to OEMs and other customers. Each pit is equipped with advanced electronics and diagnostics to provide stateof-the-art trouble-shooting capabilities. Pumped storage systems Typically used as fill-in generation at times of peak demand, although green in terms of generation, they obviously consume power when pumping water back up to the high level storage. Efficiency in the motors, pump sets and the generators is crucial to an installation’s viability as they are normally run on very low percentage margins. An improvement in generating, or pumping efficiency, especially during routine maintenance work could

Dynamic balancing of rotating elements is an important aspect of the manufacture and the repair of any turbo machinery. A rotating element that is out of balance can cause major operational difficulties

therefore make the difference between a site being viable or not. Some pumped storage installations use separate turbines and pumps while others employ reversible turbine/ generators which can act as both

High Speed Rotor Balancing As the stator is completed, so attention falls to the rotor, which can also benefit from the improved insulation materials technology. Rotor field coils will usually be reinsulated as part of a refurbishment project along with the replacement of any damaged components. Clearly, the rotor will need to be re-balanced before it is returned to service. Dynamic balancing of rotating elements is an important aspect of the manufacture and the repair of any turbo machinery. A rotating element that is out of balance can cause major operational difficulties, which may prevent the timely start-up of a facility if it has to be re-balanced. Furthermore, the unbalanced element can cause internal damage that will rob a machine of its design efficiency, reduce machine reliability, and increase the costs of operation and maintenance. For any applications that require high speed balancing, this process requires a specialised balancing bunker, but very few of these are available to the


Some pumped storage installations employ reversible turbine/ generators which can act as both pump and turbine

Issue 14 PECM



Advances have been made in the design and construction of the high voltage stator coils used within the generator, which can provide improved efficiency and reliability this technology and is offering free thermographic surveys to both new and existing customers.

pump and turbine. One cost effective alternative approach is to use a reverse-running centrifugal pump, which can improve the efficiency of the pumping cycle and thus reduce operating costs. Maintaining these pumps and the associated generators requires expertise and experience as well as access to the latest in pump design innovations, which Sulzer, as one of the world’s leading pump manufacturers, can provide. Preventative maintenance A power station needs to optimise output in order to meet demand as efficiently as possible, but, inevitably there comes a time when maintenance repairs, either electrical or mechanical, will be required. Therefore, a programme of periodic, preventative maintenance can be combined with condition monitoring techniques to improve the reliability and longevity of the equipment. Employing a range of condition monitoring equipment, combined with suitable analysis techniques, can provide an accurate assessment of the status of turbines and generators, allowing operators to ensure continued production. One of the most useful tools is vibration analysis, which can indicate potential problems with bearings and large rotating parts; combined with thermal imaging, it can produce an accurate indication of the overall status of the plant. Additional testing of the electrical windings, especially partial discharge (PD) analysis, can also provide very useful information on the overall


The resin rich coil uses a thermosetting epoxy resin infused mica tape for the slot


PECM Issue 14

condition of the generator. PD can cause insulation degradation, which if not remedied, can lead to reduced output of the generator and premature failure of the insulation system causing stator failures. The appropriate use of condition monitoring provides an excellent maintenance tool and can ensure efficient generator output. Thermographic surveys The use of infra-red cameras for predictive and preventative maintenance is becoming more common, especially when assessing high value equipment or where an unexpected failure could cause considerable disruption. These cameras can be used to analyse the running temperatures of bearings, motors, electrical connections and other equipment and, as such, can indicate potential areas for concern without having to stop any of the machinery. By applying infra-red technology, engineers are only required to carry out maintenance procedures when they are required, rather than on a fixed basis, which improves efficiency and reduces maintenance costs. Sulzer believes that more clients can benefit from

Complete Hydropower solutions Sulzer is a leading provider of engineering solutions for the power generation sector, from on-going condition monitoring to complete turnkey projects. The company has developed a large network of service centres capable of maintaining all rotating equipment such as turbines, generators, motors and pumps as well as employing experienced engineers, equipped to complete projects on site if necessary. The high voltage coil manufacturing facility based at the Birmingham Service Centre, employs an in-house copper rolling mill to enable roundthe-clock coil production to meet even the tightest deadline. Using the latest CAD systems, precise quality control and extensive testing, modern coil production can significantly improve the performance and efficiency of any generator which is due for refurbishment. Employing the latest materials technology and manufacturing processes enables the hydropower sector to maximise the efficiency and reliability of the existing infrastructure as well as develop new opportunities. Sulzer has the expertise, tools and equipment to provide engineering support to its clients for any scale of project, from engineering supervision to completion of the largest repairs to turbines, generators and pumps. Author: Graeme Robertson, Head of Operations UK for Sulzer

Doing AD Well: Improving Operational Performance


ith 388 anaerobic digestion (AD) plants, the industry is already generating sufficient green energy to power half of the households in central London (710,000 homes), however, the industry is far from reaching its full potential. AD is a constantly evolving, adapting technology which is always driving hard to reduce costs, increase outputs, cut carbon footprints, and to develop new, innovative high-value products.

Dodd, noted at our National Conference last December, “operational performance underpins the economic viability of projects, confidence in the sector’s health and safety record, the quality of outputs and the professionalisation of standards across the industry.” If you are to maximise outputs, ward off the regulators and ensure a safe operating regime, then the decisions made on the type of technology used for your AD plant will have a fundamental impact on the plant’s efficiency.

This year’s UK AD & Biogas 2015, which we will be hosting at the NEC in Birmingham on 1-2 July, will showcase the latest technology and services from the AD industry to around 3,000 visitors. There’s plenty to showcase as the industry comes under increasing pressure to improve operational performance, manage environmental risk and find new ways of maximising the process outputs.

Plants designed for one type of feedstock do not necessarily work as effectively for other varieties and so matching the feedstock composition of your farm to the type of digester is vital. PROjEN’s Process Consultant, Dr Les Gornall, explains that “to reduce parasitic electrical loads and maximise gas production, digesters need a feedstock that is best described as ‘good soup’; high in organic matter and free of contaminants. It’s also crucial to choose the right bacteria for the

As the Head of Operations for Tamar Energy, Kyrone

feedstock and digester operating temperature. Make the microbes happy and they will thrive. After all, a digester is a living organism that needs to be attended to every day.” Another aspect that operators need to consider is the need to extract the greatest possible value from an AD plant’s outputs. HRS Heat Exchangers’ International Sales Manager, Matt Hale, challenges those AD operators who fail to utilise the heat output from the plant, “not using the heat naturally generated as part of the AD process could be costing operators thousands of pounds each year, particularly if they’re adding heat elsewhere. By using a heat exchanger to capture and transfer this waste heat, a well-designed system could recover 40 per cent of the heat produced by the plant.” Heat is often an under-utilised valuable output of AD, which can then be used for a wide variety of purposes, including feedstock preheating; digester heating; pasteurisation; evaporation; or to heat nearby buildings. Richard Gueterbock, Director of Clearfleau, a company which designs and builds on-site AD plants, emphasises that investing in technology which complements your existing business model is most likely to maximise your returns, “AD plants are designed to take a certain load and a certain feedstock so the key thing for us is making sure the client operates the plant in the way in which it was designed. AD is a biological

process which needs to be optimised, so careful and effective monitoring is fundamental.” Ensuring that you select the right equipment to operate your plant at the highest possible standard is also essential to maintaining investors’ confidence in AD projects. Jelf Insurance Brokers’ Renewable Energy Executive, Carl Gurney, warns that “if the industry fails to raise its standards then insurers, due to claims levels, will either apply premiums that are unsustainable or not offer cover at all.” The water sector in particular has lead the way on developing and commercialising new AD technology given the sector’s focus on upgrading and maximising the output at existing sites. The results are resounding, with the Digest of UK Energy Statistics (DUKES) reporting that electricity generation from sewage sludge increased from 603GWhe in 2009 to 761GWhe in 2013 – an increase of 26 per cent, almost entirely from existing sites. Whether an operator is considering developing new AD sites or not, it is vitally important that the industry continues to adapt and develop in a safe and sustainable way to maximize performance and returns. Getting the most out of AD involves both optimizing existing technology and investing in new R&D opportunities – and the carbon and economic case for doing so is clear. enquiries@adbioresources.org Issue 14 PECM


Control & Automation UNIGATE IC/FC – readyto-install bus nodes for all industry protocols Ready-to-install UNIGATE IC bus nodes from Deutschmann Automation relieve automation manufacturers from having to develop interfaces and thereby help them offer products for various protocols with little one-time development effort. The all-in-one bus nodes in a 32 DIL housing have been designed for embedded solutions for direct integration into terminal devices. The modules comprise a microcontroller, flash, RAM, and a bus controller. They handle the complete communication on the bus side, thus reducing the workload of the application’s microprocessor.

Eight integrated I/Os and easier Modbus configuration Deutschmann Automation announce innovations to their UNIGATE CL converters for DIN rail installation. The protocol converters enable the integration of existing devices in various fieldbus and Ethernet environments. The modules are now also available with eight integrated, freely configurable I/O interfaces. Users can define each I/O as an input or output and apply their individual switching logic in associating I/Os with each other. Thereby, UNIGATE CLs can be used for direct and application-specific control of actuators, sensors, and signaling devices without requiring external I/Os from other manufacturers.

UNIGATE ICs are connected to the host processor via a UART interface. Amongst others, Deutschmann offer models for Profibus, DeviceNet, CANopen, Modbus TCP, PROFINET (according to the PROFINET V.2.2 specification), EtherCAT, EtherNet/ IP, Ethernet TCP/IP, LonWorks, and BACnet. Furthermore, models with an RS232 or RS485 interface are available for Modbus RTU and Modbus ASCII. Thanks to the identical hardware and software interfaces and functionality of all UNIGATE IC devices, manufacturers can offer various protocol options to their customers.

The integrated I/Os are configured via the same script that is the basis of Deutschmann gateways, handling the conversion of the terminal device protocol to the respective fieldbus or Ethernet protocol. Implementing another improvement, Deutschmann have made the configuration for Modbus applications easier by enhancing WINGATE functionalities and adapting the UNIGATE CL firmware. Now, all settings for the connection of gateways with terminal devices via Modbus ASCII or Modbus RTU as well as the fieldbus-side Modbus communication can be configured by means of the WINGATE configuration tool alone – without any extra programming.

Email: info@deutschmann.de

Email: info@deutschmann.de


Automation in Enclosure Assembly Rittal’s acquisition of Kiesling in 2013 was a milestone in the company’s ability to support its customers. The machines and solutions from Kiesling now facilitate the optimisation of the complete workflow in panel building manufacture, from machining of the panel parts and automated wiring of the panels to testing of the finished panel, supported by a diversity of handling systems such as the Assemblex. This joint expertise aligned with Rittal’s other subsidiary companies Eplan (design) and Cideon (technical IT integration) means that automating the production of control panels has now become far more accessible. It means panel builders can, if they wish, provide end to end services and solutions throughout their value chain, while optimisation of the whole work flow is possible, from the design to the technical IT integration. As if to underline this point, Rittal’s sales in automation equipment and software are up year on year, indicating some, if not all, panel builders are taking advantage of the opportunities automation presents.

Tel: 01709 704000


Rockwell Automation Launches PanelView 800 Graphic Terminals with Faster Boot-Up Time Rockwell Automation reduces boot-up time and increases installation flexibility with the new space-saving AllenBradley PanelView 800 family of graphic terminals. The terminals, available in 4-inch, 7-inch and 10-inch display sizes, feature an 800 MHz CPU processor, up to 256 MB of flash, and dynamic memory to reduce boot-up time, making it two times faster than the previous PanelView Component terminal. The terminals also offer improved touch-screen responsiveness and can be configured in portrait and standard landscape mode for greater installation flexibility. “The PanelView 800 family of terminals builds on the Rockwell Automation Connected Components Workbench software’s value of giving machine builders simplified engineering, easy configuration, faster installation and reduced start-up time,” said Chee Wah Lee, product manager, Rockwell Automation. “This family of graphic terminals is ideally suited for meeting control and visualization requirements in a wide range of simple, standalone applications, such as pump stations, packaging machines, labelers and stretch-wrap machines.” The PanelView 800 graphic terminals are specifically designed for use with the Allen Bradley Micro800 and MicroLogix control systems. The terminals’ high-resolution screens with LED backlights can display up to 65,536 colors, providing a sharp display for a wide range of applications. Built-in Ethernet and serial communications ports (RS232, RS422 and RS485) support easier controller connectivity, while USB and microSD ports make file transfers easier. The terminals are also certified for Class 1, Division 2 hazardous locations.

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


PECM Issue 14


Cygnet 2/3-inch sCMOS camera provides full HD up to 60Hz The Cygnet 2/3-inch sCMOS camera provides full HD up to 60Hz. Scientific CMOS (sCMOS) technology stands to gain widespread recognition across a broad range of demanding imaging applications, due to its ability to simultaneously deliver extremely low noise, fast frame rates, wide dynamic range, high quantum efficiency, high resolution and a large field of view. The 2.1MP 2/3 inch Scientific CMOS sensor with 5.5µm x 5.5µm pixels enables ultra sharp image resolution and with a Quantum Efficiency of over 63% @ 500nm and greater than 34% @ 850nm, the Cygnet offers optimum photon collection and is available in both monochrome and colour versions.

Tel: 01992 637211


New All-Gigabit Stratix 5400 Industrial Switch Helps Manufacturers Address Growing Network-Bandwidth Requirements

Rockwell Automation has expanded its Allen-Bradley Stratix family of industrial switches with the Allen-Bradley Stratix 5400 switch, an allgigabit option that helps manufacturers achieve higher network speeds for their increasingly high bandwidth applications. The switch also supports both Layer 2 switching and Layer 3 routing for a range of network configurations. “Network convergence, increased reliability and the growing adoption of high-speed devices across The Connected Enterprise are driving the need for a higher-performing and more versatile industrial switch,” said Mark Devonshire, product manager for Rockwell Automation. “The Stratix 5400 switch provides this capability and helps confirm that manufacturers have a robust architecture in place as network demands continue to broaden.” When used as a Layer 2 switch, the Stratix 5400 switch is ideal for industrial environments experiencing an influx of high-performance, gigabit-speed end devices, such as IP video cameras and telephony. It’s also fit for heavy-industry applications that require resilient network topologies. When used as a Layer 3 switch, routing is enabled between segmented networks to help achieve better performance. The switch uses an all-gigabit design for high-performance network and end device support. The GE Power over Ethernet (PoE) and additional GE fiber port options enhance scalability and help meet a wide range of application needs.

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


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.

groov is a zero-programming, web-based 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.

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.

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.

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

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.

In addition to Modbus/TCP networking, groov supports OPC Unified Architecture (OPC UA) to communicate

For mobile devices like iPhones, iPads, and Androidbased 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. 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. Availability: groov 2.3 is available immediately. Choose either the groov Box hardware appliance (GROOV-AR1), or groov Server for Windows software (GROOV-SVR-WIN). 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

.. Burkert helps to improve efficiency at UK car engine plant hen a system integrator working for Nissan in Sunderland (JEB Contractors) identified a control process within the engine casting plant that was in need of improvement, the team requested vital input from flow control specialist Bürkert. By designing and installing an electronic control solution to replace the manually adjusted flow control valves, a significant improvement was made to efficiency and reliability of the process.


The Nissan Sunderland car plant builds more than 500,000 cars per year. There are two parallel assembly lines building a wide variety of models that require the engine plant to keep pace with the car production lines, meaning that the engine line has to change model production on a regular basis. The engine line is supplied by the engine casting plant which uses a number of different production settings to produce 3 different petrol engine models which are produced and tested on site. One of these processes is the cooling process for the freshly cast aluminium components, which was controlled by a variety of manual valves. When the time came to change the engine model, these valves had been adjusted by hand to the new settings required for the next production run. The change-over process was time consuming and the final settings often had to fine tuned. As part of a project to improve this control process, the system integrators on the site invited Bürkert to offer suggested solutions and improvements to the current system. The design engineers from Bürkert assessed the requirements of a new system and the current control infrastructure before suggesting the use of the type 2836 proportional valve which would be controlled through the type 8605 pulse-width modulated (PWM) controller.


PECM Issue 14

The engine component cooling process is controlled by a PLC which uses a proportionalintegral-derivative (PID) controller to precisely set and monitor the flow rates of the cooling system. The PLC produces a 4-20mA control signal for the required flow and this signal is used by the PWM controller to set the flow rate in the proportional valve. To ensure that the desired flow rate has been achieved, a flow signal is fed back to the PLC, which can then make any adjustments if required. This control loop ensures that the process is continuously monitored and therefore provides a far more accurate process. The type 2836 solenoid control valve is a direct acting valve which can be made from brass or stainless steel, depending on the application. Capable of handling pressures up to 25 bar and available with a range of orifice and port connection sizes, the type 2836 can be designed to meet a wide range of requirements. In this case, the design expertise of the Burkert engineers ensured that the correct parameters were selected in order to deliver the required performance. The PWM controller can either be combined with the valve itself, or, as in this



Picture shows the Qashqai Engine production line at Nissan Sunderland. Image provided courtesy of Nissan Motor Manufacturing (UK) Limited.


Burkert type 8605 pulse-width modulated (PWM) controller is used to control type 2836 proportional valves, replacing a manually adjusted system.

case, mounted in a separate enclosure and connected to the valve by a control wire. This range of options is designed to ensure that different environments and control arrangements can be accommodated. The input signal can be configured from a range of options including 0-20mA, 0-5V, 0-10V or 4-20mA as in this case. The completed design has greatly improved the accuracy of the flow control system as well as significantly reducing the time taken to change the various settings to prepare for the next engine type. In doing so, the facility for applying even tighter quality control parameters has been added and the total efficiency of the engine casting line has been improved. Craig Kerr, Area Sales Manager for Bürkert, comments: “This is a great example of a systems integrator making use of the design expertise of Bürkert to help them make significant improvements to the control of a fluid control system. Working with integrators, automation companies and panel builders allows us to combine knowledge to produce improved efficiency. It is often the case that the on-site engineers will identify a system that could be improved, but need some specialist technical help in making that goal a reality.”

Your search is over with BVM. Technology that you will treasure.

We like to make life easier. At BVM we take your design brief, develop a prototype, consult during trials and streamline the production. If you are developing a product with an embedded computer at the heart, let BVM take the strain, allowing you to concentrate on your speciality, be that process control, factory automation, mobile data collection, nuclear processing or railway safety. Everything from design, manufacture to delivery, we take care of it. Tel: +44 (0) 1489 780144 Web: www.bvm.co.uk Email: info@bvmltd.co.uk Email: sales@bvmltd.co.uk

Control & Automation

RS Components brings the Internet of Things to automation and control RS Components (RS) is a worldleading distributor of automation and process control (A&C) components from market-leading brands including Siemens, Phoenix Contact, Honeywell, Mitsubishi Electric Automation Systems, Omron and Schneider Electric among many others. The company’s extremely wide A&C portfolio ranges from control gear to sensors, contactors to pneumatics, and PLCs to motor controllers, as well

as an extensive selection of machine guarding equipment to make working environments safer. Now, RS is expanding its automation and control offering with innovative new products that will enable the remote monitoring and control of machines to meet the growing needs of managing industrial applications in the fast emerging paradigm that is the ‘Internet of Things’ (IoT), which is connecting literally billions of devices to the Internet in countless applications. A core component in the IoT is advanced connectivity technologies, especially Ethernet but also wireless for many new services and applications. The IoT can offer significant benefits for manufacturing companies such as lowering costs, boosting productivity and streamlining system complexity. A new breed of increasingly standardized Internet-based network architectures are making it possible to connect up plants or factory floors to the smart processing capabilities of enterprise

computing via Industrial Ethernet and many different wireless networking solutions. But key to the industrialization of the IoT is the ability to deliver industryhardened products that are robust and reliable and guaranteed to handle high signal speed and quality. For example, RS has a wide range of robust sensors for remote monitoring and wirelesscapable devices that cover multiple protocols, such as wireless LAN Ethernet port adaptors and access points, which open up conventional A&C networks to wireless capabilities including cellular technologies. RS has the portfolio and the expertise to make the Internet of Things really work for A&C companies of all sizes. uk.rs-online.com

Positioning control: Not where you should be? Torsion and elasticity could be to blame.


hen we think of a gearhead, we tend to assume that it is incompressible and rigid, the truth is it still bends, compresses and has elastic properties. This has an effect on the difference between the perceived motion (encoder counts) and the actual motion of a drive system –we are not where we are supposed to be!

torsion. This is the actual elements of the mechanical system twisting under load. The more the gearhead is loaded the more it twists, the more it twists the more energy stored and the larger the displacement error.

When measuring anything we need to keep in mind how the instrumentation works and what are its limitations, to interpret the data we receive from it correctly and in the right context. An encoder will change its output status as the shaft rotates at that measured point. Should the drive chain twist under load, the end with the encoder (normally on the back of the motor) may be static in comparison to the actual motion occurring at the end of the gearbox. This is usually accounted for by play or “backlash” in the system, but there is a more hidden element; the drive chain

The drive chain torsion begins with the motor shaft twisting, then the gearhead twisting and so forth through the drive chain. Normally the twist of the motor shaft is considered negligible as loads are comparatively low, it is usually when large gearing is involved (hence larger loads) that this twisting affect and backlash is more pronounced. Energy is stored in twisted drive chain like a twisted rubber band, so when the system is disabled this elastic energy is released, turning the motor backwards. Above are real measurements of a maxon motor fitted with a gearhead showing the


PECM Issue 14

release of this energy as it back drives the motor. In this case the motor rotated over 4 times when the drive was disabled. If this motion is not accounted for it may result in poor position accuracy. To hold a position under load we would always recommend a holding brake, especially if the load exceeds motor continuous torque specifications. The maxon EPOS controllers have an automatic brake control which controls a brake as the motor is enabled and disabled (timing of brake is adjustable by the user). By Mark Gibbons Technical Engineer, maxon motor uk ltd www.maxonmotor.co.uk









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PECM Issue 14

Issue 14 PECM


AT4 wireless establishes its first anechoic MIMO OTA test Laboratory

AT4 wireless has just established its first anechoic MIMO OTA Testing Laboratory AT4 wireless announces that it

has completed the set-up of a new Laboratory for Over the Air (OTA) Testing MIMO measurements at its Malaga, Spain H.Q. This facility will conduct radiated performance measurements for cellular and wireless devices in a multipath environment simulating a wide range of real world scenarios.

It is expected that a larger percentage of LTE and Wi-Fi devices will support MIMO in the coming months; AT4 wireless is opening this laboratory first of all to support R&D and pre-testing for its customers so they can be ready for future certification requirements from PTCRB and CTIA.

consists of a fully anechoic chamber supplied by ETS-Lindgren, supporting a 16 antenna ring designed to generate single and multi-cluster environments, along with Anite’s Propsim F32 Channel Emulator. AT4 wireless has worked closely with both ETS-Lindgren and Anite for many years.

The AT4 wireless OTA MIMO facility

“AT4 wireless has already been testing

Climate control from the smallest to the largest. ENCLOSURES



OTA MIMO in Japan together with a partner lab* but in that case with a reverb chamber, so this is our first anechoic MIMO OTA facility at the AT4 wireless Group and other geos may follow as the market evolves.” “We are confident to effectively support the R&D and pretesting projects demanded from our customers with the high quality of the recently


inaugurated facilities and with our experienced technical team. At the same time, we are working to obtain the accreditations needed to offer certification testing services that we expect will be demanded later on this year once the standards are approved” said Juan Carlos Soler, Global Regulatory Labs Manager, AT4 wireless, S.A.

AT4 wireless has worked closely with both ETSLindgren and Anite for many years.


SOFTWARE & SERVICES www.rittal.co.uk

Control & Automation

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.

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


PECM Issue 14

Effective, economic corrosion protection: nsd tupH for aluminum drives NORD DRIVESYSTEMS manufacture permanently corrosion-resistant drives by means of the nsd tupH sealed surface conversion system. Aluminum drives are thereby given a smooth, ultra-hard surface that, in contrast to paint, is unaffected by blows or scratches. The drives are tested and proven in applications with a maritime atmosphere. Previous to that, they have proven their resilience against blistering per ASTM D714, corrosion per ASTM D610-08, and scribe per ASTM D1654-08 according to DIN EN ISO 2409. Additionally, ASTM D3170 Gravelometer test showed absolutely no loss of adhesion or chipping. The ASTM B117-09 salt spray test according to DIN EN ISO 9227 produced no corrosion even after 2,000 hours. In demanding atmospheres, nsd tupH drives can be used much beyond the usual service life of paint-coated systems. Their resilience and prolonged service life significantly reduces the service and maintenance requirements placed on customers.

Email: info@nord.com


Control & Automation

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QC 01/05/15

Precision Pumps Designed for Robotics Due to the movements of modern robotics with the requirement of both ‘reach’ and ‘rotation’ to complete the programmed task, weight and size are critical


he Beinlich DARTec® and VISCO.pump® offer a solution to those obstacles whilst delivering fluids at both a high precision and with very low pulsations. Although the pumping technologies are very different, they are ideally suited to dispense fluids such as glues, silicones, sealants and paint exactly where you want it, at the rate required (0.01 to 6.0cc/rev model depending – Max speed 400rpm). The DARTec® gear pump comprises a pair of mating gears contained within a series of plates. In order to achieve precision, reproducibility and the best possible total efficiency the clearances inside are adapted depending on the medium, the differential pressure (up to 150 Bar) and the viscosity. In

addition the use of coatings and special materials can protect against corrosive wear. In addition Beinlich’s new progressive cavity pump VISCO.pump® is especially suited for abrasive media, dosing and dispensing proportional to speed. Accuracy and repeatability is ± 1% and is based on the volumetric principle of an endless (infinite) piston whereas the core components rotor and stator form a perfectly sealed metering chamber. The eccentric movement of the rotor allows for a low-shear motion of the medium from one chamber to the next chamber without crushing the media and is optimally designed for dispensing fluids and pastes filled containing fillers up to 20 bar depending on the model.

Contact us today for further application information: T: 0115 9017111 www.ukflowtechnik.com

Issue 14 PECM


The New Temperature & Process Controllers The most powerful PID Controller on the market is now the easiest to use! 8 '%&#.$,.*+!# 8 40.#*#)5#./0')# 8 1)) 10,01+#3'0&  1665,%'! "-0'2# ,+0.,) 

8 ,1*-#./0,#0 1))5#+1 ,+7%1. )# 


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

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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

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GENERATOR REPAIR KEEPS THE LIGHTS ON IN DARwIN he power station in Darwin started life as a 200MW gas fired installation with three gas turbine generators that started full production in 1987. Having provided the population of Darwin with electricity for 25 years, it was important to ensure the generators continued to provide reliable service. This led to the owners calling on the services of Sulzer to carry out an overhaul of the generator including a rewind of the stator.


The 42kVA generator, operating at 11.5kV, was originally built in 1986, but after more than 25 years in service, the time had come for an overhaul. Using the OEM drawings, combined with the latest CAD, the engineers at Sulzer were able to start on the initial design stages and plan the logistics that would allow the contract to be completed on time. Once the project was underway, two teams of Sulzer engineers, on opposite sides of the world, set about the wide range of tasks required to complete the refurbishment. The service engineers on site in Darwin


PECM Issue 14

began with dismantling the generator, while in Birmingham, UK, the coil shop worked on the design of the new high voltage bars and the dummy stator that would be used to check the dimensions of every one of the 108 bars as well as the support blocks for the windings. Generators can be installed with a variety of coil designs, including ‘frog-leg’ coils and diamond coils but larger machines more commonly have bar wound stators, mainly because of the sheer size of a finished coil makes handling difficult. Once the bars have been installed the coils are formed by connecting the relevant bar ends together, brazing and then taping.

it was important to ensure the generators continued to provide reliable service. Throughout the manufacturing process quality control is essential; starting with the controls over raw material quality to measuring every coil for dimensional accuracy to the final electrical tests.

Every process is checked against the original drawings and specifications to ensure that the finished product can be easily assembled and produce efficient and reliable service for many years to come. For Sulzer, the production process for the new bars starts with the raw copper, which is processed using its own in-house facilities to draw and anneal the base copper. The copper strip is manufactured to exacting tolerances before being coated with the first layer of insulation and cut to length. Each strip is then layered together with many others to make up the basic bar construction, but, its position within the bar must be transposed by 360° in order to reduce eddy current losses. This is a crucial design characteristic and is more commonly known as the Roebel transposition, which would be required in the bar design for this generator. Once the strips have been properly arranged, a resin tape is applied and they are consolidated in a heated, hydraulic press which ensures the alignment of the conductors within the slots; this is crucial for delivering the maximum efficiency of the refurbished generator. Meanwhile, in Darwin, the generator was being dismantled and showing signs of its age with some considerable oil contamination of the stator windings being discovered. Having recorded all of the necessary


The 42kVA generator, operating at 11.5kV, was originally built in 1986, but after more than 25 years in service, the time had come for an overhaul

measurements, the old coils were removed and the stator thoroughly cleaned before the core was flux tested. The flux test is used to measure the condition of the stator core insulation and thus detect any local insulation damage, which can cause the formation of larger eddy currents and local hot spots. Once complete and with a clean bill of health, the stator could be repainted and the rebuild process got under way. This generator design consists of 54 bottom bars and 54 top bars, all of which have to be manufactured to tight tolerances in order to ensure they fit exactly into the stator slot. Each bar has to be formed and shaped by hand, using the CAD-designed, wooden formers that allow every bar to be produced with exactly the right shape and dimensions. The final shape is then checked again in the wooden dummy stator that was constructed earlier. Every bar is tested in the dedicated test cell with the results recorded and kept in the engineering archives. Testing includes tan δ, which relates to the power factor of the bars as well as strand-tostrand short circuit testing and the outer corona protection (OCP) surface resistance measurement.


Once all 108 bars have been installed, the insulating wedges are fitted before being secured to the end winding brackets


With the stator nearly complete, the high voltage terminals were cleaned and tested at 25kV to prove their insulation resistance

“Starting with the controls over raw material quality to measuring every coil for dimensional accuracy to the final electrical tests, every process is checked against the original drawings and specifications to ensure that the finished product can be easily assembled and deliver reliable and efficient service for many years to come.”

Mike Stanley, General Manager of Sulzer’s Birmingham Service Centre, explains: “Improved production techniques and insulation technologies allow modern coils to improve the efficiency and reliability of existing equipment. Throughout the manufacturing process quality control is essential to maintain production of high quality, uniform coils.

At this point the logistics team at Birmingham take over, having already constructed the shipping crates for the bars. Carefully packaging the bars to ensure they arrive undamaged is crucial to ensuring a trouble-free installation in Darwin. The shipment is timed to coincide with the disassembly of the stator on site, so as to avoid any unnecessary delays.


Larger machines more commonly have bar wound stators, mainly because of the sheer size of a finished coil makes handling difficult

Once all 108 bars have been installed and secured to the end winding brackets, with wedges in place, each bar is subjected to a final high voltage test to be certain that none of the insulation has been damaged during the installation process. With the

test results recorded in the project file, the next step is to braze the bar end windings together in order to create the final coils, before taping, sealing and applying the class “H” top glass tape.

each bar is subjected to a final high voltage test to be certain that none of the insulation has been damaged during the installation process. With the stator nearly complete, the high voltage terminals were cleaned and tested at 25kV to prove their insulation resistance before they, too, were installed. Having completed the checks and minor work to the rotor, the generator was reassembled and returned to service, ready for another 25 years. Issue 14 PECM


Premium efficiency AC electric motors from standard stock to customised solutions

Low and High voltage options Safe or Hazardous area IE2, IE3 or IE4 efficiency Brook Crompton. St Thomas’ Road, Huddersfield. HD1 3LJ. Tel: +44(0)1484 557200 Fax: +44(0)1484 557201


Drives & Controls

Power Transmission Solutions

KTR manufacture a range standard and bespoke flexible couplings for shaft-to-shaft and engine flywheel applications. We also manufacture an extensive range of hydraulic accessories including bellhousings and the new “eco” OAC oil/air blast cooler with continuous variable speed control.


Toughest shell in the shellfish line

Exico motors are back!

Krijn Verwijs is one of Europe’s foremost suppliers of shellfish products including oysters, lobster and in particular fresh blue or common mussels. In its Yerseke - Netherlands based shellfish production centre, rapid drive corrosion due to the seawater-infused atmosphere has long been a major concern. NORD aluminum geared motors with a special surface conversion treatment now provides an economical solution to resolve this issue. Frequent drive replacements therefore used to be the order of the day at Krijn Verwijs until the company learned of a new design approach for drives deployed in aggressive environments: NORD DRIVESYSTEMS’ ‘CLEAN DRIVE’ nsd tupH surface treatment. This technology enables aluminium geared motors – which can be very easily and effortlessly washed down – to achieve stainless steel grade resistance to corrosion. Krijn Verwijs has begun to roll out CLEAN DRIVE nsd tupH systems that are sure to provide considerable longer service lives in the salt-rich atmosphere. Though these aluminum geared motors do come at a premium compared to the price of conventional cast iron units, both lab trials and extensive real-life testing in the factory in Yerseke indicate that nsd tupH systems will last for the better part of the typical 10-year lifetime of a conveyor line, or even outlast the line altogether. Krijn Verwijs will therefore no longer have to purchase five to ten replacement drives for every unit, nor bother with the expense and effort for associated maintenance work.

NORD GEAR LTD. (U.K.) Tel: 01235-534404 www.nord.com

The Exico name is returning to the UK industrial motor and inverter drive market with some familiar people on-board. After a 10 years hiatus during which the original company was subsumed by a global conglomerate, the successful original format is back with an updated range and typically great technical support and customer service. Based (again) in Wellingborough, Northamptonshire, Exico is targeting predominantly OEMs and re-winders with a full-range product offering; including plenty of UK stock and a modification service. The highly experienced technical support team are also based at the East Midlands site and so are directly available to customers who want instant advice on motor specification and problem solving. Exico’s motor range includes: single phase motors; three-phase motors (IE1, IE2, IE3 and IE4); ATEX explosion-proof motors; marine motors; medium and high voltage motors. It also supplies variable speed drives, gearboxes, accessories such as brakes, fans, encoders and slide rails and coolant pumps for machine tools. As well as standard motors Exico UK is able to build integrated drive packages and to supply bespoke motors with, for instance, windings for non-standard voltages, shaft modifications, fitted brakes and encoders, and marine motors for use both on and below decks. Much of this technical work is directly overseen by Managing & Technical Director Jerry Hodek, (pic left) who has a Masters degree in electrical engineering and 25 years experience in the motors industry.

Tel: 01933-277930 Email: info@exico.co.uk www.exico.co.uk Issue 14 PECM


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Machines containing Variable Speed Drives associated with RCCBs

DC Residual Currents: Due to the topology of 3 phase inverters, under certain fault conditions they will generate smooth DC residual currents in the AC supply.

Complying with essential installation safety requirements!


mall stand-alone machines/ equipment containing 3 phase VSDs must not be connected to circuits protected by standard RCDs. Connecting 3 phase inverters downstream of standard RCDs will affect the prescribed operation of the RCD and therefore does not meet the Electricity at Work Regulations. EWR 4(1) 65. The safety of a system depends upon the proper selection of all the electrical equipment in the system and the proper consideration of the inter-relationship between the individual items of equipment.

RCD Protection with VSDs / Electricity at Work Regulations Where the precautions taken include an RCCB to reduce the risk of death

or injury (Regulation 8): Three phase VSDs must only be used with Type “B” RCCBs. The Duty Holder (Regulation 29) makes reference to the Machine / VSD manufactures recommendations relating to the type and characteristics of the RCCB required. If not clearly stated in the operating instruction they would need to obtain the manufactures recommendations in writing, for safe installation and maintenance (PUWER Regs).

perspective cannot be ignored, as can be seen from the following example. Figure 2 shows the frequency range of various leakage currents present in a system containing a 32 amp VSD; at 50Hz the leakage current is less than 3mA , however the actual maximum leakage current occurs at 7815 Hz and is approaching 2000mA. RCD Types AC and A; only detect leakage currents at nominal supply frequency i.e.UK = 50Hz.

Understanding the risks

DC Residual Currents: Due to the topology of 3 phase inverters, under certain fault conditions they will generate smooth DC residual currents in the AC supply. DC currents flowing through standard RCDs will result in magnetic saturation of the AC sensing coil. The device will not function as intended, with regard to the safe detection of earth leakage currents. The Electricity at Work Regulations makes reference to the IET Regulations as a guidance document (unless the site is specifically covered by another code of practice such as Mines & Quarries), existing Regulation 331.1 is quite clear in its requirement “An assessment shall be made of any characteristic of equipment likely to have harmful effects upon other electrical equipment”. A simple risk assessment carried out under Regulation 331.1 in accordance with existing Health & Safety legislation, on a system containing VSDs and requiring RCCB protection, will quickly identify that Type B RCCBs must be used with a characteristic that is compatible with the operational and safety requirements of the installation, for People and or Fire protection.

AC operational leakage currents: VSDs and their associated EMC filters

and motor cables, generate leakage currents at nominal supply frequency (50Hz) and at various harmonic frequencies. Leakage currents in the higher frequency ranges can be significant and from a safety

Chaz Andrews – Technical Manager, Doepke UK Ltd

If you would like more detailed information relating to this subject, Doepke UK have a free 60 page Technical Application Guide Available on request, or log on to WWW.doepke.co.uk to download the guide or obtain further information on RCCBs. For technical support please e mail chazandrews@doepke.co.uk

Electrical & Electronics Close, cover, protect with Bulte sleeve caps Do you need to close a tube, cover pieces or protect a thread? We have the solution. New Bülte sleeve caps enables this and provides an aesthetical finishing. The standard material is Polyethylene (PE), which is resistant to various chemical products. It also is flexible, non corrosive, non toxic as well as being very light.

Cost effective control panel cooling

Thanks to its special properties Polyethylene is also suitable for a wide variety of industries including: medical, aerospace, railway, toy, food, chemicals, electronics, electrical, building…


Protection caps are available from inside diameter from 5.0 to 20.0 mm and height from 22.0 to 36.0 mm.

t t t t


Bülte offers a range of colours: white, red, yellow, blue… Minimum quantity 50 000 pieces by reference. Samples and prices are available on request. For more information : www.bulte.com


PECM Issue 14

Electrical & Electronics Fujikura introduces new Fibre Recoater Series Fujikura is introducing a new series of Fujikura fibre recoaters the FSR-05, FSR-06 and FSR-07. The recoaters feature easy-toexchange moulds for common coating sizes including 196 µm, 255 µm, 280 µm, 450 µm, 670 µm and 1,000 µm. All recoaters consist of a programmable resin injection quantity and colored and non-colored fibre recoating capability. The FSR-06 and FSR07 recoaters include proof testers to test the strength of fibre after recoating. The FSR-05 recoater is the only model without a proof tester and is ideal for manufacturers that don’t require constant proof testing after each recoat. The FSR-06 model includes a proof tester with a linear clamping system for devices in which confirmation of reliability is required. The FSR-07 includes a mandrel proof tester and is ideal for reliability proof testing as well as tension testing to failure. All fibre recoaters feature automatic and easy operation as well as easy mould and recoat material exchange. Additionally, the recoaters include a PC interface via USB. Compatible with special recoating compound, the recoaters provide a higher stiffness recoating of 900 µm jacketed fibres.


ODU-MAC® now offers even higher performance!


ODU now offers the entire compressed air and fluid range of ODU-MAC with higher flow rates and/or high operating pressure. The electrical connector technology specialists’ in-house development and production increase the flow rate for the compressed air valves by approximately 20 percent, while the operating pressure for the fluid modules is boosted by ten bar (145 PSI). Customers in fields ranging from industrial and measurement technology, to testing engineering and medical technology will benefit from an expanded range of applications and at least 100,000 guaranteed mating cycles. Examples include use in shock wave therapy devices in which tailor-made ODU-MAC connector fluid contacts are installed. High contact security, wide range of modules, robust design and versatile solution possibilities are available specific to this connector. The new modules are also 100 percent plug-compatible with the previous versions and are available as one or two-pin compressed air modules, or as a two-pin fluid coupling module. The customer can choose between a shut-off and a non-shut-off version. Further information on the company and the ODU-MAC modular rectangular connector series can be found at www.odu.de.


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

Hayakawa Is A Driving Force In Value Engineering




As the global economy continues to make its recovery, Hayakawa is working at the forefront of high value engineering to support and strengthen growth in UK manufacturing. Maintaining a competitive advantage is vital to UK companies operating in fast-paced global markets and high on the agenda is finding new, innovative ways to improve performance, drive manufacturing efficiencies and reduce expenditure. With a commitment to delivering high value engineering that demonstrates tangible and beneficial results, Hayakawa has brought a host of innovations to the UK manufacturing sector that are providing both performance enhancements and cost savings. Hayakawa designs and manufactures wire harnesses and cables, with a specialism in delivering high value engineering, for automotive, rail, appliance manufacturing and renewable energy sectors. The company also provides a competitive PCB assembly service and the sale of electromechanical components.

www.hayakawa.co.uk Issue 14 PECM


Electrical & Electronics ODU Push-Pull Circular Connectors ODU MINI-SNAP is an ideal self-securing circular connection for a multitude of application areas.

• Quick and easy mating and demating • Blind mating in difficult-to-reach places • Definite and secure locking condition

• Easy cleaning of housing possible • High connector density • Low space requirements


ODU-UK Ltd. Phone: 01509 / 266433 sales@odu-uk.co.uk

Cables Britain Limited

CBS Group Limited puts your secure power in safer hands

CBL has developed a track record of specialist cable supply into many industrial sectors. Amongst their portfolio is an Addressable Heat Detection Cable System.

Power resilience demands your attention. Unfortunately, installing a backup power supply is only the first step and cannot guarantee you won’t suffer unexpected downtime, damage your reputation and ultimately lose production and money. Maintaining these systems is just as critical. At CBS Group our skilled maintenance engineers ensure your UPS and battery systems are secure, reliable and will operate effectively when required. Covering ALL major brands of UPS, CBS Group delivers the reliable maintenance your secure power supplies need. Call or email now to discover how CBS Group can secure your power.

Tel: 01252 714 100 Email: brett.smith@cbsgroupuk.com www.cbsgroupuk.com

“LISTEC” is a heat sensor cable for protecting high risk areas. Used in many industrial applications from food processing to mining or in any harsh environment where conventional detection methods could prove problematic. • • • •

Insensitive to Humidity, Dust, Frost, Vibration Easy to install and maintenance free Temperature settings adjustable at each individual sensor point Measures temperature AND rate of rise across the length of the cable every 10 seconds • Open protocol, easily integrated into any fire system

Email: markwigley@cablesbritain.com


Everything you expect from an enclosure manufacturer... and more! innovative enclosure solutions for industrial & electronic applications



PECM Issue 14

Electrical & Electronics DEECO LTD.

Manufacturers of Transformers. 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.

Connect 2 Expertise



4) Been Established for over 30 Years. 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

Herga’s new ultra-low-profile electric footswitch offers improved operator comfort Herga Technology has launched a new rearhinged ultra-low-profile footswitch with a height of just 10 mm that offers improved operator comfort by reducing calf and Achilles strain. With an electrical rating 24 V DC at 50 mA and SPST N/O contact configuration, the 6250 series ‘Flatswitch’ is designed to meet commercial standards for comfortable prolonged use on medical and office equipment as well as industrial machinery. The compact footswitch has a surface area of 160 mm x 100 mm and is finished in durable high impact polystyrene with IPx7 protection as standard and IPx8 on request. With its light-weight operation, the ergonomic and innovative 6250 will complement and help improve the performance characteristics for original equipment and operator controlled machinery manufacturers. Standard colour is Blue/White with other colours available for minimum order quantities – further details on application to Herga Technology.

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

Tel: 01284 701422 Email: sales@herga.com www.herga.com

Issue 14 PECM


Reduce your engineering costs by up to 50% with Mitsubishi Adroit Process Suite (MAPS) and Eplan Electric P8


t SPS IPC Drives 2014, Mitsubishi Electric demonstrated the integration of the Mitsubishi Adroit Process Suite (MAPS) with Eplan Electric P8 data for the first time, underlining the positioning of MAPS as an integrated automation lifecycle software solution. The integration enables Eplan Electric P8 users to generate a MAPS project directly from Eplan Electric P8 circuit diagrams. The Mitsubishi Adroit Process Suite (MAPS) is a lifecycle software solution with which users can create projects in order to generate control codes, SCADA templates, tags and documents for parts of a system such as valves, pumps and conveyor belts, for example. Being able to integrate Eplan Electric P8 data directly now makes the task of creating these MAPS projects significantly easier so that MAPS can guarantee value growth along the


PECM Issue 14

entire value chain, starting with the electrical design process. Integration enables system components to be connected and commissioned in accordance with documentation, without having to write a line of code for the control system, design a single faceplate or generate a tag in the process. System components can be controlled and operated right away, enabling development costs to be reduced by up to 50 per cent and commissioning to be carried out much sooner. Changes within the MAPS project are reflected in the MAPS database. If necessary, control codes, graphical displays in the SCADA project, tags and documentation can be updated automatically at the push of a button, thus ensuring consistency between documentation and the actual state of the system throughout its lifecycle. This makes troubleshooting and

The integration of the Mitsubishi Adroit Process Suite (MAPS) with Eplan Electric P8 data enables Eplan Electric P8 users to generate a MAPS project directly from Eplan Electric P8 circuit diagrams.

maintenance easier, guaranteeing improved system availability, since scheduled and unscheduled downtimes can be kept to a minimum. Eplan Electric P8 from e-F@ctory Alliance partner Eplan Software & Service facilitates project planning, documentation and management of electrical automation projects. The automatic creation of detailed evaluations based on circuit diagrams is an integral part of the comprehensive documentation facility and can provide the data required for downstream project phases such as production, assembly, commissioning and servicing. Engineering data from other project areas can be exchanged via interfaces to CAE software and guarantee consistency and integration across the whole product creation process. eu3a.mitsubishielectric.com/fa

Electrical & Electronics

Global manufacturer & distributor of fasteners & components Full service provider offering end to end support from engineering & design through to specification, manufacture, quality control & logistics. Screws | Nuts | Bolts | Washers | Self Clinch | Brass Inserts | Plastic Products Spacers & Pillars | Locking Nuts | Rivet Bushes | Blind Rivets | Blind Rivet Nuts Security Fasteners | Circlips | Micro-Diameter & more Contact TR: sales@trfastenings.com www.trfastenings.com

New BOGE white paper explains how to reduce compressor energy usage BOGE Compressors has released a new white paper that explains how to reduce energy use in compressed air generation whilst maintaining the performance of a compressed air supply. With up to 30 percent of a site’s total electricity usage often used to produce compressed air, this free white paper offers guidance on how to tackle high and costly usage by boosting energy efficiency. The white paper covers a variety of topics that contribute to effectively maximising energy efficiency when generating compressed air and optimising compressor performance. This includes detecting leaks, enabling businesses to identify energy losses with the intention of implementing change to prevent unnecessary costs, and heat recovery, for the purpose of reusing energy for applications such as water and space heating.

Tel: +44 14 84-719921


Superior Multi-Metal Corrosion Protection in Any Enclosure! Coming from Cortec’s® EcoSonic line, VpCI®-105 Emitters powered by NANOVpCI® are unique, patented, compact, space-saving, high-tech systems. They are designed to provide corrosion protection for metal components and parts enclosed in non-ventilated control boxes, cabinets or tool boxes up to 142 liters (5 cubic feet). These economical, non-toxic and safe to handle emitters emit Vapor phase Corrosion Inhibitors (VpCI®s), which form a monomolecular protective coating on all metal surfaces. These emitters do not interfere with electrical, optical or mechanical surface properties, they are extremely simple, quick and convenient to install and protect during operation and shutdown.


Issue 14 PECM


Hi-Tech Composite Products for Hi-Tech Computer Facilities Fibrelite’s Composite Access Covers Prove Perfect for Data Centres #coveringtheworld!


he rapid growth of contentheavy mobile applications and cloud-computing means that the demand for efficient and secure computer hardware to store data is growing exponentially every year. As a result, dedicated data centres to house the legions of networked computers required to keep this online world turning are being built in almost every corner of the world. And Fibrelite composite covers are in the midst of this hi-tech building boom. Data Centre Requirements – Easy Access at all Times David Holmes, Technical Director at Fibrelite, explained: “Cloud storage facilities require miles and miles of fibre-optic cabling which is installed in protective but readily-accessible concrete trenches so that impaired sections can be swiftly replaced – or more cables added, as storage companies are incorporating extension plans into their new-builds. “Then, in order to maintain optimum hardware performance, each server room requires additional electrical power and battery backup systems to operate its vital environmental and

mechanical controls such as continuous cooling, fire and security alarms. These too require their own cabling in their own identifiable, readilyaccessible trench. “So taking all this into account, it’s no surprise that designers are specifying from the outset lightweight composite trench covers which can be quickly and easily removed by hand.” Fit-and-Forget – The Maintenance-Free Solution Fibrelite composite covers are available in a range of sizes and load ratings. Designed to be a “fit-and-forget” product, they are maintenance-free, lightweight, durable and very strong as a matter of course. Custom Sizes Available Custom-made trench covering solutions are available on request which means that dimensions, internal stiffeners and fibre-architecture can be altered to optimize the performance of each panel based on project-specific design criteria.

Fibrelite is the world-leading manufacturer of innovative glass reinforced plastic (GRP) composite access covers and is renowned for its high quality technical support and service

Fibrelite composite covers are available in a range of sizes and load ratings

Coloured Covers for Easy Identification Fibrelite composite covers can also be moulded in virtually any colour or colourcombination and as the pigment is added into the resin during manufacture,

About Fibrelite Founded on a tradition of quality and innovation, Fibrelite has been at the forefront of composite technology since 1980. The first ever composite manhole cover was designed by Fibrelite for petrol stations, to eliminate health and safety issues associated with traditional metal covers. Today, Fibrelite is established as a leading world player in its specialist field, with a global reputation for high quality products.

Fibrelite has high volume manufacturing facilities in the US, UK and Malaysia


PECM Issue 14

there are no problems with the colour scratching or fading over time. This means that covers can incorporate logos and/or be colour-coded to match a facility’s branding or even to identify the specific underground service that can be accessed via a particular cover.

To find out more about how composite access covers can resolve specific onsite problems please visit http:// ow.ly/IAQc0 For more information: www.fibrelite.com

Facilities Management





PECM Issue 14

Flow Measurement & Control

Non-Invasive Flow Measurement Solutions


ynasonics have developed a comprehensive range of simple-to-fit, ultrasonic clamp-on liquid flow meters with portable, hand-held and fixed models for pipes from 13mm to 5000mm in diameter.

Dynasonics meters simply clamp on to the outside of pipes and do not contact the internal liquid, technology that has inherent advantages including: zero pressure head loss, no moving parts to maintain, no fluid compatibility issues, and a bi-directional measuring range at very low and high flow rates. The most advanced model from Dynasonics is the DXN™. Incorporating innovative hybrid metering technology the DXN™ can automatically switch between transit time and Doppler modes as needed and can be provided with a heat energy feature. With a colour touch-screen interface, internal data logging, USB connectivity and advanced signal processing the DXN™ is an indispensable tool for energy audits. The TFXL™ is the economical option offered by Dynasonics that provides accurate and repeatable bio-directional flow measurement readings of clean liquids using transit time technology. Featuring a LCD display, 4-20mA analogue output and USB port, this model comes with novel integrated pipe mounting sensors for smaller pipes or with remote transducers for small, medium and large pipes. The free Windows-based software allows users to easily configure and view data. The TFX Ultra™ incorporates all the features of the TFXL™ but with additional features including Modbus or BACnet communication, a rugged aluminium enclosure and optional heat energy measurement. The DFX™ uses the Doppler technique to measure flows of liquids containing suspended particles or aerated liquids. Doppler flow meters can easily accommodate a variety of what are considered ‘difficult’ flow measurement applications such as sewage, slurries and wastewater. The UFX™ is Dynasonics hand-held, batterypowered Doppler model, the unit employs a non-invasive transducer, which is placed on the outside of pipes. For advice on choosing the most suited Dynasonics model for the required application contact Bell Flow Systems. Tel: 01280 817304 Email: sales@bellflowsystems.co.uk www.bellflowsystems.co.uk Issue 14 PECM




ipp Systems UK has recently installed six new spiral seam tanks at a new bio-energy plant development in Wakefield, Yorkshire. These include three large 1,340m2 capacity anaerobic digestion tanks, an aeration tank, a buffer tank and finally a water processing tank. Chosen for unrivalled reliability, ease of construction and maximum safety – the new containers aim to produce enough biogas to power 3000 local homes. As a by-product the system will also create soil conditioner for agricultural use. The Wakefield site has been designed to process green waste - household

and commercial food and plant materials, with the capacity to receive and digest over 65,000 tons per year. The new tank installations form part of the South Kirby Anaerobic Digestion Plant, the green waste section of the Wakefield project. In its entirety, the site aims to recycle and reclaim 90 percent of the 230,000 tons of household waste it will receive per year. The main contractor for the Wakefield project specified Lipp Systems tanks due to their exceptional performance and safety credentials. With an impressive reputation for health and safety, it was important for the main contractor to preserve these high

standards for work at Wakefield. Lipp systems tanks were found to be ideal, as the build process reduces the amount of time working at heights. All tanks are constructed from the ground upwards with apertures and equipment attached at close to ground level requiring comparably little work to be conducted at high elevation. Unlike a segmented tank, workers will not be on scaffolding or ropes fitting hundreds of nuts and bolts. A primary concern with the storage of any media is the integrity of the containment unit itself; escaping contents or odours present an issue that can require large outlays to

Lipp Systems Ltd : Andrew Shedden, Sales Director Tel: +44 (0)113 2448156 Web: www.lipp-system.co.uk Email: info@lipp-system.co.uk

correct. The Lipp Double Fold System however effectively guarantees total integrity. Steel bands are spiral formed and folded twice over at the edges with a content appropriate stainless steel inner skin and galvanised steel outer skin sandwiching sealant between the two. As a result, no attachable surfaces are available for corrosion to form from the aggressive waste inside. This provides structural strength with maximum reliability and safety. Close positioning of the tanks at Wakefield required construction operations within a relatively small space. Luckily, the erection of each tank is carried out with space saving

as a primary concern. Construction is mostly automated, with steel bands being added underneath the roof of the container, raising the structure from the bottom up. This Spiral Seamed Technology enables a relatively straightforward and speedy construction process. Further benefits of this building method include variable container diameters depending on client specifications with low assembly and investment costs. Structural rigidity was also paramount for the project. By combining different steel compounds with strong interconnected bonds, the containers have an extremely long operating life

with no structural degradation. The tanks are highly resistant to horizontal pressure, greatly reducing the likelihood of failure. At Wakefield, Lipp Systems UK provided what the company regards as the safest, most reliable digestion solution available. Cost effective with minimal manual labour required, Lipp Systems anaerobic digestion tanks offer a completely revolutionary and efficient solution.

World Class Independent Valve & Actuator Training One-day training courses from leading g industry professionals. Independent courses. No sales pitch, just quality, technical training. These courses are a MUST for those involved in the engineering industry who need to know about valves and actuators. BVAA valve courses are delivered by our lecturers who have tremendous knowledge and experience of the industry. The sessions always result in comments of the highest praise.

BVAA Training Courses: Summer 2015 Introduction to Valves - Wednesday 6th May New Date Held at Severn Glocon Group, Brighouse Members Price: £260.00 | Non Members Price: £390.00 PED/ATEX Directives - Wednesday 17th May Held at Severn Glocon Group, Brighouse Members Price: £260.00 | Non Members Price: £390.00 Introduction to Valves - Monday 22nd June Members Price: £260.00 | Non Members Price: £390.00 Introduction to Actuators - Tuesday 23rd June Members Price: £260.00 | Non Members Price: £390.00 Control Valves - Wednesday 24th June Members Price: £260.00 | Non Members Price: £390.00 Safety Valves - Thursday 25th June Members Price: £260.00 | Non Members Price: £390.00 Safety Integrity Levels (SILs) - Friday 26th June Members Price: £260.00 | Non Members Price: £390.00 Advanced Valves - Monday 29th June New Course Members Price: £260.00 | Non Members Price: £390.00 Combatting Corrosion - Tuesday 30th June Members Price: £260.00 | Non Members Price: £390.00 PED/ATEX Directives - Wednesday 1st July Members Price: £260.00 | Non Members Price: £390.00 All prices exclude VAT

For full details on each course, visit www.bvaa.org.uk/training_courses.asp British Valve and Actuator Association Limited • 1A Banbury Office Village • Noral Way • Banbury • OX16 2SB Tel: +44 (0)1295 221 270 | Fax: +44 (0)1295 258 893 | Email: enquiry@bvaa.org.uk | Web: www.bvaa.org.uk

Fluid Handling Mixing and Dispersion Specialists


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

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. Personnel 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”. 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 www.ytron-quadro.co.uk

Reverse Osmosis slashes annual fuel costs at westons Cider by £44,000 – and nets joint industry award for westons and Spirax Sarco

Westons Cider has cut its annual fuel costs by £44,000 per annum and has significantly reduced water consumption following the installation of a Spirax Sarco Reverse Osmosis (RO) water treatment system. The savings achieved led to Westons Cider and Spirax Sarco being named joint winners of Food Processing magazine’s Energy Management award in 2014. The Spirax Sarco RO system reduces fuel and energy consumption by cutting the amount of boiler blowdown and water needed. Regular boiler blowdown prevents total dissolved solids (TDS) from accumulating in the boiler, where they can cause problems such as carryover and deposits. The RO system from Spirax Sarco treats water before it reaches the boiler feedtank and removes more than 98% of TDS to produce high-quality, low-conductivity water. This has cut blowdown from 3% to less than 1% resulting in savings of fuel, water and boiler treatment chemicals.

www.spiraxsarco.com Issue 14 PECM


Health & Safety Prevention is better than cure when it comes to accidents in the workplace

Bigneat announces Optiflow, a new style of safety workstation

Research outcomes from a YouGov survey conducted on behalf of Seton in 2014 show that a huge 68% of employees report that their working health and safety needs are not completely met by their current employer. Coupled with the finding that 14% of employers admit that there is nobody within their organisation trained in any type of workplace health and safety, it is perhaps not surprising that a high proportion of preventable accidents at work occur.

Optiflow is a small bench-mounted ductless fume cabinet, downflow bench, hood, workstation (whatever you prefer to call it) which protects the user from chemical vapours, fumes or particles depending which type of filtration is chosen. Carbon filtration retains chemical fumes and vapours and HEPA filtration retains dusts and particules.

In order to prevent workplace injury and the associated costs, Seton offer a wide range of health and safety products such as anti-slip tapes, floor stands, cable protectors, and safety signs. In addition, Seton provide training solutions such as posters and DVDs to ensure that people within the organisation are aware of relevant health and safety guidelines and procedures. After all, prevention is better than cure when it comes to slips, trips and falls at work. For more information, please visit www.seton.co.uk

Optiflow provides unrestricted access for procedures and handlings that are difficult to perform within a standard fume cabinet and because it is a ductless system this compact and portable unit can be installed onto an existing work surface, located where it is most needed. Robert Monks, Managing Director of Bigneat comments, “I can honestly say that Bigneat now offers the most comprehensive range of safety cabinets and workstations on the market,” he adds “every day I am proud to tell people that we design our systems in the UK and manufacture here too.” Further information and literature on Optiflow can be found on the Bigneat’s websites at: www.bigneat.com and www.safetyfumehoods.com

Denso Protal Protects Pipeline Joints at Gas Storage Site

Traffiglove releases new hand safety report

Having previously used Winn & Coales Denso Protal protective coatings on several pipeline projects at Storengy UK’s Gas Storage Site in Cheshire, leading civil engineering and construction company J Murphy & Sons Ltd has recently used Denso Protal 7300 for protecting weld joints on the 2014 Underground Pipelines Contract with Storengy UK. The appeal for Murphy to use the Protal 7300 coating product on the contract was that, on completion of blast cleaning to gas industry standards, which correlates to Swedish standard Sa21/2, it enabled them to obtain a required coating thickness of 1000 microns in one application to the welded joints.

Bringing together the latest information and innovation in hand protection, Traffiglove has released its newly updated Hand Safety Report (HSR) 2015. As a valuable source of information for all mechanical and industrial businesses where the need to ensure hand safety is crucial, the HSR has been developed to help improve overall awareness of hand injuries and how best to avoid them.

The Protal product was used on a dual pipeline from Storengy’s exiting gas and methanol lines to Well Site H324, a distance of 1200 meters which also linked four well sites along the route. Winn & Coales Denso Protal coatings give effective anti-corrosion properties by forming a firmly bound corrosion inhibiting film on the metal surface. The result is a thick, effective physical barrier against air and moisture which remains permanently flexible. It can be applied by brush, roller or pad.

Supported by extensive research comprising the latest health and safety statistics from across the UK and Europe, the HSR 2015 specifically tackles hand safety issues and hand protection standards whilst also looking at risk assessment myths and how best to avoid Hand-Arm Vibration Syndrome. The HSR also offers advice on how to ensure the ‘best fit’ for gloves – which is crucial - as well as providing glove care and maintenance tips.

Tel: 020 8670 7511 www.denso.net

To get a copy of TraffiGlove’s new Hand Safety Report 2015 for yourself, visit www.traffiglove.com/hand-safety-report

Email: mail@denso.net

New Tygon® 2375 Ultra Chemically Resistant Tubing from Universal Biologicals Tygon® 2375 Ultra Chemically Resistant Tubing offers an unequalled combination of chemical resistance, clarity and flexibility. It is virtually unaffected by acids, bases, ketones, salts and alcohols, fitting the requirements of many applications from battery acid filling, hazardous material handling, food and beverage dispensing and use with aggressive cleaning fluids. It’s entirely plasticiser-free, eliminating fluid contamination and premature embrittlement and cracking common with many flexible tubings. It’s exceptionally smooth inner surface inhibits particulate buildup and reduces the potential for contamination. Universal Biologicals (Cambridge) offer an extensive range of Saint-Gobain’s Tygon high performance tubing formulations each engineered to meet specific user needs.

Email: info@universalbiologicals.com www.universalbiologicals.com

Innatank™ - a Revolution for the Safe Storage of Hazardous Liquids The safe storage of hazardous liquids is a perennial challenge facing the water treatment and chemical processing industries - but things could be about to change thanks to a ground-breaking innovation by leading British tank producer Forbes Technologies Ltd. Following an investment of over £1.7 million at their main manufacturing plant located in the Borders of Scotland at Kelso, Forbes has developed Innatank™. This complete self bunded tank system cleverly combines a chemical storage tank and integral bund within the same structure. Put more simply, it can be described as a ‘tank within a tank’.

Tel: 01366 389640 Email: mjupp@forbesgroup.co.uk

Bringing flair to work at height

Training Key to Staying Safe

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.

Used correctly abrasives have an extremely good safety record and manufacturers follow stringent manufacturing standards to ensure products are fit for purpose. However, problems arise when products are used incorrectly or for materials and applications for which they were not intended.

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.

Tel: 01993 826050


PECM Issue 14


So where can you go to get the correct training for your specific application, machine and environment? In most instances abrasive wheel producers and distributors can offer valuable advice but in an effort to raise standards and awareness the British Abrasives Federation (BAF) have been providing an accreditation scheme to ensure that trainers and training companies are giving the right information. For more information on BAF training programmes or a list of accredited trainers contact BAF Secretary Stuart Lane on 08456 12 13 80 or info@thebaf.org.uk. Alternatively visit the website www.thebaf.org.uk



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*Terms and conditions apply. Price quoted subject to a one day course for 30 delegates plus VAT.

Health & Safety

Tom Parker Ltd. Putting Safety First ever choose between performance and safety Tom Parker Ltd., national distributors of pneumatic and hydraulic products, is renowned for introducing the highest quality and most innovative ranges to the UK market. They were originally formed to distribute the premium quick connect safety coupling range of Cejn Sweden to the UK, but over the last 40 years’ Tom Parker Ltd. has expanded into one of the leading UK distributors. Now offering a comprehensive range of more than fifty market leading brands and over 30,000 catalogue lines, they are fully equipped to be a one-stop fluid power source. Tom Parker Ltd. is now delighted to announce the launch of its new, safety-focused short-form catalogue. Operating alongside their main biennial product catalogue, the brochure contains an overview of their complete range of safety products, safe usage of compressed air guidelines and suggestions to ensure accidents



PECM Issue 14

are easily avoided. Efficient, Ergonomic and Economical One key product range highlighted within the new catalogue, is the Cejn eSafe safety coupling, which easily ensures operator protection. This new generation of safety coupling provides the highest flow available on the market and, this in conjunction with the resulting low pressure drop, guarantees maximum efficiency and productivity. Simple to use; eSafe offers a one-hand push feature to connect or disconnect, due to its ergonomic design which offers durability and ensures a long service life. eSafe series couplings vent the downstream pressure before disconnection occurs, reducing noise levels and removing the risk of operator injury caused by hose-whip. This vented safety function is a feature on all of the products as standard. Furthermore, eSafe couplings are the first safety couplings to share the same compact dimensions and weight of a standard coupling. This innovative range boasts a low connecting force and offers a reliable solution against impact, vibration &

swivelling. Additionally, eSafe products save energy and comply with international safety standard ISO 4414, the European Standard EN 983 and OSHA 1910.95. The high quality choice Safety is a key priority when choosing goods to complement Tom Parker Ltd.’s vast but carefully selected product range. They believe the products highlighted within their safety catalogue will easily and cost effectively ensure that customers adhere to increasingly stringent safety regulations, but most importantly keep their operations running smoothly, ensure maximum profitability and keep their workforce safe. They believe that these ranges guarantee superior quality, performance and peace of mind, because you should never have to compromise. To maintain these exacting standards throughout all of their operations, Tom Parker Ltd. employs quality management systems, in accordance with BS EN ISO 9001:2000 and is certified by the BSI. Their expertly trained Technical Sales Team is on-hand to offer impartial advice and assist with all enquiries, no matter how challenging. Their Business Development Team can easily cross reference other supplier’s part numbers and endeavour to beat your fiercest quotes. Tom Parker Ltd. cater for timed deliveries and can provide text and email confirmation of arrival time for most orders. www.tom-parker.co.uk T: 01772 255109 E: sales@tom-parker.co.uk

Health & Safety

Reece Safety Products choose Fibox Arca to house their SRK24 substation rescue kits hen it comes to staff safety, personnel who are tasked to enter HV substations to carry out specific duties are in the main, fully trained to recognise the dangers associated with high voltage power equipment.


and lifesaving actions without risk to themselves.

Even so, accidents can and do happen. In such an incident, loss of life or serious injuries can be reduced by having immediate access to the correct equipment.

In more complex situations, the kits are supplied with insulated cable cutters to break power lines.

Housed in a robust 800mm x 300mm x 600mm IP66 Fibox Polycarbonate ARCA enclosure, the rescuer has immediate access to Insulating gloves and boots as personal protection, combined with an insulating platform and insulated rescue hook to drag the unfortunate victim away from the live feed; the Reece Substation Rescue Kit allows the rescuer to take rapid

A 5-36kV voltage detector on an insulated pole is also included to check for a safe condition before endangering the life of the rescuer.

Steve Gallon, MD of Fibox in the UK said, “This is another classic example of a forward thinking company like Reece, recognising the flexibility and long term benefits of injection moulded products in areas where traditional sheet steel and GRP enclosures would corrode in time. Fibox also point out the successful installation of many other projects, which as well as the conventional

Pic of Safety Kit housed in the Fibox ARCA enclosure

functions like housing switchgear, telemetry housings and for housing very sensitive electronic equipment for control equipment, have also included such a diverse application as to be specified as the ideal product to house fire extinguishers on the decks of boats. Tel: 01642 604 400 web: www.fibox.co.uk Issue 14 PECM


Health & Safety

How do you get that CLP label you need by the end of June 2015? Get a Brady printing solution and be compliant!

June 2015 is just around the corner!

T: E:

scilabub ltd UK Manufacturer Of Safety Gloves

Frosters Cryogenic Gloves, Aprons & Suits t For use with materials stored with liquid nitrogen and in other very cold environments. t Typically they are used for handling objects stored in the vapour stage of liquid nitrogen (ranging from -120째C to -190째C). t Protects against the spills and splashes of cryogenic materials. t Superb insulation needs less thickness giving more dexterity. t Synthetic fibre outer for flexibility. t Water resistant. t Gloves available in 4 sizes & 3 lengths. t Suits & aprons available in 4 sizes

Nomex Heat Resistant Gloves & Gauntlets Our Nomex Range is effective, durable and comfortable offering: t t t t t t t

Dexterity. 4 Sizes, 2 Lengths. Excellent Heat Resistance. Does not shrink or melt. Hard wearing. Blend of Nomex & Kevlar. Widely used in the semiconductor industry. t Competitively priced.

www.scilabub.com sales@scilabub.com +44 (0)1530 279996 80

PECM Issue 14

Health & Safety

Innovation in safety helps Lanes Group win sixth RoSPA Gold Lanes Group has won a RoSPA Gold Award for occupational health and safety for the sixth year in a row. he achievement means Lanes Group, the leading drainage and maintenance specialist, retains its RoSPA Gold Medal.


Initiatives put before the judges included a new industry-leading digital risk assessment tool that has achieved 100 per cent field operative compliance, and allows real time management review of work site health and safety. The company will receive the Gold Medal from the Royal Society for the Prevention of Accidents (RoSPA) in a ceremony at the Hilton Birmingham Metropole Hotel at the National Exhibition Centre on 14 July 2015. Only organisations that continuously set the highest occupational health

and safety standards, year after year, qualify for a Gold Medal in the prestigious annual RoSPA Awards. To achieve the success, Lanes Group had to supply detailed explanations and evidence of its occupational health and safety strategy, policy, procedures and performance across all elements of its business. The award is the second recent health and safety success for Lanes, with the announcement that the Lanes Utilities Division has been named a finalist in the Construction News Awards 2015 for Health and Safety Initiative. Initiatives submitted in evidence for the RoSPA Awards was the decision to invest over ÂŁ25,000 in implementing a SHE software system to integrate health and safety management across

Lanes’ main operational depots. Lanes Utilities Division could point to the introduction of a digital point of works risk assessment (PoWRA) tool for its Thames Water wastewater networks maintenance contract, which contributed to an accident frequency rate of zero during 2014. The digital PoWRA allows operational managers to monitor risk assessment in real time, and support field engineers on key decisions. It also has a Shout About Safety function that invites engineers to suggest safety improvements at each job. Lanes Group: www.lanesfordrains.co.uk Issue 14 PECM



SpeedMarker 1300


Specially designed to mark large bulky items and high volume small parts, the SpeedMarker 1300 can process parts up to 1250mm wide. With the ability to communicate with your own software or database, plus the option to automatically generate data matrix codes and barcodes, the SpeedMarker can legibly mark as small as 1-point font on metal and plastic with ease. Integrate our SpeedMarker series of galvos into your own production system for the utmost in flexibility. Book your customised demonstration at our South East Showroom now – 0191 417 4505


into one machine.

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



Hydraulics & Pneumatics

Issue 14 PECM


Lubricants Industrial prelube for critical power generators & marine engines

“NIS” Completes a successful 8 Months Field Trial of its NanoLub® Diesel Engine Power Generation Oil Additive

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

Parker Chomerics enhances thermal management solutions with the release of its latest THERM-AGAP™ gel with conductivity extensions to 6 W/m-k As 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.


“Nanotech Industrial Solutions, Inc.” (NIS), the USA innovative nanotechnology company and “NanoMaterials Ltd.”, NIS’s wholly owned subsidiary, have concluded an 8 month long field trial in collaboration with “Thermoguayas Generation S.A”, an operator in the field of power generation. During the field test, conducted at “Thermoguayas” diesel engine Power Plant in Ecuador, NIS’s NanoLub® Power Generation DEM5000 Diesel Engine oil additive was used with 4MW Wartisla diesel engines, resulting in an 8.6% power output increase for recently overhauled engines and a staggering 42% increase for pre overhauled engines, with an impressive overall boost in the Power Plant’s output capacity. In addition, major engine maintenance cycles (MMC) were prolonged by 75%, from 8000 to 14000 hours. USA Email: sales@nisusacorp.com


Europe & Asia Email: info@apnano.com www.apnano.com

Closer to you and your equipment Mechanical failure is the main reason for production downtime, 43% of which is due to bearing failures caused by inadequate lubrication, which is why Klüber Lubrication are dedicated to developing speciality lubricants that provide greater product durability, energy efficiency and overall lifecycle cost reduction for equipment assets. For over 80 years through close partnership with our customers, our experts have developed speciality lubricants for every application in virtually every industry aimed at meeting all your requirements whether it’s extreme loads, sophisticated materials, or optimum performance - if it’s about pushing the limit of what is possible then Klüber Lubrication solutions are in demand.


PECM Issue 14

Machining & Machinery Our DATA LOG can tell you! MEASURE ANALYSE



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CNC - Spezialmaschinen

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© iStock

01925 817803



Composites versatile and durable

– like a


5-Axis CNC Machines for ¬ ¬ ¬ ¬

Composite Panels (Glass and Carbon) Patterns (Epoxy based and Aluminium) Honeycombs and Foams Thermoplastics

Applications For the Automotive, Aerospace, Marine, racing, sports and leisure industries, and more ...

Manufacturers of High Quality Anti Vibration Products

MAKA 5-axis machining centres are innovative high-end solutions. Process optimisation, precision, quality and reliability stand for Productivity and Flexibility.

MAKA Machinery UK Ltd

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

www.fibet.co.uk F:01282 878201


C5 Horton Park, Hortonwood 7, Telford TF1 7GX Tel: 01952 607700 Email: iy@makauk.com

Issue 14 PECM


Measurement & Monitoring The new Parsum IPP-80 in-line particle sizing probe: robust, trouble free granulation monitoring The new Parsum IPP-80 probe from Malvern Instruments brings easy to integrate inline particle size measurement for efficient process monitoring and control. Suitable for powders, pellets and granules the new probe enables the realtime monitoring of agglomeration, coating and granulation processes. The resulting data provide a secure basis for pilot plant studies, process optimization and control. A robust, sanitary design delivers long-running operation with minimal attention and includes in-built self-diagnostic tools that ensure data quality.

Heat Flux Measurements in the Micro-watt range greenTEG offers high-precision thermal sensors (gSKIN®) for process control and maintenance. greenTEG’s sensors resolve heat flux in the Micro-Watt range and detect temperature gradients down to Nano-Kelvins. Applications: mass flow measurements, real-time detection of thermal influences in high-precision instruments, non-invasive temperature measurement & profiling, as well as fouling & icing detection. The gSKIN® heat flux sensors measure three types of heat fluxes: conduction, convection, and thermal radiation. They generate an analog voltage signal proportional to the heat flux. The signal can be read out and further processed to monitor processes and conditions.

For more information on Parsum IPP-80, view the launch webinar here http://www.malvern.com/parsum-webinar


Remote Monitoring Solutions from Hosokawa Micron Get More out of Your Plant

Loop-powered BL 540 isolator for easiest 20 mA signal transmission

Hosokawa Micron Ltd’s latest, Machine to Machine (M2M) Remote Monitoring initiative can help manufacturers monitor industrial plant and equipment to deliver production cost savings, improve product quality and equipment performance and predict potential equipment failure enabling timely and efficient preventative maintenance.

For galvanically isolated 1:1 transmission of 4..20 mA standard signals, Knick provides the BL 540 isolator from its low-cost BasicLine series. By reliably decoupling the field and control levels, the device prevents system malfunctions.

‘This technology and the skills we can offer customers for improving production are relevant to both Hosokawa equipment and that of other OEMs. The expected customer benefits from improved remote condition monitoring and support are faster resolution of problems, decreased equipment downtime and more efficient operation of the plant and equipment,’ explains Iain Crosley, Managing Director, Hosokawa Micron Ltd.

At a low 1.7 V voltage drop, the device needs no auxiliary power supply but can be powered through the loop – this results in the additional advantage of a much reduced wiring effort. The isolator features a 0.2% full scale accuracy. One and two-channel devices are available in a 6 mm DIN rail housing. BL 540 isolators are CE-compliant and UL-certified. Knick provides a three-year warranty for the devices.

Email: info@hmluk.hosokawa.com

Email: knick@knick.de


New Temperature Sensor Series for HVAC and Building Technology


Profiling technology for contact paste driers and contact firing furnaces with a very low clearance

The compact, innovative enclosure with protection class IP65/NEMA 4 facilitates easy and fast installation of the sensors. Due to external mounting holes the sensors can be installed with closed housing, which protects the device from building site contamination. The new temperature sensors line matches the design of the successful E+E humidity, CO2 and air velocity sensors. The result is a comprehensive HVAC sensor choice, with a uniform look, from a single manufacturer.

The new Datapaq SolarPaq temperature profiling system is a combined solution for photovoltaic cell contact drying and firing processes. To ensure efficient energy use, ovens and furnaces used in the solar/PV industry are built with low entrance and exit heights. Consequently, in-process temperature monitoring requires special technology. Datapaq has designed an ultrathin logger (9 mm) and thermal barrier (16 mm) which can be used in all these processes. The DQ1840 steel-cased logger, developed from the established Q18 line, performs the majority of profiling runs without extra thermal protection. It withstands up to three minutes at up to 300 °C. For use in firing furnaces, Datapaq supplies the TB7237 thermal barrier which provides protection at up to 800 °C for 45 s or at 400 °C for 4 min.

Email: info@epluse.at

Email: stephan.wilke@fluke.com

E+E Elektronik expands its product range with various sensors for passive temperature measurement for HVAC and building technology.


RHEINTACHO is your No.1 choice for Rotational Speed Measurement, Control and Indication. Whether it is required for: Mobile Hydraulics, Mobile Material Handling, Large Engines, Construction Machines, Ship or Train applications, Preventive Maintenance, Service/Start-up and Industrial applications.


Newall DP500 Mill & Lathe packages launched this month Warren Measurement Systems have been Readout Company for more than thirty years.

an Independent Digital

Over 100 Years of manufacturing excellence spread over two sites in Germany and the UK has resulted in the two sites producing Machine and Process Mounted Equipment (mechanical & electrical tachometers, non-contact speed sensors & programmable speed sensors) and instruments for Inspection and Diagnostics ( hand held tachometers including ATEX models and hand held and fixed stroboscopes)

We offer Sales Service and repairs on most makes of DRO, including Newall, Acu-rite, Mitutoyo, Goodwin and Sony.

Please contact sales@rheintacho.co.uk

Please Quote PECMoffer for 10% discount off any order.


PECM Issue 14


This month the Newall DP500 Mill & Lathe packages have been launched, which are very competitively priced and targeted specifically at the turret mill and tool room lathe market. For a free quotation or service visit from one of our Service Engineers, please give Heather a call on 07796 268605

Buy on-line www.labfacility.com info@labfacility.com

Leaders in temperature measurement

Bognor Regis 01243 871280 Sheffield 01909 569446

TEMPERATURE SENSORS Thermocouple sensors mineral insulated fabricated & fine wire versions configurations for plastics & special applications

Platinum resistance thermometer sensors mineral insulated fabricated configurations for special applications

PRT sensing elements flat film wirewound class A,B,1/3DIN, 1/10DIN RO 100/ 500/ 1000 Ohm

All in stock for immediate despatch

Custom made specials to order.

Measurement & Monitoring


PECM Issue 14

Manufactured in the UK

Tinytag Data Loggers:

Robust Environmental Monitoring Solutions temperature




power usage









Tinytag data loggers include discreet units for indoor monitoring and robust loggers for the harshest environments. UÊRugged and compact UÊEasy to use UÊDust, splash or waterproof UÊData downloaded to PC UÊCost-effective Accompanying probes are available for measuring extremes of temperature, and for monitoring awkward to reach areas such as pipework. Data loggers with displays are also available.

Tinytag Plus 2

Energy Logger

Rugged outdoor/industrial temperature/RH logger

Single & three phase power monitoring

From £95 +VAT

£795 +VAT

For larger sites, the Tinytag radio data logging system uses wireless communications to automatically gather data for viewing at the user’s own desk.

Tinytag Ultra 2

Tinytag CO2

Radio system

Indoor temperature/RH logger

Discreet indoor monitoring

Ideal for larger or remote sites

From £69 +VAT

From £325 +VAT

Bundles – 3 loggers/receiver/ software from £1000 +VAT




Gemini Data Loggers (UK) Ltd Scientific House, Terminus Road, Chichester, West Sussex, PO19 8UJ, England


power usage



Telephone: +44 (0)1243 813000 email: info@tinytag.info www.geminidataloggers.com www.tinytag.info







Measurement & Monitoring Knick announces BL 560 repeater for two-wire sensors The short-circuit-proof BL 560 repeater power supply from Knick’s BasicLine series is an equally reliable and cost-efficient solution for voltage supply and signal decoupling of the much-used two-wire sensors in safe areas. Providing a 16.5 V feed voltage, the device is suitable for most industry-standard loop-powered transmitters or two-wire sensors. The galvanically isolated active current output supports a maximum load of 500 ohm at 20 mA. With the power supply also galvanically isolated, there are no problems caused by channel-to-channel coupling through the power supply. The BL 560 is CEcompliant and UL-certified. Knick provides a three-year warranty for the device.

Email: knick@knick.de


Alicat Basis Mass Flow Controllers – essential OEM flow control Alicat Basis Mass Flow Controllers – essential OEM flow control. Making you faster with 100ms control response and accessible PD valve tuning, basis are ready to control process flows in just 70 ms. Offering 1.5% of reading + 0.5% full-scale accuracy and flow rates from 1 to 1000 SCCM. Selectable on board multi-gas calibrations (Air, Ar, CO2, N2, O2, N2O) make the basis ideal for OEM gas analyser and automated gas mixing applications. RS-485 digital communications and 0-5 VDC analogue signals ship as standard. Contact Premier Control Technologies for full details. Tel: 01953 609930 email: sales@pctflow.com web: www.pctflow.com

with a 14.5cm LCD touchscreen, the Fluke TiX Expert Series takes Infrared Cameras to a whole new level With a full 180° articulating lens and 14.5cm touchscreen, the new Fluke® TiX520 and TiX560 Infrared Cameras allow thermographers to easily navigate over, under, and around objects to preview and capture images. The new Expert Series cameras are ideal for predictive maintenance, in R&D, oil and gas, and utility applications, where flexibility and higher resolution are essential, and they enable users to share their data in real time via Fluke Connect™. The responsive 14.5cm LCD touchscreens of the TiX520 and TiX560 offer a large viewing area, which enables thermographers to quickly identify issues while still in the field, as well as easily edit images directly on the camera, eliminating time in the office. SuperResolution mode boosts resolution four times, so the normal 320 x 240 pixels resolution of the images captured increases to 640 x 480 pixels, revealing even greater detail. Optional telephoto and wide-angle lenses add versatility to meet a wide variety of applications.


Isotech’s New 4000 Range of portable temperature calibrators The company has updated nine of its most popular calibrators to bring new styling and updated features. Each model is available in three different versions from a cost effective heat source to fully featured devices which include a three channel temperature indicator, temperature logging and Ethernet interface. This new “4000 Range” spans -45 to 1200°C with models that can be used as Dry Blocks or Stirred Liquid Baths with options for infrared thermometers, surface sensors and even to operate ITS-90 Fixed Point Cells. “Our customers, who range from the worlds’ leading National Laboratories to site engineers have long valued the accuracy and quality of our equipment. This new range is a response from customers demanding modern styling and more features such as more input channels, advanced logging and an Ethernet interface. We are proud to meet this demand in a new lighter and stronger rugged case.”

Isothermal Technology Ltd Tel: 01704 543830 Email: info@isotech.co.uk www.isotech.co.uk


PECM Issue 14

HBM provides precise measurements in tough conditions As more and more applications in harsh environments require powerful force transducers, which feature a high resistance to external influences, HBM – a market leader in the field of test and measurement – is pleased to announce it has expanded its range of IP68 rated products to meet this need. The new Stainless Steel C10 Force Sensor provides maximum precision in compressive force measurement, for even the most demanding of environments. The new sensor offers 75 ppm and presents excellent linearity and hysteresis values. The sensors accuracy classes, which are between 0.03 and 0.06, depending on the nominal force which ranges from 2.5 kN to 1 MN, can be freely configured according to the application with a variety of options. The sensor’s core is optimally protected from external influences such as dirt and moisture in a Stainless Steel measuring body which comes complete with an optional integrated cable to achieve IP68 rating.

Email: info@hbm.com


Queen’s Award winner to address pressure management experts on the world stage As one of the most prominent Shows in the process industry calendar, ACHEMA is once again opening its doors to global visitors keen to discover the latest products and technologies from key players within their field. The event is a highlight of the calendar for pressure management expert, Elfab Limited. The UK-based rupture (bursting) disc manufacturer has shown significant yearon-year growth over the last 10 years and has just been named as winner of a Queen’s Award for Enterprise – the UK’s highest accolade for business success. Visitors to the Elfab stand at ACHEMA can see high performance visualisations of its products in action and hear about its new and innovative projects. On the Wednesday of the Show (17th June) Elfab will also be hosting a seminar as part of the prestigious PraxisFORUM schedule. The session will highlight recent innovations that have led to the development of sophisticated burst detection systems offering greater performance and reliability. Key members of Elfab’s management team will be on stand B45 in Hall 9.0 offering expert advice. If you would like more information or would like to arrange a formal meeting during the Show, call +44 (0)191 2931234 or email pr@elfab.com

Tel: Email: www.

Customer Demand Drives SICK Fluid Level Probe Expansion Launched three years ago, the LFP range has quickly been adopted as an economic fluid level probe. The LFP Cubic’s rugged ABS housing is suited to a wide range of process conditions with temperatures from -20°C to +100°C and pressures from -1 to 10 bar. The sensor’s tough enclosure is rated IP67 and its robust design offers a long service life with minimal wear and maintenance. The LFP Inox is designed for hygienic processes with interchangeable hygienic process connections, a process temperature range up to +150oC (+180˚C in the remote amplifier version), and offers protection to IP69K with resistance to chemical cleaning and washdown. All LFP models feature a stainless steel probe or rope which can be cut to length to suit the installation conditions. The range expansion enables the probe to be used in large vessels, however, with a deadband of just 25mm, the LFP is just at home in small vessels; also the probe can be bent to facilitate insertion from a horizontal mounting position, where this is possible and necessary. LFP commissioning is made easier by the sensor’s ability to simulate levels even when no fluid is present enabling a “dry test” of the control system function, and the sensor’s easy to read display and switching gives realtime level and status information. The analogue output is flexible, using either 4-20mA or 0-10V selectable, with up to four configurable PNP/ NPN outputs. Connection to fieldbus networks is straightforward via an optional module. For more information on the LFP Family, or any of Sick’s Industrial Instrumentation products, please contact Andrea Hornby on 01727 831121 or email andrea.hornby@sick.co.uk.

Measurement & Monitoring

Professional test and measurement technology From sensor to software: The complete measurement chain from HBM The requirements placed on sensors, electronics and software in terms of operation, acquisition and analysis are continuously increasing. Optimal matching of all components in the entire measuring chain is crucial. We at HBM place special emphasis on this aspect. Worldwide, in all branches of industry: Automotive, aerospace, mechanical engineering, weighing technology and many more. For maximum quality and precision. Q

Strain gauges


Load cells, mounting aids and accessories


Force, pressure, torque and displacement transducers


Amplifier systems for test and process measurement technology


Precision measuring instruments


Software for acquisition, analysis and prediction

Further information: www.hbm.com/pecm-tm

Q Fax +49 Q www.hbm.com HBM Test andUnited Measurement + 49 803-0 803-9100 Q info@hbm.com Q 6151 Q www.hbm.com HBM Kingdom QLtdTel. Q Tel.6151 0208 515 6000 info@uk.hbm.com

HBM offers compact & precise amplifier suitable for many different applications HBM’s new eight channel universal QuantumX MX840B DAQ amplifier offers precision and adaptability to frequently varying measurement tasks, providing outstanding flexibility, excellent measurement performance and ease of use.


uitable for a wide range of different applications, its universal connectors make the MX840B ideally suited for all common sensor technologies, no matter what principles of measurement are required. The eight channels can all be individually configured and used to measure a wide range of mechanical, thermal, electrical and hydraulic quantities, such as force, strain, acceleration, torque, rotational speed, temperature, voltage, current, pressure and flow rate. The amplifier supports more than 15 different sensor and transducer types: e.g. half and full bridge circuits (strain gauge and inductive transducers), resistors, potentiometric, voltage, current, thermocouples, LVDT, Ohmic

and rotary encoders and also features an input for CANbus. In addition, the new module also supports current-fed piezoelectric transducers (IEPE/ICP) on each channel. Featuring a sampling rate of 40 kS/s and a signal bandwidth of 7 kHz, the new MX840B is ideal for measuring and analysing electrical vibrations, mechanical vibrations and noises in the time, frequency and angle domain. The new MX840B can also be distributed up to 100m and used synchronously, using Ethernet and PTP, enabling it to be integrated easily into networks.

For further information, contact HBM on +44 (0) 20 8515 6000 or via email: info@uk.hbm.co.uk or visit the HBM website at www.hbm.com Issue 14 PECM


providing NEW portable temperature calibrators with greater accuracy and additional features New 4000 Range covering -45째C to 1200째C Portable Dry Blocks, Liquid Baths and Multifunction Heat Sources Three versions from a Basic Heat Source to an ADVANCED Model with inbuilt three channel thermometer, data logging and automatic temperature cycling New Rugged Lightweight Outer Cases

Call now to request a FREE on-site demonstration - 01704 543830

Isothermal Technology Limited Pine Grove, Southport, Merseyside PR9 9AG England Telephone: +44 (0)1704 543830 Fax: +44 (0)1704 544799 Email: info@isotech.co.uk


Measurement & Monitoring

Creating Environments

Temperature & Climatic Chambers Test & Evaluation Systems

Is HAVS causing you issues? The Vexo Hand-Arm Vibration Meter

Tel: 01628 850611 www.unitemp.co.uk


buy online NOW for only

ÂŁ1,995!! 01723 584250

Issue 14 PECM


Setting new standards in the supply of technical tooling solutions

ADM Precision Tools Ltd has an extensive history in providing tooling and automated production cell solutions to the technical moulding industry. ADM set new standards in both design and manufacture of plastic processing tooling. We have a vast knowledge in a fast growing market; from a simple component to an integrated development project. We use the latest high speed machining techniques and processes. We aim to build on our continuing success from previous PDM shows by using these opportunities to demonstrate the capabilities of our facilities. These include our 2-shot moulding, terminal pin insertion tools as well as an array of many other complex and innovative solutions. Our experience in developing bespoke products means that we are able to deliver ground breaking results to achieve our clients’ requirements. We invest in the ADM tool room to acquire the latest technology to create durable, reliable and innovative high-precision mould tools. Our multi-cavity tools are made with Husky, Hasco, Fastheat and Synventive hot runner manifolds and shut off nozzles. We at ADM, in conjunction with AMS Technical Plastics Ltd, our sister company, supply a comprehensive and precise solution to a vast array of industries. These include automotive, electronics, medical, consumer appliance, telecom and defence. We at ADM are proud to have played a key role in the design and development of products for high profile companies including Siemens, Boots, TRW Automotive, Aston Martin, BMW and Nokia.

See us at the PDM Exhibition, 16 & 17 June 2015, Stand B003 ADM Precision Tools Ltd. Unit 5, Park 17 Moss Lane, Whitefield, Manchester M45 8FJ Tel: 0161 872 8881 • Email: Designroom@adm.eu.com • Web: www.adm.eu.com

PDM Preview

PDM celebrates 10 year anniversary T

he Plastics Design and Moulding Exhibition and Conference (PDM15) celebrates its 10th anniversary as the UK’s premier annual event for the plastics industry. Returning to the Telford International Centre on 16 and 17 June, the event will be co-located with the new Plastics Packaging Show and the second Plastics Recycling Expo, and has already attracted over 100 exhibiting companies. The two-day PDM Conference focuses on a range of the industry’s most topical issues including skills shortages, EU membership, sustainable design, automotive lightweighting and 3D printing. Highlights include: • An overview of the UK Auto industry by Luke Hampton, supply chain director at the Society of Motor Manufacturers and Traders (SMMT) • Skills shortage in the plastics industry are apprenticeships the answer? • Richard Brown, Managing Director, G&A Moulding Technology Ltd • Plastics, lightweighting saviour; welding of automotive plastics components. Best practice and assessment of joint integrity by Farshad Salamat-Zadeh, Chartered Polymer and Adhesive Engineer and Senior Project Leader at TWI


PECM Issue 14

• •

Failure in Polymer Products - it doesn’t just happen! by Justin Taylor, Principal Consultant, ipolytech, Telford Material innovations in injection moulding by Dr Mark Barnett, Head of Warwick Scientific Services

There will also be a number of ‘shop floor’ sessions for engineers, providing practical expertise in areas such as moulding techniques and machine care. A popular feature of previous shows that returns for 2015 is the Plastics Consultancy Network’s Plastics Surgery. Visitors are invited to bring along questions they may have relating to plastics design and moulding and PCN’s consultants will be on hand to offer effective, creative and cost-effective advice and solutions.

and Kongskilde UK. Other exhibitors include product design companies, rotational and blow moulding machinery suppliers, toolmakers, rapid prototyping specialists, moulders and mouldmakers, masterbatch specialists, software suppliers and materials testing specialists.

Major names from every part of the UK plastics community have confirmed their presence at PDM15 including Distrupol, Plastribution, Negri Bossi, Premier Moulding Machinery, Billion UK, BMB Plastics Machinery, Kuka Robotics, Luxus, Mouldshop, Rutland Plastics and Chess Plastics.

Organisers have also reported a new level of interest from overseas businesses keen to showcase their capabilities to the UK market, now regarded as the growth area in Europe. Such exhibitors include Italian-based M.P Srl, Austrian-based Meusburger Georg GmbH & Co Kg, Swiss company U-NICA Gruppe, 3D Design Technologies Ltd (Cad2parts Ltd) from Turkey and Luxembourg-based CODPRO.

Companies exhibiting at PDM for the first time in 2015 include: Igus UK, Cad2parts, South West Polymer Supplies, Hotset UK

To register to attend PDM15 visit: www.pdmevent.com

Process Technologies

- Withstands over 260°C of heat and remains flexible to - 60°C - Insulates to 8,000 volts per layer - No adhesive means no loss of bond strength even years after application and no messy residue upon removal - Creates a permanent airtight and watertight seal in seconds! - Resists acids, fuels, oils, solvents, salt water, UV rays and more!






X-Treme Tape self-fusing insulating and repair wrap Capable of withstanding extremes in temperature, pressure and voltage, X-Treme Tape is a self-fusing insulating and repair wrap, which forms an air and water-tight stretch seal by sticking only to itself by means of a cross-linked polymer bond.


apable of withstanding extremes in temperature, pressure and voltage, X-Treme Tape is a selffusing insulating and repair wrap, which forms an air and water-tight stretch seal by sticking only to itself by means of a cross-linked polymer bond. The tape features the highest bond strength in the industry along with high tensile and dielectric strengths. As no adhesive is involved in the fusing process, a strong, permanent

air and watertight bond is created once the tape comes into contact with itself during application. The lack of adhesive means that the bond strength does not weaken once applied, with tests indicating no deterioration in performance even five years after application, nor does it leave any messy residue when removed. X-Treme Tape is used extensively as a permanent repair on leaking pipework or damaged electrical wires or cables, as an insulator for electrical connections, or as a clean

and mess-free form of protection whilst maintenance work is carried out. X-Treme Tape can be used indoors, outdoors or under water, and is resistant to UV and salt water, as well as many acids, fuels, oils, and solvents. Having an operating temperature range of -60°C to 260°C, X-Treme Tape is also a Class H insulator, with no loss of performance when used continuously at 180°C. X-Treme Tape is developed and manufactured by Mocap Inc., at their manufacturing facility in Missouri. For customers in the UK and across Europe, stock is held at their European headquarters in Telford, Shropshire. Further information about X-Treme Tape can be found by visiting www.xtremetape.eu or by calling Mocap on 01952 670247. Issue 14 PECM


Raima RDM workgroup database selected for demanding Scada applications ETM Professional Control GmbH, a 100% owned subsidiary of the Siemens AG, has selected the RDM Workgroup database from Raima as a core element of its SCADA system SIMATIC WinCC Open Architecture.


he SIMATIC WinCC Open Architecture forms part of the SIMATIC HMI range and is designed for use in applications requiring a high degree of client-specific adaptability, large and/or complex applications and projects that impose specific system requirements and functions. The object-oriented SCADA system SIMATIC WinCC Open Architecture allows companies to implement solutions tailored to their specific customers helping save valuable engineering time. ETM’s solutions are particularly placed in the areas of traffic, water, energy, oil & gas, building automation industry as well as research.


PECM Issue 14

“ETM needed a product with the performance to handle bigger amounts of data with an increased data throughput rate”, explains Steinar Sande, CEO of Raima “RDM Workgroup also provided the necessary platform independence by supporting Windows, Linux and Solaris.”

ETM’s solutions are particularly placed in the areas of traffic, water, energy, oil & gas, building automation industry as well as research. Raima Database Manager (RDM) is optimized for embedded, real-time, in-memory and mobile applications,

delivering flexible and reliable solutions for collecting and storing large volumes of data, providing intuitive methods for managing and navigating through information quickly, and enabling data to be moved in real-time. It provides software developers with a wide variety of powerful programming tools and customizable building blocks that enable them to solve the most complex data management challenges.

About ETM Professional Control GmbH ETM develops the SCADA system SIMATIC WinCC Open Architecture. SIMATIC WinCC Open Architecture forms part of the SIMATIC HMI range and is designed for use in applications requiring a high degree of client-

specific adaptability, large and/or complex applications and projects that impose specific system requirements and functions. ETM professional control is a 100% owned subsidiary of Siemens AG, headquartered in Eisenstadt, Austria. Organizationally and functionally ETM is assigned to the Industrial Automation Systems (I IA AS) business unit.

About Raima Raima delivers high-performance, always on database technology for both in-memory database usage and persistent storage devices. Raima’s core focus is to develop database management solutions for everything from small, embedded devices up to enterprise level hardware systems. The Raima Database Manager (RDM) products are cross-platform, small footprint, fast and reliable database solutions which are made to collect, store, manage and move data.

The Raima Database Manager (RDM) products are crossplatform, small footprint, fast and reliable database solutions which are made to collect, store, manage and move data. They are used worldwide in a wide range of data management solutions in industries such as industrial

automation systems, military flight control systems, telecom routers & switches, financial trading systems, medical equipment, data backup solutions, consumer electronic devices and more. All products feature solid and reliable ACID compliant database technology and employ a number of advanced solutions to meet today’s complex data management challenges. Examples are moving data from small lowpowered embedded devices up into larger enterprise systems, building highly-available database systems, database partitioning support to facilitate data distribution and scalability, and interfaces allowing access to the data from a range of external sources. Raima Database Manager (RDM) products include options to meet a variety of data management architectural designs by providing a choice of data models and access methods to solve the most stringent performance requirements. For more information on RDM or to download the SDK for evaluation visit: raima.com/products

The object-oriented SCADA system SIMATIC WinCC Open Architecture allows companies to implement solutions tailored to their specific customers helping save valuable engineering time

“ETM needed a product with the performance to handle bigger amounts of data with an increased data throughput rate”,

Process Technologies The Filter Press Co. Ltd The Filter Press Co. Ltd supplies all types and sizes of Filter Presses to the EU market. The field of filtration and separation is not a new concept to this company, as they have been in this type of industry for many years, servicing the Chemical, Pharmaceutical, Food, Oil, brewery, water treatment, and many other sectors of industry. We supply Filter Presses from 0.01m³ up to 20m³ solids capacity, from 450mm square plates up to 2000mm square. Filter Presses used are the Plate & Frame, Chamber, and Membrane, there will be a press to suit your requirements in size and throughput. We do have a small Chamber Filter Press that can be easily transported to site for trials if required, along with various sizes of filter media. The plates are made of Polypropylene, and so can be used on most applications. For more details please contact sales@filterpress.eu

Triaster’s weekly webinars Triaster, based in Oxfordshire, delivers a Business Process Management and Improvement Solution. Our Process Libraries are a single source of truth for all processes and documentation; assessable and used by your whole organisation. Our completely customisable approach means a Triaster Process Library fits seamlessly with your corporate brand and strategic objectives (see example). Attend one of Triaster’s weekly webinars for some more detail. These 30-minute webinars give an introductory tour of a Triaster Process Library and a high level understanding of how the Triaster Solution enables effective management and improvement of business processes. They are free to attend. To register please go to: www.triaster.co.uk/why-triaster or call +44(0)870 402 1234

Specialist Power Screw Products Ex stock power screws & nuts Precision-machined components Self-reversing screws and followers Accredited by Aerospace, Nuclear & Chemical customers Specialist leadscrew & power screw products

Call C all 01482 325676 Kingston Engineering Co (Hull) Ltd, Pennington Street, Hull, East Yorkshire, HU8 7LD, UK Fax 01482 216438 Email: sales@kingston-engineering.co.uk



PECM Issue 14

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

Fax: 0208 339 7371

Email: sales@blackfast.com Web:


The Filter Press Co. Ltd. Process Filtration Solutions

Filter Press

t Filter Presses can be divided into “recessed plate” and “plate and frame” Presses, which are used for solid – liquid separation of various processes, slurries, and sludge’s. t The Filter plates are compressed together using a hydraulic system, or they can be electro mechanically operated if required. t The solid particles and liquid are separated through a filter cloth which is matched to your particular process. t These Filter Presses are simple and safe in operation, and very economical to use. t Our Model sizes include the: 320mm, 450mm, 630mm, 800mm, 1 mtr, 1.25 mtr, 1.5 mtr and 2 mtr square plates. t An impressive Filtration area of up to 2000 m². t Filter plate materials can be: reinforced Polypropylene, Cast Iron, Stainless Steel, or to our customer’s spec.

Stainless Steel Multi-Bag Filter Vessel t With flows through these filters of up to 840m³/hr. t Our Stainless Steel Multi-Bag Filter Vessels are manufactured in many sizes and configurations utilising a large filtration area. t Using from 2, up to 24 easily fitted and sealed polypropylene filter bags. t The size of filter bags are from No 1’s to No 4’s and are easily removed and replaced. t The Filter housing shell is designed for pressures up to 10 bar, with a filtration accuracy level down to 0.5µm, and temperatures up to 110ºC. t They are designed for use with liquids and gases. t Material of Construction can be 316L, 304, Carbon Steel, or come coated with a chemical resistant protective coating or exotic material.

Belt Filter Press

t A Belt Filter Press is an ideal sludge-dewatering system which is widely used in the food stuff, chemical, coal, paper making, and wastewater sewage industry. t A Belt Filter Press can also be used for liquid-solid separation in many other processes. t The main feature of this type of press are high efficiency, good dewatering effects and low power consumption.

Basket Centrifuges

We can supply New ATEX Certified basket Centrifuges for many industries, in all sizes and manufactured in Stainless Steel, Carbon Steel, Exotic steels, coated in Rubber or Halar, or to our customer requirements. We also supply refurbished equipment. We also supply Decanter, Disc Stack, and Worm Screen Centrifuges. More info at www.cesluk.co.uk

All the above types of Filtration Equipment are widely used for chemical, pharmaceutical, dyestuff, metallurgy, foodstuff, textile, printing and dying, paper making and sewage treatment industries.

Please visit www.filterpress.eu The Filter Press Co. Ltd www.filterpress.eu sales@filterpress.eu South Side Works, South Street, Huddersfield, West Yorkshire, HD1 4UG Tel: 01484 548200 – Fax: 01484 502274

Process Technologies

New TC Model t 500 - 2000kg/hr t Touch control screen t Full modulation feature 50-100% firing t Natural Gas, Light Oil, LPG and Bio Fuel t Automatic facility option t >98% Efficiency * t Steam in 3 minutes t Compact construction t Lightweight, suitable for mezzanine floors t Factory tested prior to dispatch to site t

Electrical Range t Compact t 8 - 160kg/hr Steam output t Modulating ouput t Skid mountable t Steam in 3 minutes t Automatic facility option

Dual fuel option

Junior & Universal Range t 80 - 2000kg/hr t Natural Gas, Light Oil, LPG and Bio Fuel t Automatic facility option t >98% Efficiency * t Steam in 3 minutes t Compact construction t Lightweight, suitable for mezzanine floors t Factory tested prior to dispatch to site

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

Liquid Chiller Temperature Control Systems Mydax stands apart from other chiller manufacturers by providing the elite chiller system on the market, utilizing patented proportional refrigeration control, rugged tubular steel frames and state of the art touchscreen controls. Expert use of flowmeters, pressure transducers, pulse width modulated valves and variable frequency drives allow precise temperature and fluid flow control. Long term system performance is insured by incorporating high quality components and decades of experience. Thorough system testing and a dedicated support team utilize built in diagnostic and safety devices to keep all chiller systems performing to design specifications for years. Made in USA. Our wide temperature range industrial chillers, available ultra precision temperature stability and our ability to utilize Multi Channel designs for a smaller footprint and an economical solution for multiple cooling loop applications where 1, 2, 3 or more temperature control loops are needed, makes Mydax a unique solution for your applications. When quality and reliability count, turn to Mydax. When your temperature control needs have special requirements, interfaces and demands, Mydax has the answers. Mydax custom designs and manufactures every temperature control system to directly meet their customer’s needs, whether it’s a one of a kind custom chiller or 100+ OEM systems. Please call or visit Mydax online for more information. www.mydax.com


PECM Issue 14

CVE Package Plant t compact t Pre-pied, Pre-Wired t Skid mounted t Fully factory tested t Lightweight t

Easily maintained

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

Mydax is bringing Laboratory Precision to the Industrial Market Mydax has successfully designed, developed, and delivered three custom refrigeration chillers that utilize ultra-precision temperature control to Lyncean Technologies, Inc. Lyncean Technologies, in Palo Alto, CA, developed the technology for a new local synchrotron X-ray source based on research at the SLAC National Laboratory and Stanford University. By using laser pulses to collide with accelerated electrons, the CLS (Compact Light Source) is a new breed of X-ray generating source that reduces the size of synchrotron equipment from tens of thousands of square feet to the size of a small conference room. Temperature stability is critical for high power RF components such as accelerator structures where even the slightest shift due to temperature expansion/contraction can affect the performance of the overall device. Mydax met this challenge by designing and manufacturing three chiller systems capable of providing up to 66 kW of cooling while holding the heat transfer fluid temperature to within ±0.05°C about set-point. Mydax 3MP28W1 Chiller Two chillers, model 3MP28W1, were each comprised of three independent recirculating loops. Two of these loops were capable of cooling or heating 2 kW at 20°C, while the third loop was capable of cooling or heating 4 kW at 20°C. All three loops had independent temperature set-point functionality between +14°C and +50°C, and maintained fluid temperatures to within ±0.05°C about set-point. Mydax 1MP222W2 Chiller One chiller, model 1MP222W2, was capable of cooling 66 kW at 20°C. Utilizing a 25 horsepower compressor and recirculating heat transfer fluid at a flow rate of 110 GPM while under load, the chiller maintained fluid temperatures to within ±0.05°C about set-point.

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

New TC Model t 500 - 2000kg/hr t Touch control screen t Full modulation feature 50-100% firing t Natural Gas, Light Oil, LPG and Bio Fuel t Automatic facility option t PM5 Facility option t Pressure range up to 32 barG t >98% Efficiency * t Remote compatible with Profibus/ CANbus etc. t Steam in 3 minutes t Compact construction t Lightweight t Suitable for mezzanine floors t Factory tested prior to dispatch to site t NOx Gas reduction option t Dual fuel option

SC Range t 80 - 2000kg/hr t Natural Gas, Light Oil, LPG and Bio Fuel t Automatic facility option t PM5 Facility option t Pressure range up to 32 barG t >98% Efficiency * t Steam in 3 minutes t Compact construction t Lightweight t Suitable for mezzanine floors t Factory tested prior to dispatch to site t NOx Gas reduction option

Electrical Range t Compact t 8 - 160kg/hr Steam output t Modulating ouput t Skid mountable t Steam in 3 minutes t Automatic facility option

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

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

Duty Standby with CVE Package Plant

CVE Package Plant t compact t Pre-pied, Pre-Wired t Skid mounted t Fully factory tested t Lightweight t Easily maintained

Containerised Plant t Easily relocated t Self contained plant room t Full lighting and heating t Fast site connection

Servicing & Repairs of Rotary Valves and Diverter Valves Free of charge assessment by a DMN engineer Genuine spare parts used to the original manufacturer’s specification Comprehensive 12 month warranty with continued support with all refurbished DMN valves Refurbishment service by the original manufacturer ATEX certification and validation services

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



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


PECM Issue 14

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



Process Technologies

Simscene Focus: Heat Exchanger Simulation Concentration Heat And Momentum Limited (CHAM) – a long-established consultancy controlled by world-renowned scientist Professor D Brian Spalding FRS – develops and applies its PHOENICS Computational Fluid Dynamics (CFD) software to a range of processes involving fluid flow, heat and mass transfer, chemical reaction and combustion. CHAM has developed a low-cost, easy-to-operate CFD-based simulator for shell-and-tube heat exchangers, called HeatEx, that embodies the best available computer models of all the features which conventional industry-standard design packages either ignore or guess, including: ◊ realistic flow patterns within baffled tube banks and headers; ◊ non-uniformity of tube-and shell-side heat-transfer and pressure-drop coefficients; ◊ temperature dependence of fluid properties; and ◊ start-up and shut-down behaviour. HeatEx simulates the thermal performance of three-dimensional shell and tube heat exchangers, providing a pragmatic aid for designers and manufacturers to develop moreefficient and cost-effective heat exchangers. HeatEx can handle all the usual TEMA (Tubular Exchanger Manufacturers Association) flow configurations, with arbitrary numbers and shapes of baffles, number of tube-side passes, etc. It predicts the overall effectiveness and pumping-power requirements and reveals the internal flow distributions, locations of maximum tendency to tube vibration, low-velocity locations where deposits may occur. All the things which operators truly want to know. HeatEx employs a computationally-economical “space-averaged” CFD technique to permit designs to be modelled using portable computers, and enable the heat-transfer behaviour of the entire heat exchanger to be predicted swiftly and accurately. It overcomes most of the limitations of the manual and numerical methods currently used to rate heat exchanger performance, by removing simplifying assumptions, such as: ◊ uniformity of fluid properties; ◊ uniformity of heat-transfer coefficient; and ◊ independence of time.

HeatEx offers a choice of TEMA shell types in addition to the default “E-type.”

The fluids occupy the same region separated by the metal of the heat-exchanging surface. For convenience, the temperature contour plots for the tube region (left) and shell region (right) are displayed side-by-side.

User inputs The user is offered drop-down menus to select options and enter data, including: ◊ Flow configuration [eg concurrent or counter-concurrent flow options] ◊ Geometry options [eg user-defined or TEMA selection] ◊ Impingement plate options ◊ Tube pass type [eg type, number, size and layout of tubes] ◊ Baffle type [eg type, number, size and layout of internal baffles] ◊ Material properties [eg physical properties, thermal resistances] for tube-side and shell-side fluids ◊ Initial conditions [especially for time-dependent scenarios] ◊ Boundary conditions [flow rates, temperature, density, pressure, etc] ◊ Gravity [orientation] ◊ Output [display options] ◊ Steady-state / Transient options ◊ Numerical settings

HeatEx generates output files and display defaults automatically – for single- or multirun cases – plus further, user-defined display options.

Contact Sales@cham.co.uk for the full range of available licensing options. Concentration Heat And Momentum Limited (CHAM), Bakery House, 40 High Street, Wimbledon Village, London SW19 5AU, UK Tel: +44 (0)20 8947 7651 Fax: +44 (0)20 8879 3497 Email: phoenics@cham.co.uk Web: www.cham.co.uk

Product News PULS Launches CostEfficient DIN-Rail Power Supply Family

Rugged Tablet Lockers and RFiD Tool Trolleys for Automotive

PIANO has now extended the PULS product range to service new market segments. Applying new techniques and concepts from design to manufacturing, the new PIANO series offers reliability, service lifetime and efficiency figures usually only available in higher cost products.

Within the Automotive Sector, processes and procedures are put in place to ensure that staff can work quickly and efficiently to maximize on vehicle turnover. Whether your business is a small service centre or a large production plant it is crucial to have tools and equipment in the right places, with the right people, at the right times so that work can be completed quickly and to a high standard.

The new design achieves an MTBF of more than 1.4 million hours and efficiencies of up to 94.5% with a minimum service lifetime of typically 40,000 hours. These innovations have been made possible by a smart single-board design with cost-saving polycarbonate housing. These new supplies are purely convection-cooled and can operate from -10°C up to +70°C. Easily mounting onto any standard DIN-Rail and with large-sized terminals making installation simple and fast. The ‘DC-OK’ signal that can be used to monitor the unit’s output voltage.

Email: sales@puls.co.uk


By placing the keys, tools and equipment that staff rely on within an iLockerz tool trolley or locker your team are offered fast and simple access that allows them to get on with the job at hand. Combine the simplicity and security of the iLockerz with the easy to use and automatic report generating web software and your business will get more from its equipment, team and premises within weeks. iLockerz can be used within your Automotive workplace to effectively manage Power Tools, Diagnostic Laptops, Calibrated Socket Wrenches, Spanners, Keys, Cameras, Trade Plates and any other equipment that is important to its operation.


UK pressure vessel firm adds precision tanks to range

Fujikura enhances splicing products to support biomedical industries

Pressure vessel producer SR-TEK has added precision pressure tanks to its ST series.

Fujikura Europe, one of the world’s leading manufacturers of fibre optic cables and equipment, has used 25 years of experience in the speciality splicing sector to enhance its technologies and products, including the LAZERMaster™ and ARCMaster® series, for use in the biomedical and research industries.

The reservoirs are supplied with precision air regulators and digital gauges to give the most accurate pressure setting and reading. The tanks provide an unprecedented pressure control and are particularly useful for applications requiring accurate flow rate and fluid deposits.

Simon Kay, technical consultant for SR-TEK says: “The need for better accuracy in fluid deposit is now an essential process requirement to eliminate wastage and reduce rework and costs within manufacturing. This new range of precision pressure tanks will help to combat the inefficiencies of some air pressure tanks and make the whole process more effective and cost-efficient”.

Fujikura’s advanced splicing technology includes high-end CO₂ laser heating systems, to enable cleaner splicing with no contamination, no electrodes for low maintenance costs and little or no instability at all. Alongside the new products Fujikura will also be providing engineering and optimisation services in specialty splicing for fibre preparation applications. These include custom hardware or software design, process improvement consultation and advanced splicer training. A typical CO₂ laser has an output power fluctuation of +/- 5 per cent which produces inconsistent splicing results and may cause irregularity and ripple in a taper profile. Fujikura’s new products for biomedical industries have a power stability feature which allows a stable laser output enabling highly repeatable processes.



Hidrostal’s pump cleans carrots for consumption

KDPES launches AS-6600 Accelerometer Simulator

Hidrostal Ltd, renowned manufacturers of pumping products to the water industry have provided a leading fresh vegetable grower and supplier, Produce World Group, with an enhanced solution for the cleaning of carrots in the vegetable processing operation.

Designed to simulate the output signals of many commonly available accelerometers the AS-6600 provides users of condition monitoring and data acquisition systems with the ability to check and verify the measurement capabilities of their systems over a broad range of frequencies and amplitudes prior to use or as part of an ongoing maintenance regime.

Available in 1L and 5L sizes, the ST precision tanks are equipped with a digital pressure gauge which has a tolerance of +/- 0.05psi and a fast acting safety relief valve. They also offer lockable pressure regulation from 0 to 100psi with a tolerance of +/- 0.05psi.

Hidrostal have supplied Produce World with an immersible pump to aid it in the prewash process at its Yaxley site which deals exclusively in organic vegetables including carrots. Upon arrival at the plant the carrots are off loaded from a lorry and prewashed using recycled wash water. Produce World had previously used an enclosed web, open belt conveyor method in this process but the pump that Hidrostal have supplied is part of a new open catchment design with a sloping bench arrangement to the sump area. The boom wash system aids the movement and flushing of newly arrived field carrots off the lorry at the very start of the process into the sump. The wash water is pumped using Hidrostal’s immersible pump to a rotary screened drum where most of the solids are filtered out before re-entering the boom wash system once more. This process occurs each time a lorry arrives with fresh field carrots.

KDPES is a specialist designer and manufacturer of instrumentation, cabling and system integration solutions. As UK representative for the Meggitt Sensorex product line we also offer customers a range of standard and ATEX rated LVDTs, RVDTs, Inclinometers, Accelerometers, Gyros, IMUs and Signal Conditioners.

Tel: 01635 550440 Email: lucy.ogden@hidrostal.co.uk www.hidrostal.co.uk

Tel: 01767 651058 www.kdpes.co.uk

Video pyrometers For hard-to-reach and hot processes

HRH The Duke of York visits BSRIA as a part of 60 year celebrations

The video pyrometers optris CSvideo 2M, CTvideo 1M/2M and CTvideo 3M are digital infrared thermometers with video sighting. They allow an easy sensor alignment through a PC or tablet. Thus, the infrared thermometers with video sighting are ideally suitable for temperature measurements of hard-to-reach processes and applications, where the measuring object is too hot for the laser sighting to be visible. The new infrared thermometers enable for an exact spot size marking from 0.5 mm through simultaneous video sighting and double laser sighting and measure temperatures precisely from 50°C to 3000°C. Response times from 1 ms allow an integration into fast processes. By measuring in the short wave length range of 1.0 µm, 1.6 µm or 2.3 µm, measurement errors on surfaces with low or unknown emissivity can be reduced.



PECM Issue 14

Email: enquiries@kdpes.co.uk

As a part of their 60 year celebrations BSRIA were visited by HRH The Duke of York, KG on April 13th. The Duke visited BSRIA’s Bracknell Headquarters where he met with Senior Staff before touring the BSRIA test laboratories and meeting the test engineers. The Duke follows in his father’s footsteps as His Royal Highness The Duke of Edinburgh visited BSRIA in 1962. During his visit The Duke was shown the full extent of the geographical coverage of BSRIA’s Worldwide Market Intelligence division which has researched over 94 countries, and was given an overview of the consultancy and research work BSRIA undertake and how this has delivered improvement in the Built Environment.

Email: bsria@bsria.co.uk


Software & Systems Publishing Interactive 3D PDF Documentation

iMoulder Plastic Injection Molding App

Theorem’s Publish 3D Document suite of products enable the publishing of 3D CAD data from CATIA V5, NX, PTC’s Creo Parametric, and JT applications into a PDF document containing embedded interactive representations of the 3D model. The data can be annotated and additional files transported with the document. By password protecting the PDF document the IP remains secure. Anyone with access to Adobe Reader can view and interrogate the document without specialist CAD software, which opens up opportunities for sharing information within organisations and supply/ distribution chains, allowing improvements to assembly, cost and quality.


Applauded by many plastics industry professionals and with over 30,000 users Worldwide, i-Moulder is regarded as the essential app for the plastics industry and now includes even more handy features. What’s New? i-Moulder user interface and basic features have been updated and expanded including extra material descriptions, overhaul of the trade names database and addition of 10 really handy injection moulding calculations and 14 industry standard unit conversions. Basic iMoulder is FREE and available on iTunes and Google Android Play. Users can upgrade to access Calculations & Unit Conversions from within the app for the price of a cup of coffee. (+ $3 in-app purchase.) Available on iPhone and Android

Strong, Simple, Reliable

GSM Graphic Arts

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.

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.

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.

• 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.

Varitronix launches new range of LCD Touch Screens


aritronix has announced the availability of a new range of Projected Capacitive LCD Touch Screens, for use with a stylus, a gloved finger or bare finger. The screens have been developed to operate with Varitronix-developed, in-house software which allows the “touch technology” to be optimised to differentiate between false and genuine touches. The technology ensures that false touches are rejected, even when liquid is unintentionally present on the screen – the touch-sensitivity is fully restored when the liquid is removed. In addition, wet, damp (or sweaty), bare fingers are not a problem – accurate tracking is still ensured. The Touch Screens are also glovedfinger compatible – the glove can be made from cotton, leather or plastic (eg for medical applications). A stylus


PECM Issue 14

can also be used, with a minimum diameter of 3mm - Touch Screens which support a stylus diameter of 2mm are currently under development. The screen size options vary from 1.77” to 17”.

Two options are offered for the hardness of the screen glass – the standard glass is 6H and the harder glass option is 7H. A custom silkscreen can be applied to the surface of the glass.

With international certifications including ISO 9001 for general quality management and ISO/TS 16949 for quality management of automotive products, the new range of LCD Touch Screens are manufactured to very high quality standards, providing durability and long-life. The Touch Durability is 10M touches.

Applications will include industrial, commercial, automotive and medical markets. Contact Varitronix UK on 01344 303 077 or email sales@varitronixuk.ltd.uk Website: www.varitronix.com

Software & Systems 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


Alert the right engineer, with the right information, at the right time, every time

Issue 14 PECM


Man and Machine CAD Training Academy ur goal is to help you optimise your design process. Whether you are in the architecture, plant or construction industries, we have the experience to understand your business and what you are trying to achieve, and we have the expertise to enable you to do it better.


Established in 1989, Man and Machine is part of a pan-European group, operating in 11 countries, with over 750 staff and over 500,000 installed CAD seats. We provide expertise in digital design and data management with over 60 years of combined technical experience and extensive industry. Our specialist knowledge has allowed us to develop a wide variety of services that address the needs of our customers’ across multiple industries to enable them to design, visualise, and simulate to the highest standard. Man and Machine’s professional training centre is a fantastic environment where customers can learn


PECM Issue 14

from industry experts, gain authorised qualifications and ensure that any CAD investment is utilised to its full potential. If you are looking to improve design efficiency, reduce costs and bring products or infrastructure to market faster, Man and Machine’s consultative approach will help you to gain a competitive advantage and leverage your own expertise to increase productivity and innovation.

To ensure learning outcomes are met, all of our CAD training solutions come with post training support for one month. Being an educationallyrich environment, the training academy allows you to select an appropriate learning track to help you derive the most from your software investment. To ensure learning outcomes

are met, all of our CAD training solutions come with post training support for one month. Students also receive an Autodesk or Man and Machine certificate on completion and all Autodesk CAD courses are taught using the official Autodesk courseware. Man and Machine are an authorised Autodesk Training Centre (ATC) and an approved Certification Centre, allowing students to receive an industry recognised Accreditation. “Man and Machine were able to drop straight in as our new reseller and provide a seamless transfer from our previous supplier. They have been able to give us all we need on the software side and have also provided a flexible training

program for a couple of our new starters”. Nick Slater - ITAB Shop Concept For more information on all of the CAD services Man and Machine provide including our latest training schedule and upcoming webinars please visit, www.manandmachine. co.uk, call 01844 263700 or email marketing@ manandmachine.co.uk.

Man and Machine’s professional training centre is a fantastic environment where customers can learn from industry experts, gain authorised qualifications and ensure that any CAD investment is utilised to its full potential.

Brevini provides mobility and lift for mini cranes in Transformers 4 film

These winches are also subject to customisation to ensure an exact fit within a particular application


Our relationship has become stronger due to our abilities to create synergies during complex, innovative projects and to provide customized solutions

he longstanding relationship between Brevini and Ormet, an Italian manufacturer of lifting and material handling equipment, has reached another milestone with their products featuring in the latest instalment of the Transformers movie franchise. The film features the Jekko mini cranes which use hydraulic winches and track drive systems manufactured by Brevini. The Jekko mini crane range was created by Ormet to provide customers with a range of products that can be manoeuvred into hard to access locations but still have the necessary power to complete a variety of lifting tasks. For many years Brevini has been supplying Ormet with the hydraulic winch drives for integration into its wide range of cranes and lifting systems; more recently it has been providing the track drives as well which provide the driving force for the mini cranes. “Our relationship has become stronger due to our abilities to create synergies during complex, innovative projects and

to provide customized solutions”, explains Brevini Power Transmission’s COO Stefano Brevini. The decision to use the Jekko SPD 360 minicrane in several action sequences has made Ormet machines visible outside of their usual and most popular applications in construction, industrial maintenance and agriculture, in fact anytime that large quantities of materials must be safely lifted and moved in a small, cramped space. The WHL range of hydraulic winches is specifically designed to satisfy the needs of OEMs that manufacture stationary or mobile cranes as well as drilling machinery. With 11 models in the standard line up, the winches feature a Brevini planetary reduction gearbox inside the drum; a design that provides a range of capacities from 1,000kg to 8,000kg line pull. These winches are also subject to customisation to ensure an exact fit within a particular application, and to ensure flexible operation with long term reliability. There are also a number

of accessories and design options available, such as a grooved drum, rope winding control system and various special coatings to combat the most severe of environments. The Jekko range also uses the CTM series of track drive units, produced by Brevini Fluid Power, and specifically designed for smaller industrial and construction machines. The geared motors feature a single planetary reduction with options for fail safe brakes and motion control valve which can safely control the downhill descent of the machine by creating a controlled braking action. “Thanks to the integration between the different products from the Brevini Group the range of components available to our customers is vast and can satisfy the most innovative needs,” concludes Stefano Brevini. “Seeing them used in scenes from a blockbuster hit like ‘Transformers 4: Age of Extinction’ is certainly a reason to be proud.” www.brevini.co.uk

Issue 14 PECM


Storage, Handling & Distribution




Beaverswoodsupply Co Ltd, Units 8-10 Metro Centre, ToutelyRoad, Wokingham RG41 1QW Tel 0118 979 6096

Birmingham Manufacturer Launches world’s Smallest Battery-Powered Counterbalance Truck The smallest and most powerful batterypowered counterbalance truck in the world has been launched by Wilmat, the West Midlands based manufacturer of materials handling equipment. The Bulldog heavy duty counterbalance truck was developed by the firm in Steward Street, Birmingham, to offer unprecedented manoeuvrability in even the smallest of spaces coupled with real lifting power. The smallest Bulldog (1933mm in length) has a 300kg lifting capacity and a lift height of up to 3300mm. For more information on Wilmat’s range of counterbalance trucks please call 0121 454 7514 ex.1 or visit the website www.counterbalancetrucks.com

email sales@beaverswood.co.uk

Lift Safe Solves Heavy Battery Lifting Problem for Adept Power Solutions Lift Safe, materials handling equipment and mobile work lifters specialist, has lightened the load of Adept Power Solutions (APS) by supplying it with a bespoke lifter to move large industrial batteries. APS, of Andover, Hampshire, provides solutions for customers’ site issues, sales, and services for uninterruptable power supply (UPS) electronic devices for the power protection industry. The company is currently undertaking a contract to replace 42 tonnes of batteries and redesign two complete battery/UPS rooms for the London headquarters of a global banking organisation. “As soon as I saw the job, I knew I would want one of Lift Safe’s specially made lifters,� says Colin Smith, DC Battery Specialist at APS, who co-designed the sitespecific lifter with Lift Safe and the project works on site.

Tel: 0161 626 9628 www.liftsafe.net

Email: enquiries@liftsafe.net

Full Drain & Cone Tanks 1360 – 17000 Litre Capacities Currently 12 Sizes Available – Choice of Cones & Frames - Call today to discuss requirements

Enduramaxx PO Box 895 Portsmouth Hampshire PO6 9DB | www.enduramaxx.co.uk | sales@enduramaxx co.uk


PECM Issue 14

Web www.beaverswood.co.uk

023 9259 3049

Storage, Handling & Distribution £3.5 Million Amazon order is largest ever for Stertil Dock products Stertil Dock Products has won its largest ever order to supply Combilok vehicle restraint systems for 14 Amazon sites throughout Europe. Before securing the contract, Stertil Dock Products was asked to participate in exhaustive trials, in competition with other manufacturers, at Amazon sites in the UK, France and Germany. The trials were highly successful in proving the performance and reliability of the Combilok across a whole range of lorries and vans including double deck trailers. Consequently, Amazon placed an order, with a contract value of £3.5 million, covering the supply and installation of more than 500 Combilok systems. The Combilok was developed to reduce the risk of unintentional vehicle movement on loading bays and offers a ‘safety net’ by holding vehicles in one place until loading or unloading is completed. Also, the Stertil Combilok vehicle restraint system helps to ensure the safe loading and unloading of vehicles by eliminating the common problem of poor communication between drivers and distribution personnel in loading bays.

Stertil Dock Products Tel: 0870 770 0471 www.stertil.co.uk








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Issue 14 PECM


Storage, Handling & Distribution

Stanley Handling Stanley PowerMate Powered Stairclimbers

C3412 – The new generation “Compact Crane”

Stanley Handling is one of the UK’s leading independent materials handling specialists For over 60 years we have been providing a wide range of materials handling equipment, designed to increase efficiency in space, time and budget. Our extensive range of Powered Stairclimbers move heavy and awkward loads up and down stairs and on and off vehicles with maximum speed and safety. In many cases Stanley PowerMate Stairclimbers enable work normally requiring two persons to be accomplished by one. From the smallest lightweight Stanley Sprinter, which can lift between 110-170kg, to the PowerMate M2B which has a capacity of 680kg, Stanley Handling has the right stairclimber for your particular requirements. Stanley PowerMate is synonymous with safety and professionalism – reducing back strain and operator fatigue and eliminating product and premises damage during the delivery cycle.

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


PECM Issue 14

Tel – 01582 767 711 Email – sales@stanleyhandling.co.uk www.stanleyhandling.co.uk

Storage, Handling & Distribution Print EU Regulation 1169/2011 Compliant Labels Food allergens can be life threatening and the only way people can manage a food allergy is to avoid the foods that make them ill. Therefore, the European Union installed a new consumer regulation that focuses on allergens in food. From 13 December 2014, the EU Food Information for Consumers Regulation (No.1169/2011) outlines the new requirements for businesses, which are providing food sold prepacked and non-prepacked (loose) such as food sold in a restaurant or takeaway. A product label is the first source of information for people with food allergy and/or intolerance to help them decide if they can buy and eat that product without risking an allergic reaction. Primera’s LX-Series desktop printers utilise the latest high-resolution inkjet technology to print brilliant full-colour labels. With spectacular 4800 dpi print resolution and high throughput speeds these compact and affordable printers print on a wide range of different label, tag and ticket materials including inkjet-coated high-gloss, semi-gloss and matte labels. Labels printed on high-gloss material are highly scratch-, smudge and water-resistant.

Email: sales@primera.eu


2 New Valla Mini Cranes delivered Cooper Tires Ltd, the UK manufacturer of performance tyres based in Melksham has taken delivery of 2 New Valla Mini Cranes for a variety of lifting tasks in the factory including mould changing, loading and site maintenance. The cranes a Valla 35E and 75E – 3,500kg and 7,500 SWL are both DC Electric power, with full pick and carry duties, helping to reduce manual handling as well as eliminating dangerous fumes and reducing noise emissions. The cranes were supplied by the UK distributor Hird UK Ltd who offer full sales and after sales support as well as operator training.


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SSI Schaefer Limited 01264 386600 solutions@ssi-schaefer.co.uk www.ssi-schaefer.co.uk

Issue 14 PECM


Storage, Handling & Distribution Bespoke Solutions from Bradshaw Electric Vehicles

If you can’t find what you need when looking for a Transport Solution, Bradshaw has the answer.... Efficiency is key for most businesses, as well as health & safety.... But how do you tackle a manual handling problem with a better solution that is going to be both efficient and safe, when that problem is a little more different from the standard? Often companies come to us with a problem that they are facing and which they need a transport solution to. It could be anything from needing to transport waste/recycling, delivering food, laundry or supplies in a hospital, for grounds maintenance, transporting baggage in airports, to moving people at events or staff around a large facility. All of the above solutions are standard for us, we have a product range to suit all of these requirements....HOWEVER, this doesn’t help you if you require something that’s a little different and you may be struggling to find what you need. This is why at Bradshaw we have a team that can design and manufacture a bespoke solution for you.

Bradshaw Electric Vehicles New Lane, Stibbington, Peterborough, PE8 6LW Tel: 01780 782621 www.bradshawelectricvehicles.co.uk


PECM Issue 14

1 of 2 Klimate doors installed at Trevon

Trevon – Investing in their future with High Speed Doors T

revon Industrial Finishers Ltd, based in Colne just outside of Burnley is a family run business which is celebrating their 40th anniversary in 2015 and is a service first partner of Akzo Nobel. Run by father and son; Trevor and Jon Crabtree the business is experiencing significant growth and investment. For a number of years their factory unit has been subject to the elements and in particular the wind due to its location adjacent to the Lancashire Pennines. They have toyed with solutions including strip curtains and various door types but nothing has provided a sufficient long term solution. Then, during a visit to a customer in 2014 they had their first experience with a high speed door. The site had a number of high speed doors in place and was only too happy to give Trevon a demonstration of how the doors worked and why they used them. Trevor and Jon both agreed that high speed doors were a possible solution to their ongoing problems so they got in touch with BID Group to ask about the Klimate range of doors. They looked at other companies that offered similar products but due to the fact that they had seen the Klimate doors in operation and they were relatively local it was decided that they would invest in two of the doors initially.

When asked what their early thoughts were on the doors both Trevor & Jon were unanimous in their answer;

They looked at other companies that offered similar products but due to the fact that they had seen the Klimate doors in operation and they were relatively local it was decided that they would invest in two of the doors initially. “The doors serve a number of purposes to us, not only do they provide a barrier to the wind, rain and cold they look great and help to improve the professional appearance of the business. In our line of business it is crucially important that we control the circulation of air within the building to prevent cross contamination, the high speed doors help in doing this massively. Another added benefit which we didn’t foresee at the outset is that due to the clear vision panel in

the curtain it allows for greater levels of natural light to enter the building and makes the general working environment much nicer and pleasant”. Trevon have also visited the manufacturing base of BID Group since the doors have been installed to see for themselves the work that goes into the production of the doors and in particular how the metal work is powder coated as this is what they specialise in. They were able to provide some very useful feedback that will go to improve the process of powder coating which will ultimately benefit all of the BID group customers and the staff internally. Another couple of openings have already been earmarked for high speed doors in the future and BID Group look forward to helping with any requirements that may arise.


Issue 14 PECM


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Subcon Preview World-class Engineering at China Prices With over 30 years of expertise in production engineering, Track Components provide solutions to your component needs. Based in Amersham, near London, our 25,000 sq ft manufacturing facility incorporates the latest machining technology and equipment. We produce a vast range of components to industry sectors, which includes, Medical, Defence, Lighting, Hydraulics and Pneumatics. Components are machined in-house to your drawings and specifications, may be enhanced by a range of surface finishes, including: heat treatment, anodising, plating or painting by our approved sub-contractors. We are able to offer: • Competitive pricing

ISO 9001 accredited, British owned and managed company in the heart of industrial China. 18 years experience in China and specialising in metal and plastics engineering: • Metal castings (5g to 20MT) o Sand castings (iron, steel, aluminium) o Gravity castings (aluminium) o Diecastings (aluminium, brass, copper, magnesium) o Investment castings (stainless steel, steel, iron, aluminium) o Lost foam castings (iron, steel) o Shell castings (iron, steel) • MIM (Metal injection moulding) – Stainless steel, steel • Powder moulding/Sintering

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We have a track record of supplying customers in USA, UK, Australia and many other countries with engineering parts, products or complete projects at China prices but with world-class engineering quality. We have four locations in three provinces in China: Guangzhou, Xintang, Shanghai and Jinan. View our website www.chinasavvy.com or contact our Managing Director, Christopher Devereux by email at cpd@chinasavvy.com or by phone +86 20 8388 7080 Ext 10 (GZ Of�ice) or +86 139 2416 9140 (mobile).

• Registered to BS EN ISO 9001 • PPAP, ISIR & FMEA documentation Please visit us at Subcon Show, stand S129 in Hall 4 Track Components Limited Units 3A & 3B Corinium Industrial Estate, Raans Road, Amersham, Buckinghamshire HP6 6JQ Tel: 01494 723755, sales@trackcomponents.co.uk www.trackcomponents.co.uk

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The Engineer Design & Innovation/Subcon Show 2nd - 4th June The Engineer Design & Innovation Show is a highly anticipated new show which will be co-located with both Subcon & Advanced Manufacturing to provide visitors with everything a design engineer needs to take a product from concept through to market.

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On display will be our extensive range of space saving Smalley Crest-to-Crest® flat wire wave springs and Spirolox® edge wound retaining rings. These innovative products are available to suit a host of applications and can be produced to suit shaft or bore diameters from as little as 5mm to in excess of 2,000mm. They are available in a wide range of materials including carbon steel, AISI 17-7, 302 & 316 stainless steels, Inconel, A286 and other exotic alloys. In addition, TFC will be demonstrating our supply chain expertise which provides significant benefits to customers by reducing costs associated with the purchase, stockholding and handling of a wide range of low-cost fastening and ancillary items. This area of TFC’s business has developed strongly over the past decade and our logistic systems have been designed to offer a flexible inventory managed system that caters for specific customer requirements whether it is a simple fax/e-mail request or an on-site bin location operation. TFC are excited to be part of this new innovative platform being held at the NEC Birmingham from the 2nd - 4th June and, if you are planning a visit, we would be pleased to welcome you to TFC’s stand, T10.


Call now to speak to our expert team about our products +44 (0)1435 866011


PECM Issue 14

✓ ✓ ✓ ✓ ✓ KASTO / Advanced Manufacturing Show / NEC / 2nd - 4th June / Stand A17

KASTO is the world’s leading manufacturer of high productivity sawing machines - manual, semi-automatic and fully automatic. Horizontal and vertical bandsaws including block saws, circular saws and even hack saws are included in our range. Whatever the application, from job shop to mass production with robotic sorting, we have a solution to suit your needs.

A focus for UK manufacturing Over 300 of the world’s leading subcontractors will be showcasing their capabilities at Subcon from 2 to 4 June at the NEC, Birmingham. ubcon provides the UK’s foremost showcase of companies offering contract and subcontract manufacturing services and runs alongside the Advanced Manufacturing Show and a new event focused on design and product development, The Engineer Design & Innovation Show.


Together the three shows will provide a focal point for engineering-based manufacturing in the UK across all sectors and disciplines. The increasingly buoyant manufacturing sector is reflected in the growing strength of the Subcon show, which this year features many new and returning exhibitors. Subcon is the UK’s only event that is completely focused on contract and subcontract manufacturing, including machining, moulding, fabrication, electronics assembly, finishing and treatments.

The solid core of the Subcon show is its UK exhibitors, who make up over three-quarters of the exhibitors. Subcon also offers access to global markets, with fifteen overseas countries represented in 2015, including pavilions for Denmark, Portugal, Italy, Hungary, China, India, Spain, Ukraine, Latvia and Taiwan, as well as individual exhibitors from Belgium, the USA, Greece, Slovenia and The Republic of Ireland.

The solid core of the Subcon show is its UK exhibitors, who make up over three-quarters of the exhibitors. Special features at Subcon this year include a drop-in advice centre where visitors will be able to get help with

issues relating to their business such as exporting and access to finance. An Innovation Hub will also give visitors the chance to talk to companies that have successfully built their business by innovating and learn from their experience. Visitors to Subcon can also take part in the free-to-attend Engineer Conference. This brings together top speakers from industry and academia to examine the hot topics and key issues facing manufacturing companies. Speakers come from leading organisations including The Manufacturing Technology Centre, Jaguar Land Rover, Airbus Defence & Space, the High Value Manufacturing Catapult and the AMRC. Exhibitors at Subcon include the Midlands Assembly Network, Lipco, WEC Group, Tata Steel, Gee Graphite, Tridan, Muller England and Mini Gears. Following its successful launch in 2013, the Advanced Manufacturing Show returns to the NEC alongside Subcon. Featuring over 50 manufacturers and suppliers of advanced production engineering technology, the show highlights the critical advanced manufacturing technologies that UK companies need to invest in to stay ahead of the game in international markets. These include machining and turning centres, sheet-metal working, metrology, tooling, work-holding and CAD/CAM software. The show will feature live machining demonstrations and new product launches highlighting the technologies that UK companies need to stay ahead of the game in international markets. Exhibitors include XYZ Machine Tools, Matsuura, Delcam, Renishaw, Hexagon Metrology, FARO, Kasto and Trumpf. Nigel Atherton, Managing Director of XYZ Machine Tools, said: “We had a very positive response at the last Advanced Manufacturing Show in 2013 and this encouraged us to rebook for 2015, when we will have new products to exhibit, such as the innovative XYZ 2-OP portable vertical machining centre. Since its launch it has been very well-received and the audience at the Advanced Manufacturing Show should recognise the potential that it brings in terms of reduced manufacturing costs through efficient use of labour.”

Visitors to the Advanced Manufacturing Show can also attend free conference sessions specifically dedicated to advanced manufacturing technology. Presentation topics include Industry 4.0, the factory of the future, additive manufacturing and the project to build Britain’s new aircraft carriers. The Advanced Manufacturing Show runs alongside Subcon and a new event, The Engineer Design & Innovation Show. This focuses on everything an engineering designer needs to do their job: from high-end products and services used to realize their concepts – such as new design software and 3D printing – to the components, materials and innovative technologies that go into these nextgeneration products.

Exhibitors at The Engineer Design & Innovation Show include Warwick Manufacturing Group, Proto Labs, JMP (Division of SAS Software), Panasonic Electric Works, Laser Lines, Spaceclaim Corporation and Tharsus.

“Our service covers the entire process of taking a product to market and we believe that having all of this capability under one roof is faster, more efficient and has less risk than other, more traditional methods.

Visitors to Subcon can also take part in the free-to-attend Engineer Conference.

“The co-location of the Design and Innovation show with Subcon is particularly relevant to us as our capability covers all aspects of the product development process from design through to manufacture.

Pam Robson, Head of Marketing at Tharsus, adds: “We work with customers to develop, manage and manufacture products that make it to the market and sell.

Engineer Design & Innovation Show Tharsus

www.advancedmanufacturingshow.co.uk/amsregister theengineer-designinnovationshow.co.uk/tedisregister www.subconshow.co.uk/subconregister

Issue 14 PECM


Subcon Preview BOGE delivers reliable and efficient custom engineered solutions for compressed air

Chinasavvy brings world-class engineering and manufacturing at China prices to SubCon 2015 British owned Chinasavvy, with its manufacturing headquarters in Guangzhou, China offers cost effective, yet high quality services to an international client base. At SubCon they will be demonstrating a wide range of engineering and manufacturing including six different casting services, precision machining and metal fabrication which covers everything from aluminium to stainless steel materials. Also on show will be examples of Metal Injection Moulding (MIM) of stainless steel parts. “We’re glad to be back at SubCon” says Christopher Devereux, Chinasavvy Managing Director and also Vice Chairman of the British Chamber of Commerce Guangdong, “Since we were last at SubCon were nearly three times larger and service customers in six continents for world-class engineered products”. Chinasavvy specializes in sub-contract manufacturing and is an ISO9001-2008 accredited company. They can be found on stand S329

Custom engineered compressed air solutions from BOGE Compressors are helping customers meet their compressed air needs in complex industrial environments. From conception right through to manufacturing, commissioning and maintenance, BOGE’s custom engineered solutions are delivering a reliable and efficient compressed air supply in even the most challenging applications or the most extreme ambient conditions. Designed to be economical, safe, efficient and durable, BOGE’s custom engineered solutions are tailored to the specific requirements of the customer, enabling them to maximise compressed air productivity. The custom engineered solutions available include both oil-free and oil-lubricated compressors, heat recovery and energy optimisation, compressed air treatment, and nitrogen or oxygen generators. These solutions are available in a variety of housings to suit a variety of environments, including: turn-key systems, which include pipework, cabling and ducting; plug-and-play containers; and on base frames. To ensure the perfect solution, BOGE offers both a full and partial service depending on customer needs. This includes an initial analysis of customer requirements regarding output volumes and compressed air quality and the production of concept designs. Once the designs are approved, BOGE then begins manufacturing and testing the bespoke compressor before safely shipping it to the customer’s pre-determined site, where it is safely installed by experienced BOGE experts and commissioned. In addition, BOGE offers post-installation servicing and support to ensure the compressor is consistently performing at its optimal level.

Tel: +44 14 84-719921


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PECM Issue 14

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= Air/Water = Oil/Chemical/Gas = General Purpose = Steam = Food & Beverage = Custom Built Large Bore = Armoured Dixon Group Europe Limited 350 Walton Summit Centre, Bamber Bridge, Preston PR5 8AS

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The Dixon Family of Quick Release Couplings offers complete Interchanges to all major manufacturers. U Sizes from 1/8” to 21/2” U Full Interchange Guide Available

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The TD series also comes ready to use, with no programming required

New temperature transmitter from ifm electronic makes life easier for food industry


ust launched by ifm electronic is the TD series, the latest addition to this leading manufacturer’s temperature sensor range, designed to make a food process plant operator’s life easier. The new TD series is an all in one unit with integrated electronics, process connector, and probe. This ‘one part number’ approach simplifies the ordering processes for the customer. On delivery the TD series offers a simplified installation process at the customer application, being ready to install, no assembly required. The TD series also comes ready to use, with no programming required – although this is made possible, by the inclusion of IO-Link. On delivery, the TD is scaled for 0-100°C (unless the 0…300°F version is ordered), and the IO-Link facility allows the user to take advantage of the full -40 to 150°C range.


PECM Issue 14

The new TD series is a fully hygienic instrument with ifm “look & feel”, and M12 connector, and housing in full 316 stainless steel, with an IP69K seal.

G1/2” hygienic conical fitting, with more to follow. The probe length options include so far five lengths of 30, 50, 100, 150, and 250mm.

With its small, one piece housing and added value of a local display at the price point of a blind unit, ifm’s TD series is believed to be unique under the hygienic temperature transmitters. There is certainly not much else on the market that features integrated 4 segment, LED display, IO-Link, factory pre-setting combined with a fast response time (T05= 1s, T09=3 s).

The TD series will operate in an ambient temperature between -25 and plus 70°C, and withstand a pressure range of -1 to 160 bar. As the units are pre-scaled and configured there is no need for pushbuttons, making it easy to seal the housing to IP69K.

The connection options present further advantages of the TD series; it can be wired as a three-wire or as a two-wire loop-powered device. Using the IOLink facility would require a four-core connection in order to access all the possibilities that IO-Link offers. Available process connections cover Tri-Clamp (1.5” and 2”) as well as a

All relevant standards are complied with, including EHEDG certification, 3A Sanitary Standard and of course CE and cULus listing. All parts are manufactured from FDA approved materials. For further information, contact Gemma Anderson, ifm electronic Ltd. Telephone: 020 8213-0000 Fax: 020 8213-2234 Email: gemma.anderson@ifm.com

First loop-powered temperature transmitter with LED display Two-wire temperature transmitter for food production. Bright 4-digit LED display. Fast response T05/09 = Ńż sec. Preset measuring range can be adjusted over IO-Link. Range of probe lengths and process connections available. Stainless steel. IP69K.

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

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PECM - Issue 14 2015  

PECM - Issue 14 2015