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Global Success Through Innovation

Process Engineering Control & Maintenance Issue 11 ÂŁ3.95

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

Control & 23 Automation

Electrical & Electronics

19 Air, Gas & Odour Control

Facilities 50 Management

Health & Safety


Measurement Process 73 & Monitoring 66 Technologies


Machining & Machinery 61

Storage, Handling 88 & Equipment

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

A passion for


Fast flow sensor for hot liquids The SBT flow sensor is designed to cope with fluids up to 180°C. Ideal for tempering processes in plastics, for example, the SBT can detect flows of 0.3 to 25 l/m (or 0.3 to 50 l/m), providing a 4 to 20 mA signal with extremely fast reaction to changes in the flow rate.

ifm electronic – www.ifm.com / uk/SBT Tel: (020) 8213 2222

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 11 Contents Tel: 01227 392575


News & Events


Tel: 01227 392575


Air, Gas & Odour Control


Tel: 01843 830249


Boilers & Maintenance


Tel: 01843 830249


Control & Automation


Tel: 01843 830249


Electrical & Electronics


Facilities Management


Tel: 01227 392571


Fluid Handling


Tel: 01843 830249


Health & Safety




Machining & Machinery


Measurement & Monitoring


Process Technologies


Product News




Software & Systems


Storage Handling & Distribution


Water & Effluent Treatment


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 & Maintenance when responding to items in this issue. Every effort is made to ensure the accuracy and reliability of material published in Process Engineering, Control & Maintenance however, the publishers accept no responsibility for the claims or opinions made by the contributers, 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 concent of the publisher.


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 11 PECM


Advanced Engineering 2014 is set to break all records 11-12 November, 2014, NEC Birmingham, UK

ore show streams, more exhibitors, more speakers and more special features … this year’s Advanced Engineering UK group of events, to be held at NEC Birmingham on 11th and 12th November is already shaping up as the biggest and best yet: quite an achievement for an event that has grown over six years of showcasing the UK’s burgeoning engineering, manufacturing, technology, innovation and supply chain capability.


Bringing together streams of engineering capability Already established as valuable events in their own rights, Aero Engineering Show 2014,

Composites Engineering Show 2014, Automotive Engineering Show 2014 and Auto Electronics 2014 provide focused individual environments for latest technologies and solutions, product and process innovation, plus industry supply chain capability supporting current and future market requirements. The combination of such highly synergetic show elements, under one giant roof, provides a hugely exciting integrated experience for supply chain sourcing, technology transfer and business development. Ian Stone, Managing Director of show organisers UK Tech Events comments: “Such an assembly of multi-sector knowledge, skills and capabilities generates a quite unique dynamic for visitors, exhibitors and partners alike in that it allows the

drawing of ideas and possibilities beyond already quite defined groups, affording an opportunity to look over the shoulders of other segments of the high value engineering community. Or, putting it another way, assess the partnership, marketing and sourcing possibilities available across the UK’s advanced engineering and manufacturing sectors”

Individual show streams

More show streams, more exhibitors, more speakers and more special features …

The Aero Engineering Show 2014 represents the UK’s only dedicated show and open conference for the aero structures, power plant and aero systems engineering communities: it is a unique annual showcase of technology and engineering suppliers supporting the UK’s critically important Aero Engineering supply chain, the second largest in the world.

Reflecting UK industry’s increasing demand across diverse sectors for harnessing the benefits of composites materials, the Composites Engineering Show 2014 is a single UK showcase of the very latest in composites materials, composites processing equipment, tooling and technologies, related design and simulation technology, specialist composites processing services, composites test and inspection technologies, and much more.

Representing the UK’s only dedicated show and open conference for Automotive body, chassis, powertrain and supply chain engineering, the Automotive Engineering Show 2014, provides a showcase of specialist UK and international engineering services, technology and supply chain partners supporting the UK’s multiple vehicle engineering programmes – from passenger cars to performance vehicles; from commercial vehicles to motorcycles, specialist low carbon vehicles and the engine sector.

The further Automotive Electronics 2014 event supports the drive to new levels of vehicle functionality, safety and efficiency, including exciting developments in infotainment and telematics. New for 2014, Performance Metals Engineering This year, augmenting the advanced materials agenda already established across the Advanced Engineering UK group of events, Performance Metals Engineering 2014 will add a new and significant dimension, usefully complementing the established and valued Composites Engineering show. The addition of this new stream is in response to increasing demands for higher performance from metallic materials in a range of capabilities vital to tomorrow’s engineering programmes… greater strength, lighter weight and extended functionality with processing efficiency. Issue 11 PECM


Ground-breaking innovation Alongside these main sector streams, an additional focus programme will showcase the enabling potential of graphene (the new and much talked about material for multiple applications) as well as the game changing possibilities for printable electronics. As in previous years, the objective will be for visitors to cover a wide span of UK advanced engineering, manufacturing and supply chain, and for exhibitors to set out their stalls before a significant proportion of decision makers in UK industry. Ground-breaking innovation is further highlighted in the increased range of feature ‘technology in action’ special features, allowing visitors to get up close to a whole range of exciting technology and innovation-based exhibits – from supercars, to aerostructures, from low carbon engineering to future electronics… and much, much more.

Experts sharing knowledge

This critical mass of engineering and manufacturing excellence, with a predicted 650+specialist exhibitors covering 20,000m2 of showcase floor space, is further supported by six show floor-based open conference auditoriums offering more than 200 expert technical and strategic speaker presentations during the two days of the event. No surprise then that the organisers are confident of seeing even more visitors than the 12,000 plus who attended the 2013 event.

Pre-register now You can pre-register now for a FREE ENTRY badge, which covers all five show streams and linked open conference programmes. Visit: www.advancedengineeringuk.com


PECM Issue 11


Join us where the UK advanced engineering sectors come together

Five key engineering events converge in one hall: Advanced Engineering UK 2014

Once again, the Advanced Engineering UK group of events brings together OEMs, primes and all supply chain tiers, to meet and do business across some of the UK's highest-growth advanced engineering sectors. Whether attending as an exhibitor or a visitor, each of the 5 co locating advanced engineering shows provides you with a business forum and supply chain showcase within its own sector, and those of its co-locating sister events. Automotive – Aerospace – Composites – Motorsport – Marine – Consumer – Energy – Electronics and more . . .

Hall 5 of the NEC this 11/12 November. Register now for your FREE entry badge at: NEW FOR


Media and industry Partners include


Advanced Engineering Preview

Solutions for industry


Your partners for: • Industrial power tools • Accessories & hoses • Tool repair and servicing for all major brands • Maintenance programmes • Hand Arm Vibration testing • Tool audits & assessments • Noise assessment • Trigger time monitoring • Airline efďŹ ciency assessments • Dust extraction systems • Training





Visit us on stand B18 Tel: 01327-703813




The moment you have absolute confidence in your results. This is the moment we work for.


Discover Smartzoom 5 – Your user-friendly, reliable digital microscope from ZEISS. Smartzoom 5 is ideal for quality assurance and quality control applications in virtually all fields of industry. Visit Stand F72 at Advanced Engineering UK 2014 for more information. www.zeiss.com/smartzoom


PECM Issue 11

Advanced Engineering Preview

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

at the nd D96 , NEC g show Visit ineerin th Nov. g n E o 2 Aer th to 1 om 11 n sta HBM o


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

Benefit from highly accurate and reliable data acquisition equipment. HBM will showcase its extensive range of DAQ equipment on stand D96 at this year’s Advanced Engineering show. Key personnel will be available to demonstrate the latest products that meet the demands of high-quality engineering in the aerospace and automotive sectors for the swift and accurate capture of data combined with analysis, often in real-time, to ensure maximum efficiency.

HBM will demonstrate its CANhead channel system that is primarily aimed at the aerospace sector for measuring strain or force. The measuring chain includes HBM’s CANhead distributed amplifier system, U10M force transducers and the MGCPlus. The

10-channel CANhead amplifier modules can be installed in immediate proximity to measuring points while standard fieldbus cables connect the CANhead modules to a communication master. HBM has improved its U10M force transducer with IP68 degree of protection making the transducers suitable for use in challenging ambient conditions. The cable is connected directly to the transducer contrasting with other models that utilise a bayonet-type plug. Measuring torque Measuring torque and rotational speed will be demonstrated utilising a radial engine fitted with HBM’s T40B digital torque flange combined with a TIMECA interface and a Beckhoff controller. The T40B digital torque flange from HBM gives speed measurements along with direction of rotation monitoring in addition to torque measurement in one compact system. Force & displacement Force and displacement will be

measured with an eccentric press featuring HBM’s PMX data acquisition and control system combined with the U9 force transducer. HBM set industry standards with its PMX data acquisition and control system. The PMX enables the precise acquisition of many quantities including force, torque, vibration, angle of rotation and rotational direction. Presentations HBM will also be giving presentations during the show. On Tuesday, 11 November, Karl-Heinz Haase, Product Manager for Optical Strain Gauges and Interrogators will look at determining the strain in composite and lightweight materials with his presentation on “The Benefits of Fibre-Optical Technology in Structural Testing of Lightweight Materials”. Issue 11 PECM


News & Events NOV MONO Marks Distributor Anniversary With Special Presentation The world’s leading supplier of progressing cavity pumps and associated equipment has marked the 20th anniversary of one of its key European distributors with a special presentation. NOV Mono presented a special ‘MonoT™ Man’ trophy to Madrid-based Albosa, in recognition of the outstanding service which the company has provided during two successful decades of serving the Spanish market. Albosa was founded in 1994 to market, distribute, service and support the wide range of Mono™ progressing cavity pumps, grinders, screens and aftermarket parts throughout Spain. “We established Albosa to work exclusively with Mono, rather than being a multi-brand distributor,” says proprietor Manual Modrego. “Our aim was for customers to see us as an extension of the Mono brand in the Spanish market – a distributor that was 100% integrated with the manufacturer whose products it supplied.”

Tel: 0161 339 9000


UK Manufacturing Company Secures Major Export Contract for Gas Analysis Equipment to be used in Smartphone Production Cambridge Sensotec Ltd, a UK based manufacturer of scientific gas analysis instruments, is proud to announce the signing of a major contract to supply the company’s Rapidox brand of oxygen gas analysers to Heller Industries Inc. Heller Industries is the world’s leading solder reflow oven manufacturer based in the USA, with manufacturing plants in China, Korea and Malaysia. Heller solder reflow ovens are used to solder the circuit boards included within many electronic devices such as; smartphones, MP3 players, digital cameras, tablets and laptop computers. As the global demand for electronic products increases, so does the demand for quality manufacturing processes.

Tel: 01480 462142 Email: david@cambridge-sensotec.co.uk

Power Electrics Record Breaking New Sponsorship Deal

New Website Features Makes Replacing Obsolete Automation Parts Easier

Power Electrics - the UK’s largest privately owned generator specialist - is embarking on its first major sponsorship deal: a global engineering adventure with BLOODHOUND SSC. The BLOODHOUND Project aims to inspire a new generation of scientists, engineers and mathematicians by designing and building a supersonic racing car which will set a new 1000mph World Land Speed Record in South Africa in 2016.

Leading automation supplier Northern Industrial have integrated some useful new features to make it easier for users to replace obsolete automation parts. So far, over 30,00 parts from a wide range of manufacturers have been matched with equivalent and follower products.

As an official product sponsor, Power Electrics is of paramount importance to the project. They will ensure the BLOODHOUND Team have the temporary power they need to achieve their mission, supplying them with diesel generators and ancillary equipment for their major events across the UK.

Northern Industrial, who supply a huge range of automation parts and repairs, are specialists in supporting users of end-of-life equipment that is no longer supported by the manufacturer. They hope the new feature will give customers the information they need about replacing obsolete parts such as variable speed drives which can be much more cost-efficient than buying a rare, end-of-life part. The compare feature also lets users see how two parts stack up against one another, to make sure the recommended replacement has all the features they are looking for.

www. powerelectrics.com

Tel: 01254 673747

Imperial College Non-Destructive Evaluation Group choose LG Motion for novel XYZR gantry scanning solution with force controllable vertical and rotary axes

Fluke offers free iPad® for real-time sharing of thermal imaging data

A novel motorised XYZR gantry scanning system with a combined vertical and rotary positioning axis that includes the ability to measure its force, position and velocity has been supplied to the Imperial College Non-Destructive Evaluation Group by LG Motion for an interesting research project to evaluate critical aspects of a high temperature strain monitoring technique for use in power station steam lines and associated components. The technique, which allows the continuous on-site monitoring of the integrity of the components rather than the previous method which relied on extremely laborious microstructural assessment during often infrequent outage periods, involves measuring the electrical resistance between electrodes permanently attached to the component surface. As the component deforms the electrodes separate and a change in the resistance is observed.

Tel. 020 7594 7227


Manufacturing chief points to ‘outsourcing’ as one of the industrial trends of 2014 Creating value and managing risk are the driving forces behind a new global desire to ‘outsource’ according to the MD of one of the UK’s largest providers of control and automation solutions. PP Electrical Systems’ Tony Hague believes 50% of its £3m growth so far this year has come from Original Equipment Manufacturers (OEMs) looking to replace 100% vertical integration of production by sub-contracting out non-core competencies to organisations that specialise in those processes. PP Electrical, which employs nearly 200 people at its state-of-the-art facility, works with twelve of the world’s largest machinery manufacturers providing a comprehensive range of control and automation solutions. For further information, please visit www.powerpanels.uk.com, contact 01922 419109 or follow @pp_electrical on twitter.


PECM Issue 11

Email: rebeccab@nicontrols.com

While stocks last and before 31st December 2014, Fluke UK is offering a free iPad® to purchasers of one from a range of Fluke Thermal Imaging cameras. Using Fluke’s latest Connect app downloaded to the iPad, customers can generate reports and communicate results directly to their client or colleagues from the jobsite. This saves time and money, allows safer working and uses the latest innovations to become more productive. More information can be found about the order and claim procedure by clicking on the offer button at www.fluke.co.uk

Outstanding Export Performance Wins Street Crane Entry to Sunday Times/ HSBC Fast Track Listings Factory crane and hoist manufacturers, Street Crane Company, have been recognised in the Sunday Times/HSBC Fast Track Awards for outstanding growth in export sales. Over the last two years the company has achieved an average annual growth rate in export sales of 33.4 per cent, with exports now accounting for £19 million, 67 per cent of their £28.2 million turnover. Street Crane is the UK’s largest factory crane and hoist producer, serving the end user market at home and supplying crane components to other crane builders overseas.



The moment you have absolute confidence in your results. This is the moment we work for.


Discover Smartzoom 5 – Your user-friendly, reliable digital microscope from ZEISS. Smartzoom 5 is ideal for quality assurance and quality control applications in virtually all fields of industry. Visit ZEISS on Stand F72 for more information. www.zeiss.com/smartzoom

News & Events CSG Launch Own Brand Spill Kits

Increased Output and Reduced Costs in Soft Drinks Production

Cleansing Service Group (CSG,) a leading provider of emergency spill containment and land remediation services, has launched a range of its own brand spill products. The range, which includes absorbent pads and cushions, spill kits, drain mats and containment products, is specifically designed to deal quickly and efficiently with oil or chemical spills in factories and other industrial locations.

A CSG Oil Spill Kit

Announcing the launch, CSG business development manager (spills) Hugh Neatherway said:”We have many years’ experience of dealing with all types of spills and our products are the result of extensive own use to ensure that they are as effective as possible.” CSG’s 24/7 emergency response service is available to all companies and registration is free at www.csg.co.uk/emergency_hotline. The emergency number is 0800 587 3133.

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

Email: technicalsales@csg.co.uk

An increase in machine reliability and the improvement of lubrication management practices in order to maximise output in one of their plants was the objective of a globally active soft drink producer when they approached tribology expert Klüber Lubrication. One of the plant’s seven bottling lines was chosen for the improvement project. Analysis was undertaken and this developed a comprehensive lubrication plan. Following implementation mechanical breakdown was reduced, while output increased significantly. Prior to consulting Klüber Lubrication, utilisation was 55%. Klüber Lubrication went ahead with its proven KlüberEfficiencySupport package. Within nine months, production loss due to machine downtime was reduced from 7.4 per cent to 2.5 per cent, resulting in a substantial increase of production output: throughput increased to 72 per cent.

Tel: 01422 205115 www.klueber.com

Email: sales@uk.klueber.com

UKAS Accreditation is a Calibration Milestone

QED Launch New Online Book “Good Vibrations”

Calibration is best implemented by laboratory able to provide UKAS certified calibrations carried out in accordance with ISO/IEC 17025:2005 standards.

Quality Electronics Design S.A. (QED) have launched a new online book, ‘Good Vibrations’, it is a detailed introduction to vibration based durability testing. Originally released at the end of March 2014 it has now also been made available as a CD version.

Calibration is needed on many different crimp calibration types of mechanical, electrical and process industry tools. United Kingdom Accreditation Service (UKAS) is recognised by the British government to assess the competence of organisations that provide calibration services against internationally agreed standards.

The pdf version of the book allows a quick search on any issue explained in the book and allows an easy installation on your laptop or on your vibration control system. The book offers high resolution colour pictures, graphs, formulae, tables and examples on more than 380 pages.

The advantages include proven traceability to national standards and the user has assurance that the equipment provides accurate measurement, is properly maintained and frequently checked. For further information, please visit calibrate.co.uk or call 0845 365 4050 PASS Ltd, 1 Alberto Street , Stockton-On-Tees TS18 2BQ

An accompanying free Excel® file gives the reader the tools for gRMS and maximum displacement calculations of a random profile as well as calculations of displacement, velocity and acceleration for a sine profile in addition to resonance. To order the book on CD: contact goodvibrations@qed.lu The download version can be purchased and downloaded from: http:// store.payloadz.com/details/2006237-ebooks-science-goodvibrations.html

Mitsui Sumitomo at Lloyd’s Insurance Selects T V S D Product Service as Machinery Safety Partner

NORCO GRP to exhibit at Advanced Engineering Show One of the UK’s leading engineering firms in the sphere of moulding and composite structures will be displaying their specialised services at the Advanced Engineering Show, on the 11th & 12th November at the Birmingham NEC. The Poole-based company, which employs over 150 people on the south coast, provides their customers - including the likes of Sunseeker, Thales and RNLI - with a complete service from inception and development of ideas, through to plug and tool making, to the final manufactured product including full assembly. The NORCO team will be attending the Advanced Engineering Show, which is quickly becoming the number one event for the UK engineering industry. The Show is comprised of 5 events covering the aerospace and automotive sectors, composite engineering, auto electronics and performance metals. It is one of the fastest growing industry meetings and offers exhibitors and visitors a chance to see the latest and most innovative advancements within the engineering industry, alongside gaining new business contacts. Mark Northey, Managing Director of Norco GRP Ltd, said “Our team are excited to be exhibiting again at the Advanced Engineering Show. NORCO is enjoying a very successful year and this is a great opportunity to demonstrate our capabilities at the industry’s most well-respected show. We’re certain to meet customers both new and old, and potential strategic working partners.” The Advanced Engineering Show comes to the Birmingham NEC Arena on the 11th and 12th of November and will host over 650 world-class exhibitors, alongside multiple open conferences and close to 200 guest speakers. The NORCO stand is located in the Composites Engineering area of the show, stand G160. For more information on Norco GRP Ltd visit: http://www.norco.co.uk


PECM Issue 11

Mitsui Sumitomo at Lloyd’s has partnered with TÜV SÜD Product Service, the UK market leader in machinery safety, to provide machinery safety and legislation support to its clients. TÜV SÜD will support brokers and clients of Mitsui Sumitomo at Lloyd’s with on-site and online support and advice on machinery safety and machinery legislation. Lynsey Jones, Regional Risk Engineering Manager at Mitsui Sumitomo at Lloyd’s, said: “We have a unique reputation for providing brokers and clients with innovative and pragmatic underwriting solutions, a quality claims service and risk engineering support. As a Notified Body, TÜV SÜD has a proven pedigree of unrivalled machinery safety expertise, which will help us to deliver the practical help our clients need to minimise liability risk in their businesses.” Paul Laidler, Business Director for Machinery Safety at TÜV SÜD Product Service, said: “Machinery owners must be sure that their equipment is safe for operators, but at the same time guarantee high productivity. We can support Mitsui Sumitomo clients to ensure that their machinery fulfils the necessary quality, health and safety legislation, but with minimal downtime, high productivity and efficient resource usage.”


Profibus news comes to your mobile device Pl (Profibus & Profinet lntenational) has launched an app that makes its Profinews newsletter available on Apple and Android smartphones and tablets. Users can receive up-to-date information on Pl and its technologies on their devices anywhere, anytime. A push notification service informs them automatically about important topics and, in the Tech Tips section, they can receive practical advice from PI experts. Readers can share articles of interest with their colleagues and member companies can use the app to send product and company news to a global audience with a single mouse click. The free Profinews app can be downloaded from Apple’s App Store or Google Play.


News & Events F&R Products Ltd have in excess of 40 years experience in the design and manufacture of industrial water cooling equipment, specialising in bespoke designs off a standard range of equipment. We are ISO9001 and Refcom approved. UK agents for the Hyfra-Pedia range of refrigerated water and oil chillers plus the Decsa range of evaporative cooling towers. The products and services we are able to offer with regard to water cooling systems are:• Coil-in-tank water chillers • Dry air coolers flat bed • Dry air coolers packaged boxed type • Adiabatic coolers • Oil coolers • Evaporative cooling towers • Maintenance and repair of industrial cooling equipment • Annual refrigerant checks in compliance with EU Directive 842/2006

Tel: 01823 663281

CBS Concrete Products have been manufacturing precast concrete wall solutions for 20 years, supplying and installing projects throughout Europe. Our comprehensive range of walls is high quality and range from 50 cm to 4.22 m in height. Applications vary from silage clamps, agricultural storage bays, landscaping and larger infrastructure projects. We have excellent references with projects that can be viewed throughout the UK. Call Ben Chalk to discuss your project. 0808 1891258


UK First for Fast Track Product Approval Fabdec is a Shropshire based engineering company with over fifty years experience and proven capabilities in the design and manufacture of high quality stainless steel vessels for the Food, Brewery, Domestic and Commercial Water Heating sectors. Fabdec also produce Plate Heat Exchangers and SMART-HEAT, the established name in heat recovery that reclaims waste heat in refrigeration systems to generate hot water. Fabdec custom manufactures to individual requirements. Size, shape, fittings and accessories can all be accommodated through design, product engineering and state of the art manufacturing facilities.

Tel. 01691 627 200 www.fabdec.com

Email: info@fabdec.com

Cranage EMC & Safety has launched a new service for manufacturers with an ‘urgent need’ for product approval in North America and Canada and has extended its facilities to provide a ‘fast-track’ alternative to CSA and UL approval. In partnership with QPS Evaluation Services, Inc, a Nationally Recognised Test Laboratory based in Toronto, Canada, a team of around ninety engineering professionals are engaged in supporting Cranage EMC & Safety in the testing and certification of products against American (UL standards) and Canadian (CSA) standards. Cranage can either perform the product evaluations on site at your premises or in their appointed laboratory in the UK. Cranage is also authorized to perform factory inspections for ISO Type 3 certification. Testing of ‘one-offs’, which would not require factory surveillance or inspection, is accommodated under ISO Type 1 certification.

Tel: 01630 658 568



Tel: +44 (0)870 460 4234

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Issue 11 PECM


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PECM Issue 11

Chemical Process Training Equipment: Energy / Oil & Gas Sector


arbyTech Training Equipment Inc. designs and manufactures customised training equipment and services used in chemical process operations in the energy sector. The company has offices based in Calgary, Canada, Teesside, United Kingdom and Dammam, Saudi Arabia. As a leading supplier of process trainers and laboratory training equipment for over 10 years, DarbyTech Training Equipment Inc. sets the industry standard for process operations training equipment. DarbyTech trainers, demonstrators and laboratory training equipment are widely acclaimed for their quality, and safety features, in addition to their functional training capabilities. The equipment provides newlygraduated engineers, technicians and process operators with the hands-on skills they need to go directly into the workplace, making them highly sought after by industry recruiters and operations managers. Trainers: •

Three Phase Separator Trainer

“Mini Plant” Large Scale Three Phase Separator

Binary Distillation Trainer

Gas Absorption (Amine) Trainer

Heat Exchanger Trainer

Steam Electrical Generation Trainer

Tank Level / Flow Trainer

Flash Drum Trainer

Chemical Reaction Trainer

Adsorption Trainer

Fluidized Catalytic Cracker Unit Trainer

Compressor Trainer

Biodiesel Process Trainer

Bioethanol Process Trainer

Demonstrators: •

Gas Contactor / Distillation Column Demonstrator

Horizontal or Vertical Separation Demonstrator

Heat Exchanger Demonstrator

Two Phase Flow Demonstrator

Well Bore Demonstrator

Pipeline Pigging Demonstrator

Trainer Controls: •

Siemens PCS7 DCS

Emerson DCS

Foxboro DCS


Rockwell PLC

“the plant is no place to practice!” www.darbytech.ca DarbyTech is a wholly owned subsidiary of Cordell Group Limited

Hawk 3D Proto is a division of the main brand of Cutwel Limited. The division is part of the very successful engineering cutting tools supplier which has been established since 1996.


n May 2013, Senior 3D Printing Manager Ben Hawksworth and his father Paul Hawksworth who is the Managing Director of Cutwel, decided to become part of the Additive Manufacturing community for 3D Printing.

Hawk 3D Proto supply a range of High Performance Desktop 3D Printers and standalone 3D Printers. To allow you to be creative & to fulfil all of your rapid prototyping needs. We are the UK & Ireland Sole supplier of Airwolf 3D products, a proud distributor of BeeVeryCreative & also an authorised reseller of the Stratasys Idea Series. We also sell a wide range of 3D printing consumables aswell. Education is of great importance to us so please talk to us about assisting you with educational requirements. We believe that 3D Printing is of use to so many different industries, from engineering, education, architecture, product design and much more. By having a 3D Printer to allow you to produce rapid prototypes you really can increase downtime and become more productive with your manufacturing process, thus enabling you to become ahead of your competition. We also have a state of the art 3D Printing showroom in our facility. Which customers are more than welcome to visit us and we offer live product demonstrations. Please book your appointment by sending an email to: sales@hawk3dproto.co.uk


PECM Issue 11

UK emission control product manufacturer Klarius has over 10,000 individual product types available from its central UK warehouse facility in Cheadle.

Klarius Hits Target of 10,000+ Exhausts, CATs, DPFs and Mountings available from UK Stock

Charles Greaves, Operations Director, comments on the landmark figure, ‘The target of 10,000 product references available direct from UK stock is significant to us because it means we have succeeded in a whole host of manufacturing and organisational goals.’

emission control product manufacturer Klarius has hit its own target of over 10,000 individual product references available from its central UK warehouse facility in Cheadle.


supplied and the parts would be ordered ready to be fitted at a later date. Customers can invariably drop off a car in the morning and providing it is a standard part that needs replacing, pick it up in the afternoon.

Charles Greaves, Operations Director, comments on the landmark figure, ‘The target of 10,000 product references available direct from UK stock is significant to us because it means we have succeeded in a whole host of manufacturing and organisational goals. The net result for our customers is that it means they can order what they want, when they want it and rely on the fact that it is available direct from us, the manufacturer.’

This is only possible because the UK automotive aftermarket is a highly competitive marketplace and the companies that are proving to be successful are well organised and provide a great service. This in-turn is only possible if manufacturers can provide the flexibility to manufacture to meet demand and ensure that the entire product portfolio is consistently available.

Once product quality, fit and materials targets have been achieved, the only thing left is availability. Being able to rely on your supplier means that you have to retain less buffer stock, so to put it bluntly the companies that stock Klarius emissions products can operate more efficiently, taking up less space in their own stock and distribution centres yet still meet the delivery demands of their own customers. Garages today enjoy a fantastic level of product supply and availability, gone are the days when a car would be brought into a garage for assessment, a quote would be

‘Since all Klarius parts are designed in the UK at our own facility using the OE part as a reference, we can maximise the number of vehicle applications covered per part. This allows re-sellers to provide full emissions systems for a larger range of vehicle applications from the same stock. This provides stockists with a maximised return on investment in Klarius products.’ Klarius exhausts, CATs and DPFs are designed, manufactured and tested to exacting standards in the UK. The centrally housed UK stock covers over 98% of the UK car parc and is available same day across the UK.

Tel: +44 (0)1538 752 561 t Web: www.klarius.eu

AD operators see performance benefits with micronutrient technology Omex Environmental’s micronutrient technology can boost productivity - and profits - for anaerobic digester (AD) operators.


icensed operators are increasingly treating waste through ADs for the production of 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 initiatives like the Feed-In Tariff scheme. However, it is rare for an AD 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 plant and connected system do not run at full efficiency with a consequential loss of performance and output.

Omex Environmental have formulated Nutromex TEAs, bioavailable trace element additives, used in the anaerobic process to boost the availability of essential trace elements and help to improve bacterial performance and increase the methane content of biogas production. This helps commercial operators to run plants at optimum levels, maximising revenue streams and return on investment through increased profits. The amount of volatile fatty acids (VFAs) produced by the AD also decreases with the introduction of micronutrient technology like Nutromex TEA– it improves the way that food waste is ‘digested’ and helps to stabilise VFA levels, contributing greater methanogenesis for added biogas production.

Omex also provides customised micronutrient solutions, to meet the individual needs of specific anaerobic systems and operational requirements. Omex will assess a plant’s individual requirements through analysis of its influent, biomass and effluent before producing a tailor made micronutrient solution in a form that is fully bioavailable in anaerobic conditions. As well as specialising in trace element additives, Omex Environmental also manufacture and supply flocculants, anti-bulking agents, acid neutralisers, de-icers and concrete ad-mixtures, a new addition to their products. www.omex.com

Issue 11 PECM


Air, Gas & Odour Control Blower engineered to operate at up to 180oC from ACI

XOPTIX helps reduce NOx emissions from coal

Engineered for working in high temperature environments of up to 180oC, the Air Control Industries ‘EP10AH’ industrial blower is suitable for many applications too trying for many alternative units.

Close monitoring of coal milling with the XO particle sizer from Xoptix Ltd, safeguards coal from being over milled and helps keep NOx emissions levels to a minimum.

ACI’s ‘EP10AH’ is designed to handle inlet temperatures of up to 180oC without any significant temperature increase of the bearings so unit longevity and low maintenance requirement is similar to those of the standard EP10.

Xoptix Ltd, based in Worcestershire, England, have developed the in-line particle sizer XO to maintain optimum coal milling production. As world coal sources vary greatly in fuel properties and loading profiles, uncontrolled combustion conditions force operators to apply boiler settings, which are conservative and far from ideally tuned. Particle sizing technology from Xoptix has been developed for coal milling and is based on over 30 years of knowledge of laser diffraction, which can be used to determine particle size.

Low temperature rise is achieved by integrating a heat dissipation ‘spinner’ disk in a vented housing between the blower unit and impeller. This avoids the need for cooling water and all related supply and drainage problems.

Tel: 01297 529242 Email: mattforknall@aircontrolindustries.com www.aircontrolindustries.com

New all-in-one compressed air solution for high-quality surface technology Compressed air specialist BOGE has launched a new all-in-one compressed air solution for users operating in the surface technology sector. Paintline enables users to generate extremely pure, oil-free compressed air that is precisely tailored to meet their needs. It combines the most important components for generating and filtering ultra clean compressed air and covers a performance spectrum ranging from 5.5 to 22 kW. BOGE Paintline is based on an oil-injection cooled screw compressor with special filter technology. This results in extremely pure, oil-free compressed air being produced that meets the specific requirements of surface finishers. BOGE Paintline attains class 1 purity where solid impurities and residual oil content are concerned, and class 4 purity where water content is concerned. Since Paintline is an all-in-one solution, including compressed air generation, compressed air treatment and condensate disposal, maintenance costs are kept at an absolute minimum while efficiency is maximised.



PECM Issue 11

Visit http://www.xoptix.co.uk/ for the full product overview or call +44 1684 899345.

DELO develops adhesives for high-temperature applications DELO Industrial Adhesives has added new structural adhesives to its product range. These products are mainly used when components to be bonded are exposed to temperatures up to +220 °C. DELO’s new high-temperature adhesives impress by an increased shear strength of 12 MPa at such temperatures, approximating a gain of 50 percent compared to established products. Thanks to an increased glass transition temperature and an improved long-term temperature stability, up to 3 N/mm² are possible even when the bonded connection is subjected to +220 °C. The tensile strength after intensive tests, in which the adhesive is stored at a temperature of +220 °C for 1,000 h, is still above 80 percent of the initial value. This enhancement of onecomponent epoxy resins clearly expands their temperature range of use.

Email: info@delo.de


Miniveyor Air VAF series portable fans moving contaminated air out


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. 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 are still the biggest cause of lost man work days. 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. 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. 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. Built with integral interlocking ribs the fans can be stacked vertically to increase volumes. This is also helpful for storage and reduces the footprint significantly.

positive and negative airflow, so depending on which way you point them, are at home either sucking or blowing fumes and dust. Available in 3 sizes, they are powered by 110v or 230v and are used across many industries for welding fume removal, confined space ventilation, fresh air blowers and drying out flooded areas. For intrinsically safe areas a pneumatic version is also available.

The VAF series fans work on both

Visit us online at www.vaf-air.com

Air units easily withstand blows without denting, giving less downtime and greater productivity.

Issue 11 PECM


Boilers & Maintenance Plate heat exchangers for commercial applications

WTS Benefits from Economic Upturn

A hot water system using a plate heat exchanger (PHE) does not store hot water. The water is heated instantaneously and only when required.

Wellman Thermal Services, are benefiting from the productivity increase in the manufacturing sector particularly in the Aerospace, Automotive and Steel industries. Although the economy would seem to have turned a corner and is now heading in the right direction, it has not yet demonstrated sufficient growth or stability for manufacturers to invest in new capital plant. Therefore the additional production demands must be met by existing plant.

A PHE consists of a pack of plates (usually stainless steel) to transfer heat from the primary fluid to the secondary fluid. The plates and gaskets are arranged to form alternating channels between the primary and secondary fluids and arranged in this way, the plates have an extremely large heat transfer surface area and therefore considerably high loads are achieved from a very compact Plate Heat Exchanger. For large commercial applications a PHE is ideal as it is capable of producing hot water instantly and constantly at peak times. Calorifiers and direct-fired water heaters are less reliable and can empty of hot water should higher than normal demands occur. For further information on Stokvis Energy Systems, call 020 8783 3050 or visit www.stokvisboilers.com.

Fulton electric boiler provides a cure for Prysmian Group Bristol-based heat transfer specialist Fulton has supplied Prysmian Group’s Bishopstoke facility a skid-mounted electric boiler and ancillaries, steam from which is being used to cure the insulation applied to the company’s electric cables. Commenting on the process, Prysmian’s Nicolas Chevaux explains that curing is used to strengthen and increase the heat resistance of the insulation. “Without the process, the insulation would have a lower temperature resistance and hence the cable would have a lower current rating.”

Running and maintaining industrial heating plant, in some cases as much as sixty years old, requires a lot of time and effort especially given new demands for increased production, reduced energy consumption, etc. With a pedigree stretching back 110 years and incorporating some of the UK’s best known furnace builders, together with an extensive archive and spares inventory, Wellman’s Furnace Team are perfectly placed to meet the needs of manufacturing industry in keeping its furnace equipment, regardless of manufacturer, operating at peak performance.

Tel: 0121 543 0000


New pressurised deaerator system cuts boilerhouse energy and operating costs Spirax Sarco has launched a pressurised deaerator system that reduces the dissolved oxygen content of boiler feedwater to virtually nil without chemical treatment. This enables steam plant operators to reduce energy consumption, save water treatment costs, increase productivity and meet BG01 “Guidance on Safe Operation of Boilers”.

Following manufacture, batches of up to 16 drums are placed into a container where steam from Fulton’s EP100 Electropack boiler system is injected to start a curing process that can take up to twelve hours at 80°C.

BG01 gives guidance on complying with the recommended guideline BS EN 12953 Part 10 which deals with water quality and defines maximum levels of impurities including dissolved oxygen. A pressurised deaerator is one way to meet the requirements of BS EN 12953 Part 10.

Email: uk.sales.office@fulton.com



How do you make sure that your burner operation is efficient and reliable?

Your burner system is crucial, so we think it needs looking after. That’s why we created BurnerCare. We just think it adds up – Burner commissioning – on site start up service to ensure maximum efficiency. Plus Annual service agreements – planned maintenance, discounted service visits and cost effective spare parts pricing. Plus 24/7 breakdown response – single visit solution for most emergency call outs. Plus Spare parts – comprehensive stockholding for virtually any gas burner system. Plus Gas flow measurement – supply and installation of gas flow meters.

So whatever your question about burner efficiency and reliability, we think total burner care from Lanemark is the answer.

Lanemark International Limited Lanemark House, Whitacre Road, Nuneaton, Warwickshire CV11 6BW United Kingdom Tel: +44 (0) 24 7635 7405 Fax: +44 (0) 24 7634 1166 E-mail: info@lanemark.com www.lanemark.com


PECM Issue 11

Control & Automation Taking the time to learn about your plant with GEA Process Engineering

Hot Melt Glue Sensor

Automation control systems change rapidly, whilst the plant itself can take much longer to change. GEA can assist you with locating essential spare parts, planning plant wide or machine specific upgrade plans and spares holding strategies to mitigate this plant shutdown risk.

High speed detection of 1ms is also available for fast moving targets and eight sensitivity settings can be stored for smooth product changeover. For high speed production lines giving short detection output pulses from the sensor the output signal can be extended by means of a 40ms off delay timer.

Introducing the TH-12CPS Hot melt glue sensor, for quick, reliable, non-contact detection of hot melt glue. Comprising of a separate sensor head and controller, which allows a small sensor head of W18 x H33 x D22mm for mounting in crowded or tight spaces. Glue can be detected from a distance of up to 300mm away and a visible red alignment beam spot allows easy installation to the target surface.

Contact us for more information at: GEA Process Engineering Ltd, Warrington, UK Tel: 01925 812650, Email: automationsupport.gpuk@gea.com www.geaprocess.co.uk

New analog interface for POSITAL’s explosion-proof rotary encoders POSITAL has added an optional analog electronic interface to its range of explosion-proof IXARC rotary encoders. These devices have been designed to comply with the ATEX directives for Category 3 electrical products and are suitable for Zone 1 and Zone 21 conditions (i.e. potential exposure to hazardous levels of explosive gases and dust concentrations). Available housing materials include aluminum and types 303 or 316 stainless steel. The housings are designed to contain any electrical sparking and to prevent dust from entering the devices. The new interfaces make these devices suitable for use in analog control systems. Both voltage and current outputs are available, with support for several voltage ranges (0-5 V, 0-10 V, 0.5-4.5 V, or 0.5-9.5 V) and current ranges (0-20 mA or 4-20 mA).

Tel.: +48 759 / 58 40


Taken to new heights: Industrial gear units from NORD complete heavy workload at a reservoir project Swiss energy supplier Axpo is close to finishing the demanding large-scale “Linthal 2015” construction project: Switzerland’s largest hydroelectric undertaking will increase the overall output of the existing Linth-Limmern power plants from 480 MW to 1,480 MW. A new underground pumping station was created to pump water from the Limmernboden reservoir at an altitude of 1,860 m above sea level into the Muttsee lake about 600 m higher up. This elevation difference will be used to produce hydroelectric power on demand. The heart of the project in particular – the underground center for the new pumped storage hydroelectric power station – required gigantic efforts.

Email: info@nord.com


Replacement of CD profiling actuators made easy, even in single units Tasowheel Systems, a major manufacturer of different types of CD control actuators, can now deliver replacement dilution actuators and valves for paper machines even in single units, regardless of the actuator’s original manufacturer. Tasowheel has delivered more than 200,000 dilution actuators and valves during the past 30 years. But since the products have been branded Metso, Voith or ABB, surprisingly few customers know who the real manufacturer is. “Our products are made solely of AISI 316 stainless steel”, says Jukka Ahlstedt, Sales Manager at Tasowheel Systems. “The flow surfaces of the valves are hard coated to reach long life time and to give an outstanding resistance against wear, which can change the flow curves and cause quality and runnability problems.”

Email: jukka.Ahlstedt@tasowheel.fi www.tasowheel.fi


PECM Issue 11

Three function settings are available for the following types of glue sensing applications: • Inspection of glue quantity • Presence/absence of glue • Length of hot melt bead applied to surface.

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

Robust fixed pipe connections made of metal The innovative piping system EISELE ALU PRO 30 with screw connections for metal pipes is the first product line of the new PIPINGLINE. The modular system for fixed pipe connections of the compressed air supply for assembly lines sets new standards in every respect for the distribution of compressed air, gases and fluids. Compressed air offers numerous benefits: it is clean and simple to use, flexible in application and easy to regulate. That is why compressed air is used widely in production processes of all types. The pneumatic supply systems are elementary components in these systems and must fulfil the most stringent requirements for reliability, economy and efficiency. A new compressed air system from Eisele Pneumatics GmbH & Co. KG. offers all of these features: high quality, easy assembly and exceptional flexibility.

Email: info@eisele.eu


Tough torque synchros Torque synchros from motion control specialists, Astrosyn International Technology, are used to transmit and receive angular variation data from a rotating shaft with extreme accuracy over a large distance. This demanding requirement is often accompanied by the need to operate reliably for many years, without maintenance, in harsh environments. Astrosyn’s latest model D1356 is a single shaft synchro, which operates on 200/220V at 50/60Hz and features transmitter/receiver TX-TR functionality. Its rugged build is suited to applications in hot, dusty and humid environments such as ships’ engine rooms, wind tunnels and steel mills. In these situations precise angular positioning of motor-driven surfaces can be controlled and adjusted with critical accuracy using the transmitter-receiver feedback loop.

Email: astrosyn@btinternet.com


Deutschmann gateways certified for PROFINET version 2.25 Bad Camberg – Deutschmann Automation has attained certification according to the current PROFINET 2.2 and GSDML 2.25 specifications for the PROFINET models from its UNIGATE IC and UNIGATE CL series. Automation manufacturers can significantly reduce their development effort by means of these gateways and protocol converters. UNIGATE ICs are designed for direct embedment into terminal devices, while UNIGATE CL modules come in a DIN rail housing. The current generation of CLASS B certified 2-port protocol converters for PROFINET feature a FIDO communication processor which, employing PriorityChannel technology, ensures dependable PROFINET connections even under high network load or in ARP broadcast storms.

Email: info@deutschmann.de


POWERFUL SOLUTIONS FROM MURRELEKTRONIK A diverse product range, innovative design, in house test centre and quick delivery – all the elements you would expect from one of the world’s leading manufacturers in electrical equipment for machines and system installations. But with Murrelektronik you get so much more.



Our UK based sales and technical team can help with the smallest query through to fully customised system solutions. Plus, with industry experts in Food & Beverage, Processing & Packaging and Automotive, we have specialist global industry knowledge at our fingertips. Altogether, powerful solutions that help you optimise your electrical machine and system installations.



















Murrelektronik Ltd l Phone 0161 728 3133 l www.murrelektronik.co.uk l sales@murrelektronik.co.uk


PECM Issue 11

Issue 11 PECM


Control & Automation 5.7“ & 7“ Intelligent TFT display with sound MMS Electronic has available a 5.7” and 7” Intelligent TFT graphic display EA eDIPTFT57-ATP 640x480 pixel and eDIPTFT70-ATP 800x480 pixel LED backlit touch-screen display, built-in intelligence and innovative user-friendly features. These intelligent display reduce development time and cost. It provides the ideal platform for development of interactive controls. For example, a virtual keyboard, analogue rotary instrument or bar graphs can be generated on the screen with just a few simple commands. The display also provides acoustic feedback into an 8 ohm speaker. Sounds ranging from simple clicks, notes or jingles acting as warning or status messages. TrueType fonts are easy imported with the free development software. The onboard 4MB memory stores images, animations and macros. Text can be mixed with graphics, pictures and gif animations. The unit features two analogue inputs in addition to 8 digital inputs and 8 digital outputs. Onboard interface is serial, I2C and SPI or USB, RS232, RS485 with level converter.

How to Find Your ABB Drives & Spares in Seconds! HAVE YOU EVER TRIED TO PURCHASE SPARES FOR YOUR ABB DRIVES? If you have, then you are probably familiar with this scenario - your current drive supplier doesn’t stock spares, and your ABB drives representative doesn’t sell spares, as that’s the job of a different division!

FRUSTRATING, TO SAY THE LEAST. But help is at hand - Quantum Controls, Official ABB AVP Partner and leading supplier of drives and motors in the UK, has launched a brand new website at www.abbdrivespares.co.uk. This does exactly what it says on the tin it is dedicated to ABB and is a one-stop-shop for locating and purchasing ABB drives & spares for any drive range and allows you to quickly and easily find exactly what you want.


PECM Issue 11

“YOUR FREE QUICK AND EASY GUIDE TO ABB DRIVE PROGRAMMING DVD” If all that isn’t enough to convince you, ou can register for a free copy of our Variable Speed Drive technical guide DVD. www.abbdrivespares.co.uk

Here are just some of the features of this new website: •

The UK’s largest stock of genuine ABB spares

Online access to spares for all ABB drives

Online access to purchase and hire ABB drives

Easy 24/7 online ordering

Technical engineer support 24/7 ‘Gauranteed’

Specific information on ABB drive spares, new and old product ranges, their availability, the equipment they are used in, technical details and photographs. The site also allows you to access the full range of support services that Quantum Controls offers. As well as being the largest supplier of ABB drives and motors in the UK, is also the largest service partner, with a license to carry

out warranty repairs on all current ranges of ABB drives. Quantum Controls employs 15 full-time ABB drive service engineers to cover the installation, commissioning, service, repair and maintenance of ABB drives across the UK. These engineers are fully trained by ABB and Quantum is audited every year by ABB to ensure full competence and compliance to standards. Quantum Controls also offers drives for hire - over 1000 ex stock drives with power ratings up to 1.5MW, which are ideal for 24/7 breakdown response while Quantum engineers repair your damaged drive. This service is available for all drive types, not just ABB.

Visit our brand new website www.abbdrivespares.co.uk now and say goodbye to your ABB spare frustrations! Call us today on 0330 9000 247 or email your enquiry to service@quantum-controls.co.uk www.quantum-controls.co.uk

A Compact Module for Time-Critical Applications The new fieldbus modules from the MVK Metal series feature IRT (Isochronous Real-Time) functions and are suitable for conformance Class C. rofinet is a popular fieldbus system that is now open for even more applications thanks to the integration of IRT for time-critical applications. With the new MVK Metal fieldbus modules, Murrelektronik offers new components that do not only meet the conformance class C requirements, but can even be used in demanding industrial environments because they are very rugged.


Profinet is a fieldbus standard, established in automation worldwide. The number of installations based on this fieldbus protocol is rapidly growing. According to information by the Profinet organization PNO, 1.5 million new Profinet devices were installed only in 2012. This means that a remarkable number of 5.8 million devices were operating in the beginning of 2013. In future, this will surely continue to increase because Profinet is designed for the complete range of industrial automation: It is an efficient fieldbus protocol for the production industry, process automation as well as for motion control applications. Profinet is a comprehensive fieldbus system with a large number of functions and options. However, not all applications require all functions and maximum speed. Therefore, the PNO defined three conformance classes: A, B, and C, that include the minimum requirements according to plant operators. Conformance Class A (CC-A) is designed to use the infrastructure of an existing network and includes basic Profinet functions such as real-time communication (with cycle times from 2 ms) as well as alarm and diagnostic functions. In this class, it is possible to use unmanaged switches and wireless communication without any problems. Murrelektronik’s fieldbus modules meet all the requirements to use in this class. Murrelektronik’s unmanaged TREE switches are also suitable. Next, the concept for Conformance Class B (CC-B) includes network diagnostics and collecting information with the topology. All configured devices are assigned names. That way, defective devices can easily be changed with a new device that may even have factory settings. The configuration data stored in the control will automatically be

Profinet is a comprehensive fieldbus system with a large number of functions and options. used. Cycle times starting from 2 ms are typical for installations based on Conformance Class B. Murrelektronik’s MVK Metal MPNIO fieldbus modules meet the requirements of this class. The unmanaged TREE switches are also transparent for the information of the LLDP protocol. If switches are to be included in the topology of the control - regarding diagnostics and topology recognition - it is necessary to use Profinet-managed switches. A Media Redundancy Protocol (MRP) can be included to increase data security. This protocol is integrated in the MVK Metal MPNIO from software version 3.5. Highly precise and synchronous data transfer is also possible in applications according to Conformance Class C (CCC). When implementing Isochronous Real Time (IRT) in Ethernet controllers, it is possible to reach update times of 250 µs and a jitter accuracy (time offset) of less than 1 µs. This requires a special IRT chipset in the Ethernet Switch in the Profinet device. With Dynamic Frame Packing (DFP) technology, the cycle times can be reduced from 250 µs to 31.25 µs - which is exactly an eighth of the time. An IRT network with this highly precise cycle accuracy requires that all devices are equipped with an IRT Ethernet chipset. If a standard Ethernet chipset is used, synchronicity would get lost. Another advantage of IRT Ethernet chipsets is that they keep the packet switching time short. It does not wait for the whole frame to be received, as opposed to the technology known from CC-A and CC-B. The complete data packet is instead directly routed to the output port already after the first bytes (including the MAC address) have been verified. This considerably reduces the latency, especially of big packets (1,500

bytes). This is the reason why it’s preferable to use cut-through Ethernet switches that enable this fast data flow in big industrial plants where often 20 up to 80 Profinet devices are installed in one segment. With the new fieldbus module MVK Metal Push-Pull Profinet IRT, Murrelektronik presents a digital I/O fieldbus device with IRT function that is suitable for Conformance Class C applications. These devices support fast forwarding and realtime data transfer according to Profinet specification 2.3. Profinet push-pull connectors with RJ45 copper, according to the AIDA standard, or SC-RJ-POF connectors are suitable to connect the modules. This makes the MVK Metal Push-Pull Profinet IRT an excellent solution for all applications with realtime sensors and perfect for integrating motion drives. This fieldbus module is designed for consistent Profinet solutions in machines and systems, especially in the “fast” areas. The mechanical features of the fieldbus module make it suitable to withstand harsh industrial environments. It has a one-piece zinc die-cast housing with surface finishing and is vibrationresistant (vibration 15 g and shock 60 g). The push-pull connection technology enables fast installation of power and data cables without requiring tools. The module’s inputs and outputs are galvanically separated. The integrated Fast Start Up function (FSU) allows the shortest tool changing times - a top feature for robot applications. The outputs can supply 2 A, this makes it possible to connect even powerful loads, for example solenoid valves. www.murrelektronik.co.uk Issue 11 PECM


Industrial measurement specialists EMS (International) Ltd ndustrial measurement specialists EMS (International) Ltd are perhaps best known as a quality supplier of measurement solutions for the machine tool and fabrication markets through their quality motion feedback solutions for manual, CNC and PLC based machines.


In addition to a comprehensive range of optical and magnetic sub-micron linear and angular measurement systems ems-i can provide piston and cylinder style measurement in potentiometric, current or voltage formats. Backed with a custom designed service cylinder encoders as long as 1500mm have been produced for applications in the oil and gas industry. Offering near infinite life and IP67 ratings, actuation speeds of up to 3m/s and a linearity of just 0.3% they are ideal for the toughest of applications.

Not limited to positional measurement submersible level transducers, industry standard G1/2 Pressure Transducers are available without MOQ. In addition IP65 Pressure Melt Transducers are available that are ideal for rubber, plastic or other applications where the monitoring and control of material melt temperatures is required. The latest addition to the growing ems-i range is Contact or non-contact angular encoders with either 5V or 24VDC supply capable of 120RPM over a huge -25oC to +85oC temperature range. Available with ratiometric, 0.1-10VDC or 4-20mA outputs the applications are endless.

Resisitive Linear Transducers

For more information on measurement solutions for Automation, Machine Tool and Fabrication or to discuss custom requirements please contact ems-I on info@ems-i.co.uk or call +44 (0) 116 279 3035.

Industry standard G1/2 Pressure Transducers are available without MOQ. In addition IP65 Pressure Melt Transducers are available

The latest addition to the growing ems-i range is Contact or non-contact angular encoders


PECM Issue 11

PERHAPS best known as a quality supplier of measurement solutions for the machine tool and fabrication markets

Ball sector valve from Schubert & Salzer Control Systems

Wide range of uses thanks to outstanding control characteristics


he type 4040 ball sector valve is used everywhere where conventional valves break down under severe operating conditions. They are ideal for providing precise control and the safe shut-off of difficult media, such as: • abrasive suspensions of ores, coal or ash, • pasty media, • effluents contaminated with solids or containing fibrous matter, • suspensions in the pulp and paper industry, • alkalis and acids, • oils, and • oxygen, air or gaseous ammonia. The key element at the heart of the new ball sector valve in the 4040 range is the ball sector. One part of the ball sector acts as the shut-off, while the other contains a hole whose diameter is normally about 80% of the nominal size of the valve. As the valve is closing, the cross sectional shape of the opening changes from completely round to elliptical. This change in shape reduces the risk of the ball sector valve becoming blocked. At the same time, the ball sector seals off the medium even under harshest operating conditions by means of a seat ring against the valve body. The seat ring can be exchanged easily.

Outstanding control characteristics The characteristic curve of the ball sector valve has an almost equal percentage profile. This curve represents the optimum for most operating conditions, in particular during operation if the differential pressure across the valve decreases over-proportionally as the degree of opening increases. Furthermore, this characteristic shape is more tolerant where the valve is oversized, since the valve, with its flat characteristic curve at the lower end of the opening range, provides an ample control range when only a portion of the Kvs value is being utilised. Additionally, the rangeability is an impressive 300:1, substantially underpinning the properties described above regarding control behaviour. The shafts for the ball sector in the Type 4040 valves are positioned centrally. As a result, any deposits on the surface of the ball are wiped off by the seat ring. Also, when the valve is being closed, no solid parts can become trapped between the seat ring and the ball sector. Schubert & Salzer Control System’s ball sector valves are available in nominal sizes from DN 25 to DN 300.

www.schubert-salzer.co.uk Issue 11 PECM


Guarding without G uard ding w itho out barriers barriiers ... PSENsgate PSENopt PS SENop pt - 2Flexible Fl-exible advanced advanced d llight ightt curtain curtains ns

The Integrated System for Safety Gate Monitoring Greater Flexibility & Integration -Lar%&"!""!&$" !&%+"#$&#'%'&&"!%+%)&% ' !&#'%'&&"!%%&"!%&"# $!+%&"#!%#$% - !'%!"!'!&"!)&  '& "! %" -'&"$


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Maximum Safety & Energy Efficiency -!%)&#$%&+&"$#$%"!!#!&#$"&&"!'#&"  -''$$!&"!%' #&"!&" * Pilz Automation Technology Corby NN18 8TJ 01536 460766 sales@pilz.co.uk www.pilz.co.uk

Scan the QR code to find out more about the PSENsgate 2









Quality defects in Component Manufacture Quality defects can often go unnoticed

Traceability facilitates global regulatory compliance

Costs of catching defects increases at each stage in the production process

Rejects at delivery to customer increase costs, lose sales, and damage brand equity

 Issue 11 PECM



L Simple Control Solution for Fully Automated Paper Converting Machine

ocated in New Berlin, Wisconsin, Premier Paper Converting Machinery has expertise in stripping, partition assembly, and slitting machineries used to manufacture and assemble corrugated or fibreboard partitions of different sizes and finishes. These partitions serve as dividers to protect delicate items, ranging from bottles of wines to cryogenic vials, during shipping and storage. From its facility, Premier Paper manufactures and services machines that are shipped globally to customers in Europe, North, Central, and South America.

For the accurate positioning of the parting strip, a series of the Mitsubishi Electric L Simple Motion Controller is used, which indicates the detection characteristics. In the L Series PLC up to 100 recipes can be stored. (Image: Mitsubishi Electric).


PECM Issue 11

Challenge: Intuitive and flexible operation As Premier Paper began designing a new fully automated version of their Jumbo Assembler machine, a partition assembler for corrugated and fibre chipboard strips for paper converting applications, it was clear that the new machine would need an intuitive operator interface. But just as important as easy operation, the machine’s new automation and control package had to offer flexibility for future customization, changes and modifications. Typically each of their machines undergo several adjustments and reprogramming to cater to customization demands and new industry trends.

The Mitsubishi Electric MELSEC L Series determines the dimensions of the backing strip and the respective mode of transport, including continuous, interrupted or fully indexed supply and the insertion of even and odd cells. (Image: Premier Paper Converting Machinery)

On the first supply platform the separating strips are aligned accurately. (Image: Premier Paper Converting Machinery)

Operation is simple and intuitive with a Mitsubishi Electric HMI GT12. (Image: Premier Paper Converting Machinery)

Like most OEMs today, Premier Paper finds in order to design and produce machines that are unique and offer the best performance possible, they need to utilize the latest in automation and control technologies. While the company continues to lead innovation in their industry with converting machinery that is increasingly faster and more efficient in operation, they are also committed to integrating all innovations behind a simple and intuitive operator front end. Solution: An innovative automation and control system Premier Paper chose Mitsubishi Electric Automation because they offered a single, integrated automation and control system that met all the requirements of their new Jumbo Assembler machine including: Programmable Logic Controls (PLCs), Variable Frequency Drives (VFDs), Servo Controls, Simple Motion, Human Machine Interface (HMI) along with a single control software package. Starting with their PLC selection, the L Series Modular PLC platform is a simple yet flexible system, but most importantly the

Premier Paper chose Mitsubishi Electric Automation because they offered a single, integrated automation and control system that met all the requirements control platform offers future expandability that satisfies their complex customization requirements. The Assembler feeds up to 16 partition strips at a time using E-700 VFDs connected through CC-Link network. These strips travel to a second platform where a secondary set of strips are perpendicularly laid to create a perfect grid. The positioning of these strips is controlled by the L Series Simple Motion indexing registration features along with MR-J3 servo drives over the SSCNET III Fibre optic network. Up to 100 recipes may be stored in the L Series PLC, each determining the

dimension of the partition strips and how they are fed through the machine. The different feeding modes include: continuous, intermittent, full indexing, and even/odd cells. The operator is able to select any of these recipes from a GT12 touch screen very easily. Results: Future-proof machine with optimized production efficiency With Mitsubishi Electric’s flexible L Series Modular PLC and GX Works2 programming software, Premier Paper successfully integrated the machine using a single control platform and software package. The intricate feeding modes are programmed using the Simple Motion Function Blocks provided by Mitsubishi Electric. The program is easy to understand and modify for future customization and maintenance needs. Essentially, end-users have the flexibility to create infinite numbers of configurations for different partition types using one single machine. To execute the appropriate recipe for a specific partition type and feeding mode, the operator simply has to input or select parameter settings from the GT12 screen. Additionally, the control panel is sleek because the CC-Link and SSCNET III networks minimize wiring efforts and provide a clean solution. Start-up was nearly flawless, requiring very little troubleshooting during the commissioning process. Operating at extremely high speed, the new design more than doubles the overall equipment efficiency of the Jumbo Assembler utilizing Mitsubishi Electric’s integrated automation and control solution. Bob Lesch, Electrical and Mechanical Engineer at Premier Paper Converting, comments: “When I design something, I focus on what the customer wants. I also want customers to be comfortable with a well-known brand like Mitsubishi Electric.” Issue 11 PECM


Electrical & Electronics Socomec Modulys GP2.0

New HSKG high-power stud terminals from CONTA-CLIP for small cable diameters

Critical buildings and facilities are challenged with constantly evolving demands on energy performance. The supply of reliable, cost-effective power which can be scaled to meet the rapidly changing demands of a Data Centre is a vital component of the overall performance of the data facility. Socomec’s Modulys Green Power UPS - designed for complete vertical and horizontal modularity and scalability - is ideal for use in the most demanding critical IT applications and Data Centres.

CONTA-CLIP’s HSKG line of stud terminals ensures secure connections for all energytransmitting applications. The new HSKG 35 and HSKG 70 terminals connect cables with small rated cross sections of 35 or 70 mm².

The range offers power scalability up to 600kW, making it ideal for unscheduled site upgrades or incremental power evolutions. Furthermore, the installed power of a single system can be increased up to 200kW by adding power modules in increments of 25kW. For increased power and maximum flexibility, 3 parallel systems can be configured horizontally to achieve 600kW.

Tel: 01285 863300


HSKG terminals can be installed as required on standard TS 35 DIN rails in accordance with EN 60715. They are suited for rated currents from 125 to 520 A at rated voltages up to 1,000 V. Depending on the wire cross-section, the terminals are equipped with M6, M8, M10, M12, or M16 threaded studs. The wire connection range of the HSKG series extends up to 300 mm². Wires are applied to threaded bolts with crimped cable lugs and then connected securely to the busbar by tightening the hex nut.

Email: quade@conta-clip.de


Mounting accessories for economic ARCA plastic enclosures

Switchtec’s PCB mount solid state relays are robust for demanding applications

FIBOX presents a new glass-fiber reinforced polycarbonate enclosure series optimized for quick and easy installation and versatile applications. ARCA control cabinets are available in 14 sizes from 200 x 300 x 150 mm to 800 x 600 x 300 mm. Suitable for wall or pole mounting, they always retain their high IP66 protection rating. Their outer dimensions and the installation space match standard wall cabinets. Standard mounting plates can also be used with ARCA cabinets. On request, FIBOX supplies galvanized steel, perforated steel, or Pertinax mounting plates.

Melding compact size with high performance characteristics, Kudom’s KSD series solid state relays (SSRs) is available from specialist distributor Switchtec. The relays provide fast, reliable switching in a wide variety of applications across a broad range of industries.

The system further comprises an innovative mounting frame including a DIN rail frame, a front plate, and four plastic corner brackets. The frame is ergonomically populated separately before the entire assembly is placed inside the cabinet and screwed tight. 35 mm DIN rails can also be mounted directly in the enclosure body and at the inner side of the door where special mounting pods are prepared. The sides can be individually fitted with drill holes for cable feed through as per requirement.

The KSD series is available in three ratings, 3A, 5A and the KSDF version with its integrated heat sink that can switch loads up to 25A. All versions can handle load voltages of 48-280VAC or 48-530VAC as applicable. Multiple input/control voltage versions are available, namely 3-15VDC, 15-32VDC, and the popular 3-32VDC, with the KSDF version also being able to accept AC voltage input ranges of 18-36VAC and 90-140VAC.

Tel: 01642 604 400

Email: sales@switchtec.co.uk



Bespoke AC/DC PSU Built for your Application

OEM Open Frame Battery Charger

Bespoke AC/DC Power Supply Units (PSUs) are available for design-in to exactly suit project requirements. Using the dedicated design assistance from the Ideal Power ‘IP Support engineering team’, a PSU can be designed, rapidly prototyped and volume manufactured using EOS Power technology.

Ideal Power are developing a highly reliable, open-frame battery charger with a universal input that can integrate into any planned or existing charging system as an OEM solution which provides designers and installers the flexibility to achieve the desired charging system without the extra cost and complications of a fully enclosed battery charger.

With over 40-years of experience in the power supply industry, the IP Support engineering team work as a technical partner or an extension to a design team to cooperate in the design process and offer full project support covering samples, manufacturing, supply chain, shipping and even stock-holding units in the UK ready for call-off at a customer’s convenience.

Available as an install-ready, OEM sub-assembly which can be white-labelled with another brand as to appear as a complete solution, the OEM open frame battery charging systems. Considering the financial cost of replacement batteries, it is a fundamental requirement to extend the battery life as much as possible, a requirement that using this system can achieve by vastly improving the life-cycle and performance of the battery.

Tel: 0845 260 3400 Email sales@idealpower.co.uk www.idealpower.co.uk

Tel: 0845 260 3400 Email sales@idealpower.co.uk www.idealpower.co.uk

Are You Certain Of The Fill Material In Your Melt Pressure/Temperature Sensors?

Socomec’s latest innovative low voltage power solutions for railway infrastructure.

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

Email: info@terwin.com


PECM Issue 11


Low voltage electrical equipment specialists – Socomec – will present advanced solutions for the UK Rail and Mass Transportation sectors at InfraRail 2014. Socomec’s IP+ Rail range of UPS equipment has been specifically engineered for the unique requirements of UK rail sector, ensuring the safe, reliable and efficient operation of rail networks and infrastructure. Delivering robust, efficient and proven solutions, the latest Socomec UPS and Emergency Lighting technology has already been successfully implemented as part of high profile projects in both the UK and across Europe.


Electrical & Electronics DEECO LTD.

Manufacturers of Transformers. Some points why you may consider us -


Wireless Data Loggers

1) High Quality at Competitive Prices.

Cloud Based

2) Transit time to your door approximately 1 Week.

WiFi Temperature & Humidity Monitoring

3) We are in the EU so no customs documents. 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

01425 651111 sales@filesthrutheair.com

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

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

We provide . SMT & Through Hole PCB Assembly

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

. Complete Product Build

. Low/Medium Volume Manufacturing

. BGA/µBGA Placement & Inspection

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

. Test Solutions/JTAG/AOI . Global Procurement

. Lead Free Services

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

. Engineering and Design Support To meet your

Quality, Flexibility & Delivery targets

Call our sales department today

01234 266300 www.britonems.co.uk


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

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

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


Issue 11 PECM


Predict and Protect’ power quality monitoring adds new dimension to industrial systems


rotecting the operation of critical electrical systems within industrial locations to prevent system downtime and at the same time reduce costs is one of the challenges keeping facilities managers and maintenance teams awake at night. But what if it were possible to predict problems and so avoid them? Bender’s Power Quality Management (PQM) system is designed to help customers protect critical electrical systems and achieve maximum availability of electrical supply by continuous monitoring of the whole system – identifying potential problems and issues before they seriously impact on a system. It combines power quality and electrical safety to deliver an integrated solution for DC and AC electrical environments that tracks the frequency and seriousness of power surges

and interference, providing early warning of faults or failure for all critical aspects of the system to reduce downtime to a minimum. Bender’s PQM device also acts as an energy meter while checking the system quality, determining the energy consumption per cost centre and reducing high overhead costs. For example, it can determine how much energy is consumed by the measures taken to prevent system interaction, and will also show the effect of energysaving measures on the quality of the electrical supply system. Power quality monitoring is particularly effective when combined with residual current monitoring (RCM) which detects degradation in the level of insulation in an installation or component. It issues a signal when the residual current exceeds a set value that can be chosen to suit the electrical application, effectively tailoring the equipment to

the customer’s needs. RCMs are used primarily in facilities where a fault should result in a signal but not in disconnection. This enables operators to detect faults and eliminate their causes before the protective devices disconnect the installation, so increasing operating safety and cutting costs. Transparency is an important element in monitoring system quality, and Bender’s PQM units enable operations teams to identify, for example, when a power quality issue is due to interference or complex load, or whether the regional supplier is delivering poor power quality. The new generation gateway Comtraxx® CP700 Condition Monitor is the central point where all measured data is collected, filtered and evaluated to provide a comprehensive view of energy consumption and bring transparency to a data centre’s electrical service networks when used in conjunction with Bender Linetraxx PQM systems. Industrial surge suppressors provide protection from damaging power surges and spikes caused by lighting and utility accidents. But systems can also be affected by socalled ‘dirty power’ problems and interference caused by frequency converters, electronic operation


PECM Issue 11

of motors, pumps and other large equipment inside facilities, switched-mode power supplies used in most non-linear loads, and portable electronic devices including PC’s, chargers, TV’s, monitors. Monitoring the power quality of their systems to locate the source of interference and spikes and identify how and when they occur must be a priority for any facilities manager or power system engineer. But they can’t fix problems if they can’t effectively identify the issues. The PQM system provides comprehensive information on the status and performance of the power system within a data centre including line voltages, phase currents, phase conductor voltages, line voltages, active and reactive power import in kWh and kvarh, harmonic distortion, energy consumption and peak consumption, sag, swell and flicker. Importantly it delivers that information in an intelligent and transparent way, enabling managers to get a complete picture of how the power system is performing, and identifying potential problem areas. The information can be displayed by the screens on the CP700 itself or on a PC using existing IT infrastructure, and is not dependent on fieldbus wiring, eliminating bottlenecks caused by high volumes of data. Bender’s secure web-server based monitoring system also allows remote monitoring of sites. For more information visit www.bender-uk.com

Innovative Glary DC:DC Converters available from Ideal Power Glary Power Technology is the elite choice for DC:DC power conversion. Every Power Design Engineer should consider Glary first


ower conversion specialists Ideal Power are now offering a wide range of DC/DC converters from Glary Power Technology, one of the leading innovators of small footprint board mounted power conversion. Glary are renowned worldwide for producing extremely reliable power converters that exceed 90% efficiency, are thermally efficient and have an impressive power density to size ratio. These innovative DC/DC converters are available in industry-standard encapsulated and “brick� form factors ranging from 40W to 2KW and are ready to be fully customised to meet individual project requirements. Established in 1998, Glary have proved to be a reliable source for electronic design engineers seeking uncompromising PCB mounted power solutions. Glary offer a unique


PECM Issue 11

combination of industry-leading design, immense reliability and superior technical knowledge. The Glary business model is built on patents pushing the boundaries of technology by exceeding expectations for the design and manufacture of DC/DC converters. Patented Buck Reset Forward Technology exclusive to Glary, improves synchronous rectification (SR) operation by reducing the amount of components required. Achieved through a technique which improves the efficiency of rectification by replacing diodes with actively controlled switches, usually power MOSFETs or power BJTs, this innovative and unique topology design reduces heat generation, improves thermal efficiency through equal heat distribution and allows an incredible amount of power to be available.

Reducing the footprint required by the power supply on a PCB provides a major benefit for system hardware design as other system and application

Established in 1998, Glary have proved to be a reliable source for electronic design engineers seeking seeking uncompromising PCB mounted power solutions.

GLARY offer a unique combination of industry-leading design, immense reliability and superior technical knowledge.

critical components can reclaim the saved space. Glary’s Continuous improvement of designs to produce marketleading products provides an impressive featurerich product with fewer components on system board, faster transient response, lower ripple and lower RFI noise, no Tantalum capacitors are used increasing reliability, high power density in a small form factor, along with

extremely low heat generation and power loss. Singlesided component layout allows for easy mounting on the base-plate, Sink-Plate options eliminate the need for extra heat-sinks, vertical or horizontal heat-sink fins may be specified to increase compatibility with system airflow and smooth and precise edges of the base plate allow for compact assembly. When a new design is commissioned or a

modification to an existing product is required, the UK based IP Support Engineering Team at Ideal Power work together with Glary Technology. Ideal Power become a technical partner to the customer’s in-house design engineers to match the exact application power requirements. The IP Support team has over 40 years of experience in the power supply industry and provides local assistance throughout the whole design process from concept, design, quotations, samples and testing to approvals and standards compliance, shipping, stockholding and after-sales service. More information on Glary products is available here Glary - Innovators of the Power Converter and to contact the Ideal Power IP Support Engineering Team please call +44 (0)845 260 3400, email sales@idealpower.co.uk or visit idealpower.co.uk

GLARY are renowned worldwide for producing extremely reliable power converters that exceed 90% efficiency, are thermally efficient and have an impressive power density to size ratio.

Issue 11 PECM


OBO Bettermann

The enormous energy of lightning can destroy PV systems in the blink of an eye, risking the economic viability of the entire system.

Photovoltaic and Wind Power Systems from OBO T

he erection and installation of a photovoltaic system often requires major intervention in the electrical infrastructure of a building. This is reflected in the wide range of standards and regulations to be complied with. The person erecting and installing the system is liable for the correct fulfilment for 30 years of operation, and the requirements of Insurance companies, landlords and mortgage lenders come on top of that. (A list of relevant standards is available) “The overall responsibility for electrical safety is in the hands of the commissioning engineer” Through the feed-in of the gained energy almost every PV system is subject to the requirements for commercial use. For the system

operator, this creates the obligation to give the system the proper maintenance, checking and repairs. These regular recurring checks of the total electrical system components may only be carried by a qualified and system trained electrician. Throughout their lifespan, photovoltaic systems are exposed to extreme conditions. Wind and weather take their toll on all the components of the system whilst lightning and surges in voltage pose a major risk to the inverter. Protectplus can provide comprehensive protection of the entire system against damaging environmental influences. The enormous energy of lightning can destroy PV systems in the blink of an eye, risking the economic viability of the entire system. On the alternating current side, the sensitive inverter is threatened by destructive surge voltages from switching operations and network couplings. Lightning strikes generate dangerous surge voltages in a radius of 2Km. In the worst case scenario, these voltage peaks are enough to destroy the core of the system.

PV Systems are a major investment and a key power supply component. This investment should be protected against risk from lightning and surge voltages, against damage and failures from incorrect cable routing and theft. OBO Bettermann can connect systems into solutions for your complete project. From wind power turbines and associated connections to arrays of photovoltaic panels. This means we can offer you the entire electrical infrastructure from a single source. A whole branch of industry can profit from the driving force of an existing and low cost form of energy. Wind power systems have long been established as a technology for the future regarding the use of renewable energies. Modern high-performance wind power systems make extremely high demands of the quality and reliability of the components used. Particularly important is the electrical infrastructure, which is of key significance for the functional safety of the entire system. All this said OBO Bettermann can, and do provide the technical link and backup for your solutions. For further information please contact our UK office on: 01562 740666 Take a look at the OBO Bettermann channel on “You Tube” to view our “Power of 4” video, to get the full story of Lightning and Surge protection.

Setting New Standards At The Lowry The site BEMS (building energy management system) has been upgraded to the latest technology platform, to improve energy monitoring, management and reduce overall energy consumption, with a six-figure saving expected.

Working in collaboration with the facilities team at The Lowry and HFL Building Solutions, Spencer Hogg and his team at Real Control Solutions are providing a tailored solution to meet the specific needs of the site


he Lowry, an iconic cultural hub for art and entertainment in the North West has provided a unique challenge to improving energy efficiency – but a combined effort is already reaping rewards. Working together the Lowry’s facilities management team, outside contractors HFL Building Solutions and Real Control Solutions, supported by staff at the site have already overseen a 17 per cent drop in gas consumption and eight per cent in electricity with more to follow. The site BEMS (building energy management system) has been upgraded to the latest technology platform, to improve energy monitoring, management and reduce overall energy consumption, with a six-figure saving expected. Savings made on utilities will be reinvested back into making the arts accessible for as many people as possible. HFL Building Solutions, the Manchesterbased technical building services provider, has financed the BEMS upgrade over a five year period, enabling The Lowry to spread the costs of this imperative upgrade. HFL Building Solutions has been delivering a high standard of mechanical and electrical maintenance at The Lowry for eight years and is proud to have financed such a key project. Working in collaboration with the facilities team at The Lowry and HFL Building

Solutions, Spencer Hogg and his team at Real Control Solutions are providing a tailored solution to meet the specific needs of the site, that is home to three theatres galleries, restaurants, cafĂŠs and bars as well as associated staff accommodation. The chosen system for this project was the Honeywell Centraline AX solution utilising the Niagara framework platform. Due to the size and complexity of The Lowry site an IT network infrastructure for the new system to reside on had to be installed, once completed each control panel was upgraded ensuring coordination with the site operations team at all times to ensure site operations were not compromised. To complete the solution the REAL energy manager has been installed which resides within a Hawk controller and allows site the ability to analyse consumption data to ensure maximum efficiency and quickly highlight areas of concern. Staff have been brought on board with an energy screen providing details of the site consumption against target, comparison against average household consumption to give a relative perspective. The scrolling screen allows The Lowry to display information on their own sustainability plan. To find out more about go to www.realcontrolsolutions.co.uk & www.hflbuildingsolutions.co.uk

Thedriving drivingforce forceo The quality quality

Our goal is perfection – no more and no less

eof ofhighhighyycustom customsolutions solutions

NEW The NEW generation of


For many years iwis’ ELITE brand of roller chain has been used by major OE manufacturers and End Users and is seen as a critical component to countless applications where consistent quality and value for money are of paramount importance. iwis are now very proud to announce that re-development of the range with focus on key elements such as production techniques, tolerances, raw materials and our recently developed eliDUR lubrication means it just got better! In fact in many cases we have improved it’s lifespan by over 50% which adds even more value to the product, and tests within iwis’ laboratory against well know “market leaders” have proven in many cases that it is capable of outperforming it’s rivals. The comprehensive range includes British and American standard roller chains in carbon, stainless steel and nickel plated options.

iwis drive systems Ltd. Unit 8c Bloomfield Park, Bloomfield Road, Tipton West Midlands, DY4 9AP Tel: +44(121) 5213600, Fax: +44(121) 5200822

Conveyor and attachment chains are available from the UK and can be produced to order when required, and our huge range of British, American and European leaf chains on stock in the UK service a large proportion of the UK and European market. As OE supplier to the Agricultural market, ELITE combine and bailer chains are available from stock in the UK as well as our Agrisystems plant in Germany.

Preferred Supplier of the Bosch Group The range satisfies most conveying and transmission applications and customers such as Bosch Gmbh are so satisfied with the product they have decided to award iwis with it’s certificate of excellence and have recognised the ELITE brand as their No.1 product for all transmission and conveying applications.




n the nuclear energy industry more than most, safety is paramount and the design and specification used for equipment involved in nuclear generating plants are governed by a series of stringent regulations. The maintenance programs follow strict timetables with only certified contractors permitted to provide products and services, so when it comes to high voltage motors and generators, it is important to ensure that any repairs are going to make the grade. Nuclear power generation makes up an important part of meeting the global demand for energy, with 31 countries across the world using over 430 nuclear power plants to meet close to 14% of global electricity demand, a similar proportion to that developed by the hydro industry. With so many people relying on the nuclear industry, it is essential that it operates faultlessly, which

means strict adherence to maintenance programmes.

to maintain safe operation of the plant.

The typical nuclear power plant is segregated between the conventional island and the nuclear island, with the former containing the steam turbine generator and water cooling systems, which require large high voltage motors to ensure the huge volumes of cooling water are successfully circulated around the plant. As with any large rotating machine, condition monitoring offers a very useful insight into the performance status as well as the expected service life of the equipment.

The required capacity of these pumps leads to the majority being powered by high voltage motors and many of them are now in excess of 20 years old. After so many years of continual stress the regular testing regime can start to indicate problems within the insulation system. Initially, these can be monitored without cause for alarm, but plans for a major overhaul should start to be put in place in order to manage the project effectively and efficiently.

The turbine within a nuclear power plant requires considerable support from a number of pumps and motors that ensure the condensate water and cooling water systems are maintained properly. In addition to the regular pumps, auxiliary pumps are required to provide support in the event of a breakdown, ensuring there is always sufficient capacity

Most equipment of this size contains built-in vibration and temperature sensors to provide live data, while periodic maintenance, inspection and testing can provide some further insight into the integrity of the windings in these machines. Some of this preventative work can be completed by in-house engineers, but in some cases it may be necessary to call in expert engineers to carry out a complete suite of tests and to produce a definitive status report. Since they were originally built, the technology used in the coil insulating systems has moved on considerably, which means that when

The turbine within a nuclear power plant requires considerable support from a number of pumps and motors that ensure the condensate water and cooling water systems are maintained properly


PECM Issue 11

Nuclear power generation makes up an important part of meeting the global demand for energy, with 31 countries across the world using over 430 nuclear power plants to meet close to 14% of global electricity demand

a complete overhaul is planned, the refurbished motor will not only provide another long period of service, but it can also operate more efficiently, reducing running costs and increasing the return on investment (ROI). Sulzer is a leading supplier to the power generation market, especially the nuclear sector, providing customised maintenance, repair and overhaul (MRO) solutions for pump requirements and all LV and MV/HV motors including monitoring, test and assessment, rewind and repair services. This capability also extends to the turbine and main generators. Capable of delivering bespoke engineering projects to the highest standard, Sulzer has demonstrated its ability to meet the tightest deadlines, ensuring that power plants continue to operate at maximum efficiency. For those involved in the operation and maintenance of large HV rotating machines, there are many choices when looking at the repair or rewind of such equipment. The key to a successful project is ensuring that those involved will be able to deliver a high quality product, precisely, quickly and with the necessary support to ensure a timely completion, regardless of how the scope of the work changes. www.sulzer.com

Machines containing Variable Speed Drives associated with RCCBs

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.

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.

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).

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.

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

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 /

Understanding the risks

the higher frequency ranges can be significant and from a safety 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. 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. 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

Facilities Management SEAMLESS


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Providing hand wound mechanical starter motors for the following applications:

Hazardous Environments: Oil & Gas Mining Problem Environments: Marine Industrial Emergency Use: Generators Lifeboats And many more, including: Third World Agriculture


PECM Issue 11

For more information please visit us at:

www.springstarter.com Kineteco International Ltd Unit 16, Willesborough Industrial Park, Kennington Road, Ashford, Kent TN24 0TD Tel: +44 (0) 1233 811500 Fax: +44 (0) 1233 221571 email: sales@springstarter.com

Andrews Creates Temporary Chilled Store for Confectionery Manufacturer T he combination of an Andrew’s chiller and a number of air handling units proved to be the most viable options for creating a temporary chilled storage environment in a new warehouse for a specialist UK chocolate manufacturer. This application called upon the skills of Specialist Hire Division of Andrews Sykes to supply and install a totally integrated temporary cooling system. Engineers from Andrews Sykes Specialist Hire team calculated that to achieve the required low temperature would require two 550kW chillers feeding eight 150kW air handling units. Each of the AHU is capable

of delivering up to 20,160m3/h and they were strategically positioned to afford optimum air flow around the warehouse. During installation engineers from the Specialist Hire Division sited the chiller and 2 x 800kVA generators as close as possible to the warehouse without restricting warehouse access and all internal pipework was specifically positioned to avoid disruption to warehouse staff as they went about their daily routine. Andrews Sykes’ Specialist Hire Division operates with some of the most advanced equipment and has one of the largest fleet of chillers and air

ANDREWS Air handling units

handling units. The extensive chillers range includes high capacity fluid chillers capable of delivering up to 750kW of normal cooling duty whilst individual AHU have a nominal cooling capacity of 600kW. In providing short-term solutions for organisation looking to either supplement the work of an existing chiller installation or as a temporary replacement engineers, Andrews Chiller Hire will carry out a site survey to clearly understand the requirements and how best to achieve the required outcome. By providing 24/7, 365 day access to specialist engineering staff and with a nationwide network of more than 24 depots Andrews Sykes

Enclosures from the smallest to the largest. ENCLOSURES




This application called upon the skills of Specialist Hire Division of Andrews Sykes to supply and install a totally integrated temporary cooling system.

Specialist Hire Division is always to provide an extremely prompt response – normally with less than 4hr.

is renowned for this installation is supplied the 2 x 800kVa generators and a 6,000 litre bunded fuel tank.

In an emergency situation a customer faces the possibility of losing many thousands of pounds through downtime or waste product. The ideal scenario is to pre-plan where possible as was the case with this chocolate manufacturer, realising that their new warehouse would require a short-term chiller solution.

Prior to the warehouse going operational, and during the early weeks of storage, the Andrews system was live, warm air in the warehouse drawn in the AHU, circulated over ‘cold’ coils which caused a drop in temperature, the much cooler air blasted back into warehouse. This continuous cyclic process repeats to maintain set temperature.

In dealing with Andrews Sykes the chocolate manufacturer was assured of receiving a totally self-contained system, in addition to the normal hire equipment for which Andrews


Short-term hire for the new warehouse is indicative of the many successes Andrews Sykes Specialist Hire Division solves all year round, particularly

when food manufacturers ramp up productivity to cope with increased seasonal demand, where they have to ensure adequate preservation of raw materials and some will also need additional temporary chilled storage.

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

SOFTWARE & SERVICES www.rittal.co.uk

Fluid Handling Look To the East Midlands for a Distributor You Can Trust

Over the past forty-five years, Derbyshire-based Industrial Ancillaries have become established as industry-leading distributors of superior quality hydraulic, pneumatic, instrumentation and process products. Our central national distribution centre, located at Junction 29A on the M1, boasts 40,000 sq. ft. and offers convenience and confidence in logistics. We distribute to a broad range of industries including; engineering, oil and gas, chemical, mining, aerospace, construction, plumbing and HVAC, medical, pulp and paper, automotive, transport, power generation, food and beverage, marine and shipbuilding, instrumentation, process, semiconductor, analytical and agricultural. Dynamic, professional, committed and customer-focused, we continue to build on our reputation as a key player in our traditional markets, as well as seeking to expand our business by exploring new products and fresh markets. We constantly endeavour to develop and maintain strong and enduring relationships with new and existing customers, suppliers and service providers. Get in contact with us by email sales@indanc.com or call our experienced team today on 01246 242050 to explore future opportunities.

Prelubing Industrial Equipment The rigorous demands on industrial equipment are even more so in cold-weather climates and studies have proven, the majority of engine mechanical wear, almost 90%, occurs at startup. At first crank of the engine, all the oil is in the sump and at the first rotation of the crankshaft the bearings, and all galleys are dry causing metal-to-metal contact to occur damaging the engine over its lifetime. In cold weather prelube helps to circulate the thick oil prior to cranking. Prelube is a worthwhile investment to keep equipment running at peak performance, can help lessen time between top-end and inframe overhauls and extend equipment life. ESE offers a line of pumps Optimized for Prelube. VARNA Products positive displacement vane pumps utilize our patented floating whisper vane technology. The pump itself does not create pressure, it produces flow. Some models have built-in check valve and/or pressure regulator and some models are built for maintenance free operation. . Available in 12/24VDC, Single & Three Phase AC, Air, motors e. s. Flow rates to 55 l/min at pressures to 4 bars

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

ESE BV OEGSTGEEST, NETHERLANDS pumps@ese.tc www.ese.tc Tel: 31 71 5173947


PECM Issue 11

watch this video on YouTube http://youtu.be/y3mBvOUsxzk



heavily laden conveyor can have an enormous amount of potential energy, so has to be treated with the utmost respect if accidents are to be avoided. Steve Powell, Product Manager for Twiflex Ltd., an Altra Industrial Motion company, looks at parked-off conveyor brakes, and how they can improve safety during maintenance. Heavy-duty conveyors in quarries and mines, cement works and other processing plants, dockside and shipboard applications, logistics and materials handling, can carry massive loads and therefore have to be recognised as potentially dangerous. Generally, they are operated in a safe and responsible manner, with extra care being taken if unusual circumstances arise and with a number of safety systems built into them. One of the key elements in a conveyor system is a parking


PECM Issue 11

brake, which is used to lock the conveyor into one position when not in use; when it is being serviced or during a power outage. This reduces the possibility of the conveyor starting to move under its own load, a situation that could become very dangerous, very quickly. Similar conditions can apply in other fields, such as cranes and winches, elevators and escalators, manufacturing, energy, oil and gas, water and wastewater, and parking brakes can be used in these environments too, although the design may be adapted to the specific needs of each application. To cover the possibility of a total power failure, most parking brakes are spring applied. This means that when no external power is supplied to them the pressure of the spring is applied to the pad and the brake clamps shut, thereby locking the conveyor in a fixed position.

However, there is a downside that needs to be considered: while a spring applied brake offers protection in the event of a power failure, it also makes maintenance a far harder task. When a spring applied brake is powered down ready for maintenance work to be carried out, the brake is shut tight against the disc. The springs therefore need to be compressed to access the pads, which leaves a lot of potential energy in the brake. To address this issue, Twiflex Ltd, has incorporated a unique feature into its conveyor brake products, which addresses the risk of brakes clamping shut unexpectedly during maintenance, an occurrence that can pose a hazard to personnel. The ‘parked off’ feature can quickly be applied while the brake is in the field and allows for maintenance and pad removal without the risk of the brake clamping shut.

The ‘parked off ’ feature is available on many of Twiflex’s conveyor brakes including the recently released VKSD and VBS modular brakes

The end cover of the parking brake can be simply removed to allow the brake rating to be changed

Conventional industrial brake design typically employs a mechanical lock-out concept in which a nut and centre bolt arrangement is used to hold the spring force and prevent the disc from closing during maintenance. However, this lock-out arrangement only works as long as the nut can hold its integrity. If the nut fails because its thread shears, the brake will close. Unexpected closing of the brake could cause serious injury to engineers and technicians carrying out maintenance; or indeed to anyone within the vicinity of the conveyor system. The Twiflex ‘parked off’ feature is different to other solutions in that it actively removes the spring force from the brake while it is powered off, meaning that there is no force acting on the pad and therefore no potential of an unexpected closure when correctly applied. With hydraulic pressure applied, maintenance engineers can unwind an adjusting spindle, which releases the spring pack. When the hydraulic pressure is removed the spring has the freedom to extend without acting on the brake. At this point the spring load and hydraulic pressure are both zero and the brake has no stored energy. The ‘parked off’ feature has a number of benefits. First, basic maintenance such as brake pad replacement can be carried out quickly and with a reduced risk of harm from unexpected closure when compared to conventional brake designs. Second, the brake pressure can easily be adjusted by setting the brake to ‘parked off’ and adjusting the number of shims from the end cover. Finally, installation

Removal of the spindle locking plate is quick and simple

Standard tools are used for maintenance of the brake pads

The innovative Twiflex design encompasses safe working practices

The brake pressure can easily be adjusted by adjusting the number of shims from the end cover is made easier and the brake can be installed without the need for hydraulic pressure. The ‘parked off’ feature is available on many of Twiflex’s conveyor brakes including the recently released VKSD and VBS modular brakes. Further, the Twiflex engineering teams represent a world-class repository or expertise and experience, and can work with

conveyor users to develop highly bespoke and optimised brake and safety systems. In such cases, considerable time and effort is given to electronically collecting actual usage data and analysing it to ensure that all possible operational scenarios are considered during the design process. www.twiflex.com Issue 11 PECM


Health & Safety The ‘Green’ Answer to Oil Spills

asecos – the One-Stop Solution to Safe Storage

Sorbent material specialist, Oil-Dri, has launched a new 100% recycled absorbent floor granule product designed for oil spills.

The increasing amount, variety and complexity of hazardous materials in the workplace makes the need for their secure storage ever more pressing to avoid the risk of fire or explosion.

Oil-Dri Recycled is made from 100% recycled material, such as waste plasterboard from the construction industry. The company says that their new granules are the most environmentally friendly available on the market. Oil-Dri Recycled granules are perfect for absorbing all kinds of oil and grease spillage and have been exhaustively tested to prove their suitability as an economical yet highly effective absorbent material – and they have delivered exceptional results.

Tel: 01945 581244 www.oil-dri.co.uk

Email: sales@oil-dri.co.uk

Better safe than sorry with new lockout/tagout kits To support their existing Lockout/Tagout range of products, IDEAL INDUSTRIES has launched a new ‘Contractor PRO Lockout Kit’ aimed at contractors requiring a comprehensive safe isolation solution to meet an ever increasing number of fuse and breaker types from a number of different manufacturers. Many accidents and even deaths are caused by the unexpected energisation of circuits, machinery or other electrical equipment. Implementing appropriate lockout/tagout procedures can prevent these types of accidents occurring. IDEAL’s Lockout/Tagout kits help to achieve compliance with The Electricity at Work Regulations and related HSE Guidance Notes on safe working practices.

Tel: 01925 44 44 46 Email: electrical.enquiries@idealnwd.com http://www.idealindustries.co.uk/products/electrical_safety/

Safety eyewear made lighter Weighing in at just 16g, JSP’s new Stealth spectacle is claimed to be the worldis lightest safety eyewear. Said to be so light that most workers will not even know they are wearing it, the Stealth 16g uses the latest technology to offer high levels of eye protection, all-round vision, and freedom from eye strain.

To reduce risk, hazardous materials such as acids, alkalis, flammable liquids and pressurised gases need to be stored directly at the workplace in secure cabinets, so they can be safely and quickly accessed. Conforming to the requirements of EN Standard 14470 for maximum fire safety, Asecos’s safety cabinets, such as its Type 90 cabinet, protect their contents from fire for at least 90 minutes, should the worst happen. Asecos’s cabinets also prevent internal leakages and ensure any vapours are drawn off by their mechanical ventilation systems, which ensure a 30fold air exchange per hour.

Email: contact@asecos.com


Fire resistant insulated door Designed to protect people and property the LBS El 120 insulated sectional overhead door is a fire shutter that has been independently tested and shown to provide up to 132min stability, integrity and insulation. Tested and approved by Warrington Fire Research Station, the El 120 can be used as a normal door. lt will automatically close in the event of an emergency, having battery back-up, timed delay, and audible/visual turning equipment to ensure safe usage in conjunction with agreed fire strategies. Available up to 5.6m wide / 6m high the door will provide up to 35dB sound reduction and can be supplied in a variety of powder coat and stainless steel finishes.

Tel: 020 8517 6655


Comfort Safety and Style Italian company U-Power’s new Gore-Tex footwear range, an addition to its work-toleisure safety footwear, is now in stock in the UK and available for immediate order. U-Power’s Gore-Tex footwear is totally breathable and waterproof and therefore suitable for the toughest of environments and extremes of temperatures, allowing sweat to evaporate and the foot to breathe in hot situations, while keeping the foot dry and comfortable in wet conditions. In addition to their rigorous safety, protection and comfort credentials, most styles in the new Gore-Tex range are designed with a fashionable sporty look and feel.

The Stealth’s next-generation ultra-thin and ultra-strong lenses are moulded using the latest technology to deliver a thinner lens that meets the requirements of EN166 1.F.

The collection encompasses 11 types of footwear, including four Gore-Tex styles in U-Power’s Roar range. Four styles of the more traditional black and brown hiking-style boots and a rigger boot are also available. Eight of the styles have electrostatic discharge (ESD) properties, to protect against static electricity.

Tel: 01993 826050

Email: info.uk@u-power.it


Training Key to Staying Safe 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. 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


PECM Issue 11


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

Health & Safety

JSP Continues to Outpace the PPE Market with Frost & Sullivan Market Leadership Award

JSP has been given the prestigious Frost & Sullivan (F&S) Market Leadership European Head Protection Award 2014 for its commitment to providing outstanding industrial head protection products and customer service to its extensive range of end users across multi-industrial applications. In bestowing the Award on JSP, F&S recognised the company’s strong brand image and comprehensive product portfolio, maintaining the highest market share within the extremely competitive personal protective equipment (PPE) industry by a process of constant innovation by its own internal R&D department, which results in brand new and enhanced products of the highest quality. F&S Research Analyst, Shray Sharma, said: “JSP maintains a constant focus on using new materials and manufacturing technologies. It has also acknowledged the rising trend of sustainability by developing hard hats made from fully recyclable, UV-stabilised, high-density polyethylene.” The firm acknowledged that JSP has a wide breadth of head protection and covers more Standards than its rival companies. JSP has focused on developing its Evolution® hard hat line by adding new features and specifications that enhance product value, such as the 3D precision fitting harness that enables a perfect fit, so giving excellent retention and stability.

Force8™ Half Mask with h Press To Check™ P3 filters ers can a year ar when masks compared to disposablee masks.

F&S also mentioned other innovative features of JSP’s head protection range, such as its JSPCHECK™ system, which verifies the validity of helmets to guard against counterfeiting, and its Star Guide, which rates helmets by the level of protection they provide to enable selection of the correct degree of safety. In making its award, F&S also took into account other inventive features of JSP helmets, such as customisation, and integrated hearing and eye protection. Sharma added: “By structuring itself to increase manufacturing, invest in R&D and enhance supply chain efficiency, JSP has addressed key unmet needs in the head protection market.” More information is available from www.jsp.co.uk, by emailing uksales@jsp.co.uk, or calling +44 (0)1993 826050. Issue 11 PECM


Lubricants Rocol Extends Metal Detectability In FoodGrade Lubricants Packaging Food grade lubricants specialist ROCOL has added additional safety dimension to its FOODLUBE® product range with the introduction of DETEX® metal detectable caps on all grease cartridges. The move follows overwhelming customer approval for the introduction of DETEX actuators and caps on all ROCOL NSF registered FOODLUBE aerosols last year, and ROCOL says that by extending this to cover grease cartridges they can help maintenance engineers in food processing environments further reduce the risk of foreign object contamination. It means customers using popular FOODLUBE food grade greases, such as Extreme, Hi-Temp 2 and Ultra, can now benefit from the ability to detect cartridge caps should they accidentally become loose in food and drink processing areas. Find out more about the FOODLUBE range at www.rocol.com.

Prelubing Industrial Equipment

Hot dipped chain Hot-dipped chain lubrication is now offered by Donghua as part of its new UK Attachment Chain Workshop. Donghua can offer a hot-dipped lubrication service for its in-house built stainless steel attachment chain. Hot-dipped lubrication is regarded as the best type of chain lubrication available as it allows full penetration of lube into the bearing areas, providing optimum protection for the chain and reducing premature chain wear. Bob Wellsbury, MD of Donghua, explains: “Good chain lubrication represents 80% of a chain’s wear life. Premature chain wear is mostly attributable to poor lubrication and maintenance. The most effective chain lubricant is generally one that has a high viscosity (thickness), but high viscosity lubricant does not penetrate the bearing areas found in the centre of the chain around the pin and bushing.”

Tel: 01902 866 200


Solid Technical Solutions introduces non-silicone, non-hydrocarbon lubricant product line, Tec-Flon

The rigorous demands on industrial equipment are even more so in cold-weather climates and studies have proven, the majority of engine mechanical wear, almost 90%, occurs at startup. At first crank of the engine, all the oil is in the sump and at the first rotation of the crankshaft the bearings, and all galleys are dry causing metal-to-metal contact to occur damaging the engine over its lifetime. In cold weather prelube helps to circulate the thick oil prior to cranking.

Solid Technical Solutions™, a world class innovator in materials development, is pleased to introduce its product line of high-tech lubricant materials, Tec-Flon™ (GM-approved). The Tec-Flon family of non-hydrocarbon, nonsilicone, fluorinated oils and greases is designed specifically for use with plastics, in paint shops where silicones are not permitted, or in vacuum environments. The products remain effective when used for high-performance applications, even in high temperature settings.

Prelube is a worthwhile investment to keep equipment running at peak performance, can help lessen time between top-end and in-frame overhauls and extend equipment life.

Solid Technical Solutions’ Tec-Flon materials meet or exceed the performance requirements of General Motors; and are well-suited for use in electronics, optics, aerospace, cleanrooms, and general assembly applications.

Email: pumps@ese.tc



PECM Issue 11


Machining & Machinery M12 jack for field assembly by METZ CONNECT METZ CONNECT is the first manufacturer to market an X-coded M12 jack for field assembly. METZ CONNECT has developed an M12 jack for field assembly for future-proof and high performance 10 Gigabit-Ethernet cabling in communications cabling and for automation control units. The jack is offered in two variants as X-coded version: with or without flange. The flange variant is suitable for installation in equipment, machines or plants and the variant without flange is used for free line connections. In accordance with Cat.6A, these M12 jacks are suited for data transmission up to 10 Gigabits. Due to complete metal shielding with a robust zinc diecast housing, the M12 jacks for field assembly can also be used for difficult transmission conditions without problems.

Tel: + 49 (0) 7702 533-115


G P Burners’ Digital Control Conversion Fuels Improved Energy Efficiency Swindon based combustion equipment manufacturer, G P Burners, has launched a digital burner control and variable speed drive (VSD) conversion initiative. Under the programme, the company’s extensive range of analogue controlled gas fired burners may be retrofitted with a digital conversion package and VSD. The digital burner controller regulates the frequency of the power supply to the VSD, which in turn controls the rotational speed of the burner’s fan motor. This is particularly appropriate for low fire regimes, providing greater control of air flow when the fan motor speed is slowed and the gas intake is reduced for low load operations.

Email: info@gpburners.co.uk

The Ultimate Combustion Technology We are a market leader in the design, manufacture, installation, commissioning and servicing of standard and custom built burners. Our plug and go digital burner controls, with variable speed drive and touch screen interface, promote energy efficiency, optimum performance and user friendly operation. Our range includes burners for a wide variety of fuels, including: Gas Oil Dual Fuel Biogas Syngas Other waste combustible fluids GP Burners (CIB) Ltd Tel: 01793 709050 Email: info@gpburners.co.uk Website: www.gpburners.co.uk


marking and engraving systems and services Redefining systems design & supply Developing cost effective solutions Customer focused solutions Redefining customer support Website: http://www.thinklaser.com Phone: 01737 224731 ∙ Fax: 01737 249124 Email: info@thinklaser.com Address: 57 Albert Road North, Reigate, Surrey. RH2 9EL Contact: Adrian Norton, Managing Director

Family-owned engineering firm becomes a beacon of best practice for companies across the UK Hone-All Precision, a family owned and managed engineering business based in Leighton Buzzard, has been chosen by EEF, the manufacturers’ organisation, to feature as a case study demonstrating to other businesses how to tackle and improve health and safety. Hone-All Precision employs 37 staff and worked with EEF after recognising that it faced a challenge, which was to implement a world-class health and safety management system that would meet stringent legislation, but be practical enough for a small business to use on a daily basis. www.hone-all.co.uk

Issue 11 PECM


Enhancing Composite Performance The UK is at the forefront of what is an ever growing composites industry. As such, the rate of innovation in this field has been exponential. As with all manufacturing, there is a need to understand the importance of surface preparation as a means to improve product quality. Phil Dawes, Sales Engineer at Vapormatt explains why wet blasting is one of the better methods of this for preparing composite parts for bonding.


riven by the need to reduce weight without compromising structural integrity, the use of composites in the aerospace and automotive industries has been a key focus for many manufacturers. The ability to produce well bonded parts can eliminate the need for expensive fastening processes, which add weight and stresses to a component. Surface preparation has been long recognised as an important step in producing a robust bond and is key to maximising strength and durability. However, while long standing processes such as manual abrasion, dry blasting

or peel ply have been traditionally used they are limited in the ability to provide precise and reproducible results. This in turn may lead to established processes being unable to meet certification levels required for composite parts. As the demand for composite parts increases manufacturers must constantly be looking at different, and often new, ways to achieve better bonds. By looking to improve surface preparation manufacturers will be able to overcome new challenges and find new ways of using composite materials.

How wet blasting can help As an alternative mechanical process wet blasting can offer manufacturers enhanced precision and also reproducibility when it comes to preparing composite parts. The wet blast process combines compressed air, abrasive media and water in a slurry form to create a mechanical action that gives an abrasive effect. The introduction of water allows for a lubricating effect, allowing the slurry to flow across the surface. When compared with other methods the lubricated flow of abrasive from the wet blasting process will make it far easier to process complex shapes, while also delivering uniform finishes for more consistent bonds. Being able to control the process parameters, which can be, in some applications, as many as 15, provides ultimate reproducibility with predetermined recipes allowing for easy configuration and reduced set up times. Where high value composite parts, such as fan blades or engine parts, are concerned reproducibility becomes even more important. Concerns with dry and manual abrasion suggest that over processing, for perhaps only a few seconds, can reveal the underlying fibres causing damage to the part. In these situations the wet blast process can be utilised to prevent fibre damage. With controls in place for slurry as well as air pressures, a finely tuned buffer can be configured to ensure a gentler action that will


PECM Issue 11

leave the underlying fibres undamaged – even in the harshest of processing environments. Having realised some of the benefits of wet blasting, Formula 1 teams and aerospace and automotive manufacturers have incorporated it into their production process. Getting it right A critical part of determining the best method for surface preparation will be the degree to which a bond lasts.

The ability to produce well bonded parts can eliminate the need for expensive fastening processes, which add weight and stresses to a component.

Part of this will stem from testing the surface finish prior to bonding. Manufacturers will often check for surface roughness and perhaps wettability to provide data on how effective the preparation process has been. The wet blasting process gives a very consistent and matt finish that increases the surface roughness in preparation for bonding. In the case of composite parts, this will involve the removal of the resinous layers caused by the prepreg process. Being able to control the concentration of media and the various flows means recipes can be configured to achieve a range of roughness readings. After the bond has been made lap shear tests can be used to test the adhesive strength. As surface preparation is a key part of improving adhesion the test can be used to

differentiate between different preparation processes. Among the surface preparation processes available wet blasting has been able to score highly with bonds, which last longer due to the enhanced uniformity of the underlying surface finish after wet blasting.

Having realised some of the benefits of wet blasting, Formula 1 teams and aerospace and automotive manufacturers have incorporated it into their production process. Latest innovations As manufacturers look to work with increasingly complex composite structures and shapes the need to control surface preparation is increased. This has led to leading wet blasting companies developing innovative solutions for further process controllability to enable greater flexibility. With the handling of composites requiring a great deal of care the ability to remove any contaminants from the blasting process becomes critical for ensuring a successful process. Without proper filtration the blasting process can result in contaminants being blasted back into the surface of the composite and compromising the subsequent bond. To counter this manufacturers will look to specify filtration using elutriation to better control and enrich the quality of the blasting slurry. With integrated PLCs and slurry concentration meters elutriation towers can also be used to control and monitor the amount of abrasive content in the slurry, ensuring optimal levels are maintained over prolonged periods of use. Very high end systems further increase controllability, with “self-monitoring� wet blasting systems now available. Parameters such as pH, temperature, water and abrasive level, and air flow can be measured. With such extensive monitoring available the machines automatically dose themselves with more media, water or soap to ensure consistency, as well as

recording trends and wear to help plan maintenance. In practice Machines are now available to offer manufacturers a convenient and consistent means of processing a range of materials with exceptional finished quality. Having realised the need for wet blasting the National Composites Centre in Bristol have experienced extensive use of the Vapormatt Cougar wet blasting system which has enabled a number of its aerospace members to enhance and optimise the quality of their bonding processes. The mid-range Vapormatt Cougar features four gloved access points for manual handling of components with the hand-held blast gun then activated by a foot pedal. Pressure can be varied to suit the composite properties and design. A large viewing window allows the operator to monitor progress, ensuring the optimal surface is produced for the subsequent bonding process. A variety of wet blasting machines are available to suit different customer needs. Solutions range from compact manual cabinets available for selective treatment of smaller parts and research work, up to fully automated production systems for larger and more complex parts. Therefore, it is advisable to consult with a specialist in this process to get the most valuable solution for specific requirements and applications. Conclusion The wet blasting process delivers the consistency that is critical for bonding. It also provides finely blended recipes for carbon fibre, aluminium and titanium so that by varying process parameters the best results can be achieved on each material with the maximum efficiency. It is this blend of consistency and efficiency, and the fact that the process does not cause any damage to the part, which offers the right surface preparation process for composite parts. www.vapormatt.com

Issue 11 PECM



Mitsubishi Electric FA Centres in India

Ahmedabad FA Centre to support Japanese manufacturers


itsubishi Electric Corporation announced on 2nd of September, that Mitsubishi Electric India Pvt. Ltd. has begun operating, effective immediately, a new centre to provide factory-automation (FA) services in Ahmedabad with the Indian state of Gujarat, where a large number of Japanese manufacturing companies in need of FA services are operating. The Ahmedabad FA Centre will support the ongoing expansion of Mitsubishi

Electric’s FA business in India, which is targeting sales of 8.9 billion INR, or 146 million USD, by the fiscal year ending in March 2016.

such centres that Mitsubishi Electric now has in India, will provide faster, higher quality local services than ever before.

The Centre will offer FA product training, technical consultation, solutions and training support for the engineering personnel of its customers. FA product servicing operations in the Gujarat area had been handled by the Pune FA Centre, which was established in January 2012, and by local partners. The Ahmedabad FA Centre, one of five

Ahmedabad, which has a robust economy and substantial infrastructure, is aggressively attracting outside investment. The area’s increasing number of Japanese manufacturers and automotive companies in general are envisioned stimulating demand for FA products and a wide range of related services.

DLF building, location of Mitsubishi Electric India HQ India Ahmedabad FA Centre office of Mitsubishi Electric

Ahmedabad FA Centre Location: Primate, Judges Bungalow Cross Road, Bodakdev, Ahmedabad, Gujarat Start of operations: September 5, 2014 Employees: 4 Business: Engineering services, consulting, training and solutions Target FA products: Programmable logic controllers and numerical controllers, inverters, servo motors, graphic operation terminals and robots Languages: English, Gujerati, Hindi and Japanese


Machining & Machinery

Custom made threading tools for non standard threads and applications. Taps, dies, die nuts and gauging for virtually any thread form. Ready stocks for many ‘non standard’ threads. Specialist dedicated team to handle your enquiries and supervise manufacture of non stocked items. Happy to give technical assistance. Wiseman Threading Tools Ltd 11 Padgets Lane South Moons Moat Redditch B98 0RA UK 0044(0)1527520580 sales@threadtools.com www.threadtools.com

Thinklaser Thinklaser is a leading UK laser marking services company providing sub-contracted laser marking to a wide range of companies in a variety of sectors including Aerospace, Petrochemical, Medical, Automotive and General Engineering. Our fast turnaround laser marking process is high quality, permanent and non-contact for all products, components and applications, as well as cost-effective and flexible for small and large volumes. Thinklaser announce the addition of two new flatbed CNC laser cutting and engraving machines which will expand their laser marking portfolio to non-engineering industry sectors. A 3D printing service will also be added to their portfolio at the end of 2014.

Tel: 01737 224731 Email: info@thinklaser.com www.thinklaser.com

Compact Plastic Valve Manifolds Plastic systems normally integrate tee pieces, elbows and pipes to form mixing or diverting manifolds – all hand fabricated. GEMÜ have taken the complete manifold inside a single block of material and then machined the valves into the same piece of plastic! Result: tiny overall mass and dimensions compared to assembled manifolds and less connecting joints = less potential leaks. Bespoke Plastic block designs are machined from ABS, PVC-U, PVC-C, PP, PVDF and PTFE. They can incorporate diaphragm valves, solenoid valves, filter housing connections and even threaded sensor points for pH, temperature, conductivity, pressure and differential pressure devices.

Email: info@gemu.co.uk


adi Automation, a Company within the adi Group, have recently completed an S88 compliant Batch project for Mondelez at their DAIM factory in Sweden. DAIM is an international brand for which demand has increased considerably over the years. The replacement of an ageing control system gave Mondelez an opportunity to re-assess the benefits of delivering a standard model approach. This will be replicated elsewhere across the Group but is already yielding benefits at the Stockholm factory. It will see further benefits as the merging of compliant batch data is combined with product Track and Trace capability through to finished product. Tel: 0121 451 2255 Email: info@adiltd.co.uk www.adiltd.co.uk/group/

Suncombe Launch SteriWasher™ The Robust, Heavy Duty, Validateable Parts Washer The new SteriWasher™, a large washer used for industrial purposes is set to improve upon part washers used in the pharmaceutical, biotech, food, beverage, healthcare and other critical sectors, by means of new technologies to provide a more environmentally friendly, low water and energy usage washing facility in production and research environments for equipment ranging from critical small parts and tools to large mixers, drums and containers. Unlike many part washers on the market that use fold down doors, the SteriWasher™ is accessed via a hinged door, to provide a more robust machine and a washing chamber.

Email: mail@suncombe.com

www.suncombe.com Issue 11 PECM


Measuement & Monitoring New Miniature Air Flow Transmitter for HVAC

Fluke’s new Laser Shaft Alignment tool provides fast, actionable answers

The new transmitter EE671 measures air velocity up to 20 m/s. Thanks to its compact design it is ideal for mass applications in HVAC. The flow sensing element sets new standards in terms of accuracy and resistance to pollutants.

Fluke, the global leader in portable electronic test and measurement technology, has introduced an easy-to-use Laser Shaft Alignment tool that provides fast, accurate and actionable answers to keep plants up and running. The new Fluke 830 performs the complicated alignment calculations automatically and provides the answers needed to quickly align a machine. This eliminates difficult calculations and guesswork associated with traditional alignment methods and reduces unnecessary replacement parts, repair time and unplanned downtime.

The built-in VTQ flow sensing element based on thin-film technology works on the hot-film anemometer principle. Thanks to its innovative design made possible by the use of the latest transfer molding technology - the sensor is particularly resistant to contamination. A high reproducibility of the sensor characteristics, fast response time, low angle dependence and excellent long-term stability are further advantages of the high-quality sensing element.

Email: info@epluse.com


West Control Solutions launches cost-effective new SSR range West Control Solutions has launched a new range of SSRs (solid state relays) that offer cost-effective, reliable connections to your temperature controller. The SSRs are available in a range of styles and specifications to bring enhanced efficiency to a wide range of applications. The West Control Solutions SSRs meet the needs of users who are looking for improved longevity and performance. These users may currently be using an electromechanical relay - which has a limited operational life and therefore a less reliable option, particularly where there is frequent switching. In contrast, West Control Solutions SSRs with no mechanical parts are specified to function without accelerated wear in applications that require frequent switching. To view the full range visit the West Control Solutions website at http://info.west-cs.com/solid-state-relay-download-brochure.

Accurate and Reliable Monitoring of Moisture in Industrial Oils The EE364 in-line transmitter from E+E Elektronik measures moisture and temperature in transformer, lubricating, hydraulic or motor oils, and diesel fuel. This device can assist in planning condition-based maintenance operations to aid in avoiding equipment breakdown, leading to lowered costs. The EE364 can measure water activity (aw) and oil temperature (T), and calculate water content (x in ppm). The readings are available on two 4-20 mA analog outputs and a Modbus RTU interface. The analog outputs can be scaled and configured by the user with the optional converter cable and free configuration software.

The Fluke 830 Laser Shaft Alignment tool has been designed to simplify shaft alignment with an intuitive guided user interface and step-by-step machine set up process. All the user has to do is set-up, measure and diagnose.


New electronic thermostat ET011 & Hygrostat EFL012 for use at “low signal” from STEGO The electronic thermostat ETL 011 is suitable for the recognition of temperatures inside enclosures, while the electronic hygrostat EFL 012 detects the amount of humidity in an enclosure. Both allow an indirect control of heaters, as well as filter fans or cooling devices by means of an integrated change-over contact, particularly developed and designed tor switching signal voltages, and are tailored to he used in combination with the STEGO Switch Module SM0l0. They can also be connected to other devices for signal processing, such as a Programmable logic controller (= PLC).

Tel: 01372 747250


Advantage set under Wimbledon roof Datapaq measures floodlight temperatures When the sun comes out on a rainy Wimbledon match day, the roof over Centre Court can be retracted, but only after the floodlights have cooled down sufficiently. This is a safety requirement as well as an aesthetic one, as the 1,000 W floodlights are mounted directly on the roof beams and the fabric comes close to this heat source when the roof is retracted.

The EE364 is pressure rated to 20 bar (290 psi) and features G ½” ISO or ½” NPT process connection threads. Its compact size and robust stainless steel IP65 enclosure allow for easy integration into demanding OEM applications and harsh environmental conditions.

To check how soon the lights reach the critical temperature of 100 °C and the roof retract temperature, Galliford Try, the company that built the Centre Court for the All England Club, engaged the temperature profiling expert Datapaq. Connected to the sensors via 10 m trailing cables, a Q18-type data logger captured the temperature profiles with a 2 s sampling rate.

Email: info@epluse.com

Email: stephan.wilke@fluke.com


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

Tel.: +49 30 / 629 1214


PECM Issue 11



Temperature profiling in glass production At the glasstec exhibition in Düsseldorf, Germany, Datapaq (hall 14, stand A39) showcases data logging systems that provide detailed information on the thermal behavior of glass products undergoing thermal treatment. Various models from the Furnace Tracker series monitor applications such as glass container annealing, windshield manufacturing, vacuum coating, and autoclave and PVD processes. The manufacturer provides suitable data loggers and thermal barriers even for tempering furnaces with a very low clearance. The latest model for glass tempering connects up to ten thermocouples. The probes relay exact product temperature data throughout the entire heat and quench cycle based on which the furnace can be configured for optimal resource efficiency. Together with thermal imaging solutions from Raytek, this system will be the main focus of their common trade show booth.

Email: stephan.wilke@fluke.com


Fast response flow switch F or those occasions where a critical flow needs to be signalled rapidly to avoid serious consequences to downstream equipment, sensor market leader ifm electronic has released new versions of the SBY range.

Following the binary output devices capable of detecting a presence or loss of a flow within less than 0.01 seconds, ifm has now launched the SBY433 and SBY434 which provide the same fast response, but with a 4 to 20 mA analogue signal. The setting range of the SBY433 covers 1 to 25 litres/ minute, while the SBY434 can be set between 2 and 50 litres/minute, in each case with minimal pressure loss. As featured in the binary SBY, the analogue SBY is simple to adjust via the calibrated setting ring. Both have Rp ž process connection and operate on a nominal 24V DC. Permissible medium temperatures range from +10 to +85°C, and while the data are stated for water, the materials in contact with the medium such as stainless steel, nickel-plated brass and industrial plastics mean that flows other media can be signalled. The typical application is cooling water, so for applications such as cooling circuits in induction furnaces, the SBY flow switch range from ifm electronic is indispensible.

Update for the bestseller: new features for PN pressure sensor A

fter 20 years of successful ifm pressure sensor history, the new generation of PN sensors has been developed in close cooperation with users. High overload protection, IP67 for all types of the series and the captive laser labelling make the new PN sensors the perfect solution even in the harshest environments. Everything at a glance: High transparency during setup and identification of machine conditions: Although the housing size has remained unchanged, the display size has been increased once again and the two switching status LEDs on the sensor head are bigger, brighter and can be clearly seen from all angles. The display can be switched from red to an alternating indication of red or green. So switching states can be highlighted or an independent colour window can be created. Flexibility in use is important: After fitting, the sensor can be rotated for visibility from the desired direction. The new PN range also includes versions with a 1/4� external thread. ifm is committed to working closely with its customers to develop products which precisely match their needs, and the company provides expert, readily accessible technical support to help users maximise the benefits they gain from ifm products.

For further information, contact Gemma Anderson, ifm electronic Ltd. Telephone: 020 8213-0000 t Email: gemma.anderson@ifm.com Issue 11 PECM


Measuement & Monitoring JOFRA® ASC-400 Advanced Signal Calibrator Offers Best-Inclass Accuracy and Functionality The newly introduced JOFRA® ASC-400 portable multi-signal calibrator from AMETEK Test & Calibration Instruments is in a class by itself. The highly functional calibrator provides laboratory accuracy in an easy-to-use device that is compact enough to fit into a tool box or operate with one hand for easy field calibration, process monitoring or maintenance functions. The ASC-400 features an extremely user-friendly interface and high contrast color display. Its unique “menufree”, single-window interface greatly simplifies operation, allowing all functions to be controlled or set from the main menu screen. The ASC-400’s accuracy is designed to meet the calibration demands of modern sensors and transmitters. For more information on the full line of JOFRA® calibration products go to www.jofra.com

Mydax 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.


Small, versatile magnetic encoder JD Cables was set up in 1994 to supply the UK market with special cables that are normally difficult to obtain. We specialise in Polyurethane screened sensor cables for transducer, strain gauge and load cell applications and also high temperature silicones, PTFE wires, control cables and more. Many cables are supplied with approvals including UL, CSA, Harmonisation, VDE and British Standards and all are RoHS compliant. We hold specific and specialised cables for call-off and have no cutting or minimum order charge. We are “always ready to do new business”, so if you want a friendly and efficient service call us on 01923222600 or email sales@jdcables.com www.jdcables.com

Modbus RTU interface for TILTIX inclinometers POSITAL has added support for the Modbus RTU communications protocol to its popular TILTIX family of inclinometers (tilt sensors). The Modbus RTU protocol, which is openly published and royalty-free, has emerged as a de-facto standard for simple, robust and cost-efficient data acquisition and control systems built around standard PLCs and the familiar RS-485 serial connections. Modbus RTU nodes can be connected together through RS-485 serial connections with up to 32 devices connected to the bus.

FSG introduces the new MH605-II-MU series of single-turn encoders. Thanks to a seawater-proof IP68 aluminum housing and a wide temperature range of -40 to +105 °C, the devices are suitable for very demanding environments. The encoders do not require a bearing point – the angle detection system features an external magnet. With a diameter of merely 13 mm and a weight of approx. 10 g, they can be easily integrated into machines and plants with limited installation space. The units are available as different versions with a 12 Bit resolution and measuring ranges up to 360°. They can be used for instance in railway vehicles, replacing trimmer potentiometers and ensuring high-resolution operation of measuring devices. Further uses include energy and water management applications such as offshore wind turbines. Two ratiometric 0.5…4.5 V DC outputs deliver redundant signals. Thanks to their contact-free magnetic measuring principle, the encoders are virtually wear-free.

Tel.: +49 30 / 629 1214


Flexible electronic differential pressure from VEGA

The new Modbus RTU models, like other TILTIX inclinometers based on micro-electro-mechanical systems (MEMS) technology, are available in single axis (0 - 360°) or dual axis (±80°) versions. Measurement accuracy is to within ±0.1°. Durable PBT plastic housings meet the needs of most applications, with extra heavy-duty cast aluminum housings available for super-harsh working environments.

VEGABAR 80 includes electronic Differential Pressure as a standard option in all sensors in the range. No special field electronics enclosures or transducers, it only requires a standard device with a ‘slave’ electronics module in the other. Simply connect them together for your e-DP system. This means any two VEGABAR 80’s can be used, minimising cost, complexity and stocks. Mix housings: a level in a pressurised tank with a ‘submersible IP68’ sensor in a flooding bund with a standard housing on the top. Mix materials: a flush ceramic diaphragm on a filter with abrasive liquid and a recessed metal one after it. Select the sensor design: suspended, submersible ‘hydrostatic’ transmitters across screen differential in intake channels. The standard interconnecting distance is 25m, but can extend to over 100m. Connection sizes from ½” BSP/NPT (flush) upwards. The accreditation portfolio includes ATEX, SIL, FDA, EHEDGE, 3A and Marine. Communications: 4-20mA, HART, Profibus and Foundation Fieldbus.

Email: pritzkau@posital.de

Email: info.uk@vega.com



New USB Barcode Scanning Thermometer offers alternative temperature data downloads

Monitoring gas mixtures in Weld Overlay Cladding production

Want all the benefits of a paperless temperature monitoring system, but unable to wirelessly download data? UK thermometer manufacturer, TM Electronics (TME), is proud to announce a new take on their best-selling MM7000 Bluetooth Barcode Thermometer: the MM7005 USB Barcode Thermometer.

Established in 1994, Arc Energy Resources has become a worldwide contractor of weld overlay cladding products providing heavy duty protection against corrosion and wear for process and pipeline equipment used in hostile environments.

Why USB? Whilst Bluetooth downloading is a perfect solution for a lot of users, as Bluetooth is quick, easy to use, and most modern devices are Bluetooth-enabled, some users prefer a wired connection. This is where USB comes in. With USB, there’s no need to worry about connectivity or discoverability. Simply plug a USB cable into the MM7005 and download your data to computer, PDA, tablet or smartphone.

Tel: 01903 700651 Email: sales@tmelectronics.co.uk www.tmelectronics.co.uk


PECM Issue 11

Within their weld overlay process, Arc Energy utilise the 542 binary gas analyser from Systech Illinois to monitor the mixture of gases. Andrew Robinson, Director at Arc Energy says, “The weld overlay cladding process is sensitive to the mix of shielding gas being used and it is increasingly becoming a customer requirement for us to prove the quality of the gas. The Systech analyser allows us to verify that the gas is correct.”


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

Bognor Regis 01243 871280 Sheffield 01909 569446

Leaders in temperature measurement


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

Certificate No. 4746

All in stock for immediate despatch 70

PECM Issue 11

Custom made specials to order.

Measuement & Monitoring The worldwide number 1 supplier of power transmission products Torque Limiters 0,1 to 500,000Nm Safety Brakes 2 to 5000Nm Shaft Couplings to 110,000Nm ROBA®-DS ROBA-stop®-silenzio®


“Design in Mayr” 01535 663900 sales@mayr.co.uk ® www.mayr.co.uk Torque Limiters

Safety Brakes

Shaft Couplings

Portable Loggers


The Complete Energy Monitoring Solution from Elcomponent




£495 www.elcomponent.co.uk




PPP Software Features

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email. sales@elcomponent.co.uk www.spcloggers.com tel. 01279 503173

Issue 11 PECM



Process Technologies Bulte presents its new Plastimont bodies CO 251 & CO 252 :

Ecotile interlocking PVC floor tiles are the first choice for commercial garages Market-leading manufacturer of interlocking floor tiles, Ecotile, designs and produces its comprehensive range at its UK production facility - providing durable and safe flooring solutions that can be installed with minimal disruption. James Gedye, Managing Director of Ecotile comments; “Our interlocking floor tiles are frequently chosen for flooring projects within commercial garages as they offer some important benefits to this hard working sector. We have recently worked with National Tyres to install a new, interlocking floor system as part of an expansion programme including both new premises as well as the refurbishment of existing sites.”

Tel: 01582 788 232

Email: enquiries@ecotileflooring.com

Kingston Engineering Co. (Hull) Ltd. buys a Leistritz ‘State of the art’ Whirling Machine for the production of Power Transmission screws. Seeking continuous improvement, efficiency and optimisation of its production processes, Kingston Engineering (www.kingstonengineering.co.uk) decided to invest in the purchase of a top class machine tool from Leistritz, a brand well known worldwide. Leistritz from Nuremburg Germany (www. leistritz.com) is the international leader in the high speed production of internal and external threads and also in the production of special profiles. The purchase of this machine has been necessary to cope with rising demand requiring shorter delivery without compromising product quality.

Tel: 01482 325676 Email: sales@kingston-engineering.co.uk www.kingston-engineering.co.uk

Just by inserting a nut or a screw, you transform a Plastimont into a handwheel/knob. All materials should match with this product: steel, stainless steel, brass, nylon. The body is stain resistant, light and insulating: a good alternative to overmolded products. The standard material is Polyamide (Nylon) which is resistant to various chemical products, has excellent mechanical properties including wear resistance, low friction coefficient, high melting point good impact resistance and is also very light. The working temperature range is -30 to +100°C. Plastimont bodies are available in M4 or M5 28mm diameter for CO 251 and M5 or M6 31mm diameter for CO 252. Samples and prices are available on request. For more information, please contact: www.bulte.com

You’ve got the best laser, but have you got ROUND to getting the EDGE on DEBURRING? Engineering Utilities based in Leeds, have specialised in delivering metal finishing know how to the stainless fabrication world for over three decades and are delighted with the successful partnership with Portuguese Manufacturer, NS Maquinas, who have developed 2 new models of cross belts edge rounding machines, which are based on the concept of the original DM1100C machine Sheared edges must be safe, paints or coatings must adhere well, or the component may simply need a good surface finish. Even if your requirement is for all of these, there is a machine to achieve these both efficiently and cost-effectively. Using these machines can replace manual labour by a ratio of up to 8:1 and the results are perfectly consistent. The DM1100C (1100mm width capacity) is equipped with two counter-rotating cross-belts which run at 90° to the conveyor. This creates a powerful edgerounding action on all the edges of parts, whether internal or external, and regardless of their shape or material.

Tel: 0113 255 8887


Since 1986 Mydax has offered process temperature control solutions for OEM and one of a kind custom chiller applications. With the ability to provide extreme temperature stabilities of ±0.05°C for critical applications, even with high cooling power requirements up to 70kW, Mydax is bringing laboratory precision to the industrial market. Mydax also offers the CryoDax series of chiller systems for the most demanding requirements with fluid temperature ranges of -70°C to +150°C with cooling capacities from 2kW up to 15kW @ -50°C available. Please call or visit Mydax online for more information.

Tel: 0208 339 7370

462 Ewell Road, Surbiton, Surrey KT6 7EL, England

Fax: 0208 339 7371

Email: sales@blackfast.com Web: www.blackfast.com

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

Issue 11 PECM


Minimise The Risks, Think Cold Bonding Cold bonding: a safer alternative to hot work

www.belzona.com Plate bonding repair on equipment


ot work required for welding, grinding and cutting operations presents certain potential hazards when conducted in potentially explosive and flammable environments. According to the Health and Safety Executive guidance 2013, â&#x20AC;&#x153;flammable liquids and vapours such as petrol, diesel, fuel oil, paints, solvents, glue, lacquer and cleaning agents are found in many places of work. If a welding torch or powered cutter is used on a tank or drum containing flammable material (solid, liquid or vapour), the tank or drum can explode violentlyâ&#x20AC;?. In order to minimise the risk, cold bonding solutions involving materials that are applied and cured at ambient temperatures can offer an alternative solution for repair and newbuild applications on metallic surfaces. Welding in hazardous environments Welding is proven to be the most recognised repair and fabrication

method for metallic equipment and structures that joins pieces of metal by melting and fusing them together. However, in scenarios of flammable and explosive environments, the welding process is restricted, since sparks and hot metal can fly off in all directions and may drop down, creating hazardous situations. For example, if welding is to be carried out on containers or tanks, any flammable or combustible material within a 15 metre radius should be identified and controlled prior to the process. As described in the Defence Works Functional Standard Specification 031 for Internal Cleaning of Fuel Tanks, any hazardous material should be drained, cleaned, purged and tested for flammable vapors before the welding process starts. The transfer piping should also be drained, purged and blanked. Moreover, only trained welders should be involved in the process. Assessment of the risks required before carrying out any hot work makes welding a highly time

consuming process and therefore safer and time saving alternative options are becoming popular among the industry professionals. Cold applied solution Maintenance and construction welding requirements that would historically involve hot work can be completed with the use of polymeric cold bonding composites that are applied and cure at ambient temperatures. Belzona bonding was first used in the late 1950s to attach equipment ID tags and since then it has been widely used for repair and newbuild applications in a broad range of industries. As laboratory testing and field experience have shown, polymeric cold bonding composites can be applied for the repair of metallic equipment such as hoppers, tanks, flanges, support pads and pipework, as well as for newbuild applications such as creation of load bearing shims, retention of bearing rings, modification of vessel internals and equipment assembly. Over the years, Belzona materials were

Cold bonding technology used for repair and newbuild applications


PECM Issue 11

enhanced to resist higher pressures and temperatures as well as demonstrate high adhesion and compressive strength properties equivalent or greater than welding. Put it to the test In order to demonstrate the bonding strength, a tensile shear adhesion test has been conducted on two plates bonded on a deck, a 1.0m2 plate bonded using a Belzona adhesive material and an equivalent of 7mm weld along the edges of the plate. Determined in accordance with ASTM D1002, the results demonstrate that the bonded plate will be able to sustain up to 7000kN in pure shear when the weld will only be able to support up to 2000kN. This demonstrates that the bonded solution gives 3.5 times the shear resistance compared to the same plate welded round the edges with a 7mm weld bead.

A quasi-static bending test was conducted to test the mechanical characteristics of the material. The two cold bonded plates did not immediately separate when bending forces were applied. Instead the composite spread out, the bending forces across the entire surface area, both plates and the bond uniformly distorted retaining the bond, demonstrating the retention of in-tact bond lines between both steel/adhesive interfaces.

Refurbishment of 3 LNG Tanks in Algeria Based on the above testing results, an Algerian Oil and Gas asset owner turned to Belzona cold bonding technology in order to refurbish three substantial Liquefied Natural Gas (LNG) tanks in 1990. The LNG tanks commissioned in 1977 were severely corroded after 13 years of continuous service in a coastal environment in Algeria. Roofs and shells were extensively pitted due to on-going exposure to salt water and salty air moisture, resulting in severe gas leaks mainly on the roofs. The client was looking for a reliable and long term solution to repair the LNG tanks taking into account all the safety considerations and without disturbing any parts of the inner tanks and their supports. Several solutions were considered for the repair including welding of new plates to the existing live tanks, welding new plates after purging the inner tanks and the insulation spaces, or fixing new patch plates over the roofs on site using cold repairs with epoxy adhesives. For safety reasons, the use of Belzona cold bonding system was chosen to avoid the welding requirements on site, as this was a major concern considering the thousands of cubic metres of highly flammable LNG in the tanks. The main part of the project was to seal leaks in the outer skin of the tank and to bond doubler plates over the most corroded areas of steelwork. During the blasting process carried out using non-sparking grit to Swedish Standard SA 2, more live gas leaks were found on the surface of the tank and were directly sealed with Belzona 1291 (ES Metal), a rapid curing epoxy paste grade material. Belzona 1121 (Super XL-Metal) with its extended working life, was used for bonding the reinforcing plates. Belzona 1111 (Super Metal) and Belzona 1321 (Ceramic S-Metal) were used in conjunction with Belzona Reinforcement Tape to repair and strengthen the nozzles through the tank roof.

The blue line in the graph represents the control steel plate (8 mm (5/16”) Thick steel) and the red line shows that the bonded composite plate demonstrates that plate bonding achieves greater load bearing strength (force axis) and greater energy retention (area under the curve) for the same ultimate deflection (deflection axis) proving the bond is not a weak link and actually enables the two bonded plates to deliver consistently and reliably twice the strength of the single control plate. The two bonded plates act as if they were indeed one plate twice as thick as the single plate. Cleavage adhesion testing was carried out on Belzona 1111 (Super Metal), a paste grade epoxy material usually used for cold bonding applications, in accordance with ASTM D1062 at 20°C, 40°C and 60°C in order to determine the effect of high ambient temperatures on bond strength. When fully cured, the cleavage adhesion of Belzona 1111 was found to be maintained across the 20–60°C test range, i.e. the bond strength was unaffected up to 60°C, and adhesion values were actually found to be slightly higher at higher test temperatures by virtue of the higher cure temperature. Cleavage adhesion values obtained were 1330 pli, 1465 pli and 1450 pli, for 20°C, 40 °C and 60°C testing, respectively.

As the project proceeded, the ability to use Belzona materials as a structural adhesive was further investigated. Various tests both independent and at Belzona’s facilities were carried out on full size test rigs to confirm the suitability of Belzona to bond firstly the hand rail supports around the tank perimeter and finally the main vent pipe trunnion supporting several tons of pipework. The project was carried out to very stringent standards with salt contamination, blasting profiles, climatic conditions and ultrasonic thickness measurements being constantly monitored. New furniture and platforms were installed on the roofs of the three LNG tanks where the different instruments were fixed to their original positions. The Belzona solution was applied live to keep the site running with minimal disruption without hot work or use of mechanical equipment. No other alternative was deemed to provide a viable solution to the client’s requirements due to time scale and the risk of sparks. Since the application, it has been regularly inspected and has now been in service for more than ten years demonstrating the high efficiency of the cold bonding solution.

View of the three tanks in 1990

Storage tank roof repaired using Belzona

Application on site.

Issue 11 PECM


Process Technologies

All your coupling requirements from a single source

Manufacturers and Distributors of standard and specialised fasteners and fixings in metric and imperial dimensions: M1.6 – M64 and up to 800 mm long. Offering a wide range of products: Hex Bolts, Sets, Socket Screws, Pressure Plugs, Allthreads, Nuts & Washers to Din, BS, ANSI and ISO specifications. Our manufacturing facility enables us to supply bespoke products in a range of materials - Alloy, Stainless & Exotics - competitively priced with fast, reliable delivery dates. Our internal capacity includes hot forging presses, CNC lathes, grinding, threadrolling and milling machines. In-house Heat Treatment ensures we are able to maintain full control over manufactured components. A same-day delivery service from both our West Bromwich and Leeds depots is available, as well as national and international next-day service. Please check our website for more information including live access to our current stock levels.

West Bromwich Tel:- 0121 505 7551, Leeds Tel:- 0113 270 9897 Email:- sales @socketscrews.co.uk. Website:- www.socketscrews.co.uk

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 11

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



ince being established in the mid 1970s, Applied Rubber Linings (ARL) the Gloucester based rubber lining business has grown from a two-people concern to a UK market leader, renowned and respected across British industry for providing a quality product and reliable service in protective linings and coatings for process plant.

The directors and production team at Applied Rubber Linings.

The expansion shows no sign of stopping with ARL now looking to boost its customer base throughout the UK, and especially within the quarrying and aggregates markets which are being targeted as a growth market for ARL. The range of industries served by ARL is broad and includes mining, quarrying and aggregates, water and effluent treatment, waste treatment and recycling, engineering and manufacturing, power generation, oil and gas, metal treatment and processing, chemicals and dyes, marine and shipping, food, beverages and pharmaceuticals. Right across UK industry ARL helps to protect against corrosion and abrasion by supplying rubber linings and coatings for process plant, plus shot blasting and painting services. ARL also provides an on-site inspection and report service for existing linings plus on site repairs and relines as required.

Rubber lining a large valve body.

Rubber linings can be applied to process tanks and vessels, pipe work, chutes, hoppers, valves and pumps, agitators, mixers, filters, and flow meters; and will also help to reduce process noise and provide product protection. “We work closely with our customers to provide cost-effective and honest solutions to the problems of corrosion, wear and abrasion, noise and product protection, that will occur when process plant is operating in aggressive and hostile environments,” says Managing Director Keith Travell. “We focus on building long-term relationships that are based on reliability, quality, flexibility, integrity and trust.”

Unloading of rubber lined items from the steam autoclave at ARL.

Along with Production Director Robert Travell, Keith heads a staff of about a dozen, most of whom are long-term employees. Combined, the wealth of experience is vast. Between Keith and Robert alone there is nearly 80 years’ joint experience of supplying protective linings and coatings to industry. Now the drive for new clients is being boosted with the redevelopment of the company website,.“It will carry a stronger message to prospective customers,” promises Keith. “We are also renewing the lease on our factory in Gloucester, confirming our presence in the plant lining industry for many years to come.” For further information, visit www.appliedrubber.co.uk. Alternatively telephone 01452 381849 or email keith@applied-rubber.co.uk

We work closely with our customers to provide cost-effective and honest solutions Inspecting a large rubber lined pipe. Issue 11 PECM


Process Technologies Ecotile Quality - Without Compromise Ecotile extends range with 5mm interlocking floor tile – making Ecotile flooring solutions accessible to an even wider range of users and budgets.

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

Market-leading UK manufacturer of interlocking floor tiles, Ecotile, has extended its range of heavy duty industrial, commercial and domestic flooring solutions with a new 5mm tile. The E500/5 – a 5mm dove tail joint tile – is a hard wearing solution for foot and light trolley traffic. Ideally suited to industrial applications such as assembly areas and mezzanines, the Ecotile 5mm tile is also used in retail and commercial premises, the education sector and is increasingly popular within the domestic market for garages, workshops and utility rooms.

Tel: 01582 788 232

Email: enquiries@ecotileflooring.com


Thermal Process Monitoring Solutions by Orton Using Ceramic technology, Orton offers a wide selection of products to confirm the consistency and reproducibility of thermal processes from 600 to 1800C.

Call C all 01482 325676

Whether you need to monitor an existing process, duplicate it in a new location or outsource your thermal processing to another company, let us assist you in selecting the right product for your application to stay in control.

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

Contact us today via email at support@ortonceramic.com or by phone: +1-614-818-1338 to see how we can assist.


Orton works closely with engineers where thermal process verification and documentation is needed to confirm process consistency.


www.tamperevidence.com Tamper Evidence Ltd is an independent UK company specialising in the supply of products designed to show evidence of tampering, opening or un-authorised access. Such products include, tamper evident security seals, security labels, tamper evident packaging tape, security bags and envelopes, tamper resistant asset labels and hologram labels. Providing simple security solutions for transport and logistics, facilities management, aerospace, pharmaceutical and banking etc. Stock product with next day delivery is carefully chosen with quality and availability in mind, whilst full customisation and on site consultation can be offered if necessary. Their aim is to help guide customers towards finding ‘the right tool to do the job’ whilst striving for excellence in customer service with competitive pricing. Contact Now : 08432 897 837 or email info@tamperevidence.com quoting ‘PECM’ for 10% off your first order !

MASTERCUT – A Leading Edge in Blades Manufacturing and supplying Machine Knives and Blades for a wide range of industry sectors Mastercut Cutting Systems Ltd (http://www.mastercut.co.uk/index.html) has been building up a strong presence in the blades sector since 1996. Both OEM and end-user specified models of industrial knives and blades have been provided for customers from plastics and metals converting and recycling industries, from cutting textiles and the aggregates sectors throughout the UK and globally. Popular style knives are shipped from the company’s stock, while custom designs are manufactured to order in a minimum time on the company’s CNC machinery. Specialists at the company are familiar with most makes of machines for extrusion, thermoforming, converting, shredding, reclamation and supply all sorts of blades, plus wear parts and screens, plus a resharpening services on blades. Providing machine knives of high quality at very competitive prices and offering a personal approach to all customers cutting requirements, Mastercut Cutting Systems Ltd is steadily growing its business through a satisfied customer’s base.


PECM Issue 11

Product News Babcock Wanson Thermal Fluid Heaters Now Available To Rent Industrial process heating specialist Babcock Wanson UK is pleased to announce a unique new Thermal Fluid Heating System rental service. This new rental service, which can provide up to 900kW of energy to a process, will enable customers to trial a thermal fluid heater for a fixed time at a fixed rental price. Based on its market leading TPC400B Thermal Fluid Heaters, Babcock Wanson has developed a packaged ‘plug and play’ version that can be delivered to site and set up by Babcock Wanson’s highly experienced engineers. For more information, please contact Babcock Wanson on 020 8953 7111 or info@babcock-wanson.co.uk or go to www.babcock-wanson.co.uk

Techsit Ltd are launching the exciting Werksitz Range of High Quality Technical Work Seating in the UK. This unique collection of specialist seating is for use in manufacturing, laboratories, ESD areas, cleanrooms and wet rooms. Ergonomically designed for use in the hitech environments of aerospace, pharmacutical, medical, electronic and all production and research areas. To see all visit our website or contact us now. Tel: 01525 211567 Email: sales@techsit.com www.techsit.com

New avalanche photodiodes offer high sensitivities for red and green light First Sensor presents the Series 8r silicon avalanche photodiodes (APDs) with high sensitivities in the red and green wavelength range. The APDs feature a flat gain curve where the internal amplification rises slowly with the applied reverse bias voltage. Therefore, the Series 8r allows for easy and accurate adjustments of high gain factors. The new photodiodes are ideal for applications which demand fast rise times and low capacitance. The Series 8r provides APD chips with active areas of different sizes. The devices are available in leadless ceramic-carrier SMD packages or hermetically sealed TO housings. The very flat SMD packages can be equipped with different band-pass filters on request. Further, First Sensor offers custom avalanche photodiodes which can be adapted to specific customer requirements.

Tel: 01788 560426 Email: FSM@first-sensor.com www.first-sensor.com

Video pyrometers For hard-to-reach and hot processes 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.



Socks that Work as Hard as You! Workforce offer a diverse sock range designed to provide the perfect solution to the problems of uncomfortable feet experienced by many when they are working outside or in challenging circumstances. The range of socks includes designs with advanced technology such as arch support, terry cushion panels, anatomically constructed left and right feet, Silverplus™ technology and heavy gauge rib, all engineered to provide the wearer with the comfort and security they need to work better and more safely for a wide range of different tasks. The Workforce range is supported by celebrity builder and DIY expert, television’s Tommy Walsh. Tommy knows how important it is to have the best clothing and footwear for when he is working and his socks are no different. “Workforce are the hardest wearing socks I’ve ever worn and also the most comfortable. They provide me with the comfort and protection I need when I’m working hard or when I’m out and about. They’re warm, but never get too hot; they’re padded, extra strong and fit comfortably with my working boots and shoes. I don’t know how they’ve done it, but Workforce have a range of socks ideal for workwear purposes” – Tommy Walsh For safe, comfortable socks that work as hard as you do, Workforce socks are the perfect choice for engineering professionals, for a wide array of different DIY projects or simply for ensuring maximum comfort and support when worn for a number of different activities. With 17 different designs currently included in the range, practicality is always a priority and Workforce guarantees to provide a hard working sock that doesn’t compromise on style or comfort.


Issue 11 PECM


Product News Sonatest launch a new flaw detector series offering choice, customisation and performance, Take a Closer Look.

Fitzpatrick CCS Series (Contained Chilsonator System) High Containment Roll Compaction

The end user now has the freedom and flexibility to customise their instrument to fulfil their preferences and meet their application demands exactly as they need. With all units being field upgradeable, the adaptability of the unit’s capability over time is increased.

The Contained Chilsonator System (CCS) Roll Compaction Series from Fitzpatrick incorporates the latest developments in roll compaction, and showcases the Company’s newest technology. Available models range in size from lab to full-scale production Units. The CCS Series is designed to fully contain all product in its processing and receiving sections. The sealed design allows for the optional Product Containment System (PCS) to be added at the discharge. This enables the process area to be operated in an inert environment or kept under partial vacuum to maximize product containment levels, thereby enhancing the level of safety for both the operator and production facility.

Find out more about Sonatest Ltd and our products by visiting www.sonatest.com.

Tel: 01494 792898

Sonatest Ltd are pleased to announce the release of the latest range of the Sitescan and Masterscan series of flaw detectors. Retaining the best features of the established series, the new range has evolved in response to the requirements of users and their applications, combining simplicity of use with improved capability and field proven reliability.

Blue Diamond’s rapid prototyping service provides a fast solution to design and engineering problems Blue Diamond Technologies specialises in solving design, engineering and manufacturing problems for its customers. Its scope of supply includes machined components, metal parts, turned and cast parts, plastic components and sub assemblies, for applications as diverse as submersible pumps, domestic showers, vending machines and temporary buildings. Blue Diamond can produce a solid metal/plastic “Real Life” model within a 12 – 14 day turnaround. Because Blue Diamond’s qualified engineers verify all the information from the original drawing they can identify and resolve problems before they occur. Rapid prototyping results in a physical component that can be used to check fit, function, ergonomics and aesthetics. This allows the customer to check feasibility and make detailed adjustments before finalising the design.

Tel: (023) 8025 8966


PECM Issue 11



Specialist springs from William Hughes help improve car comfort and safety When you are adjusting the height and reach of the seat in your car, you probably don’t give a thought to the mechanism that allows this to happen. Springs form an important part of these mechanisms and they are used to ensure smooth and reliable operation. Each application is different and requires a spring that has been individually designed to meet the requirements for force, physical size and operational life. William Hughes are specialists in the design and manufacture of a wide range of springs and bent wire components for automotive applications. Its team of experienced application engineers uses the latest computer aided design software and specialised spring data to develop springs that are optimised for each application.

Email: sales@wmhughes.co.uk



Energy Ram and Diaphragm Pumps are designed and manufactured in-house, ensuring the vital quality, toughness and reliability of these essential products. Energy Pumps range of Ram Pumps begins with the smallest 240mm mechanical Ram, through to the 460mm hydraulic Ram Pump. With many different sizes available it ensures that there is an Energy Pump for most STW applications, including Quarries and Mines where Energy Ram Pumps are suited to tough grit and silt handling. The Hydraulic Ram Pumps are controlled by our own software, also developed “in-house”, so that we are able to tailor the Pump to your exact needs, ensuring maximum performance for the job in hand. Energy hydraulic Ram Pumps are also available in a duplex configuration which allows for higher flow rates, with pressures reaching up to 20 Bar.


The Energy Maxi, Major and Mastiff Diaphragm Pumps are the invaluable mainstay of many Sewage Treatment Works. They are competent in both primary and humus desludging and sludge transfer duties. Energy Pumps also have many applications in any industries which need to pump difficult sludge reliably and economically. The patented positive flow base of our Diaphragm Pumps, with patented anti-ragging, non-return Valves is designed to ensure that air quickly passes through the base, which then leads to an easier flow of contaminated materials. This, in turn offers low maintenance and ease of repair, when necessary. Energy Pumps are the obvious choice for many maintenance engineers. The range of Energy Diaphragm Pumps varies according to the application. The Energy Hydraulic Mastiff Diaphragm Pump is ideally suited for those jobs which require pumping difficult sludge to higher pressures while retaining longevity and reliability, plus ease of maintenance as with Energy Mechanical Pumps. The reliable and versatile Energy Mastiff Diaphragm Pump is based on our highly successful Major. Our Mechanical and Hydraulic Mastiffs allow for greater flow rates and delivery Head. They are capable of processing materials much quicker than the Energy Major Pump, for those tough-handling jobs which require the more robust Pumps. Being the smallest of the Energy Pumps the Energy Maxi Diaphragm Pump was initially the first to be designed for small STW’s. This Pump has also proven itself to be popular with Abattoirs and Potteries. All Energy Diaphragm Pumps are reliable Flood-Water Pumps and are popular with Farmers for effluent, animal-feed and Agricultural purposes.


Pumps NOV MONO Launches New Solar-Powered Pumping Solution

The Energy Savings Opportunity Scheme (ESOS) and Pump System Audits

A new product launched by NOV Mono offers an effective solution for pumping water on small-scale farms and rural lifestyle properties. The new SUN-BUDDY™ is a solar powered submersible pumping system that has been designed to combine outstanding performance, long life and minimal maintenance requirements.

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.

The result of Mono’s™ 30 years of solar-powered pump experience, the SUNBUDDY™ is a genuine, easy to install ‘plug and play’ solution. Its minimal maintenance requirements can be handled onsite, making the SUN-BUDDY™ a set-and-forget solution which delivers high-quality and cost-effective performance. Driven by solar energy, this small but efficient pump requires no diesel, grid power, wind or batteries to run. This environmentally-friendly method enables the operator to quickly recover the initial cost by eliminating all future fuel and electricity bills.

Tel: 0161 339 9000


NOV MONO Helps Increase Capacity for Pulp and Paper Producer The vertically-mounted high pressure E-Range pumps offer outstanding reliability and efficiency for applications where particularly abrasive or viscous fluids are being handled. They incorporate a helical rotor turning within a resilient rubber stator, providing a smooth low shear action which ensures the integrity of the coating mix remains intact. The pumps also feature Mono’s unique Flexishaft™ drive system that provides a single component link between the rotary motion of the drive shaft and the eccentric motion of the helical rotor. The reduced number of moving parts in the drive train eliminates wear and makes lubrication unnecessary, eliminating the risk of contamination. The Flexishaft design extends routine maintenance intervals and carries a 10-year warranty.

Tel: 0161 339 9000


Oil-in-Water Analysis by IR Absorbtion, Training Offshore oil and gas operators are required under DECC guidelines to take regular oil-in-water samples in order to meet current UKCS produced water discharge/re-injection limits. Oil Plus Ltd, in partnership with, Oleochem Project Management Ltd, now offers a 1-day course for offshore production chemists and laboratory personnel to gain certification in the OSPAR methods of sampling and analysis required to meet these strict regulations. The day consists of a theory session, followed by laboratory practical work using standards to generate the oil-in-water content calibration curve followed by test samples, using solvent extraction and Infra-Red analysis. Courses are being held in our Aberdeen and Newbury facilities: for more information please contact Christina Kingston, c.kingston@oilplus.co.uk, telephone: +44 (0)1635 30226, or visit our website http://www.johncrane.com/en/Services/ Training.aspx


PECM Issue 11

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. The scheme’s regulations are published on the government’s legislation website http://www.legislation.gov.uk/uksi/2014/1643/contents/made More information about the Energy Savings Opportunity Scheme can be found on the ESOS webpage https://www.gov.uk/energy-savings-opportunity-scheme-esos

NOV Mono provides a new pumping solution for dosing/metering applications A new range of dosing pumps launched by NOV Mono offers an efficient, reliable and low maintenance solution for applications where low flow, accurate dosing is required. The new MonoTM dosing pump provides a smooth pumping action with no pulsation and very low shear. The pump is ideal for either intermittent or continuous dosing duties in high pressure, low flow applications, and represents a cost-effective and reliable alternative to the more expensive gear pumps traditionally used for these types of duties. The new dosing pump offers many advantages, not least of which is the option to transfer low flows at high pressure (up to 72 bar/1044 psi). For more details on MonoTM visit www.mono-pumps.com or call +44 (0)161 339 9000.

Just like being on site! With a remote management solution connected to your PLC or machine you can do programming or debugging from any location.


he Netbiter Remote management solution from HMS Industrial Networks allows you to open up a secure connection to remote machinery and configure or operate it from any location. You use your standard software applications such as TIA Portal for Siemens applications or RSLogix for Rockwell applications. This functionality called “Remote Access” provides a secure data tunnel to the remotely located equipment. The new feature is used in conjunction with the new Netbiter EasyConnect EC350 connectivity gateway. How it works On your office computer, you run the Netbiter QuickConnect software and a secure tunnel is created to the Netbiter EC350 which is connected to the remote PLC or machine. You can then

You set up the connection in a matter of minutes after you have connected your Netbiter gateway.

simply open your regular configuration software (such as RSLogix or TIA Portal) and configure or debug just as if you were on site. The connection is set up via the Netbiter Argos data center in the cloud. You set up the connection in a matter of minutes after you have connected your Netbiter gateway. Solid security Security together with usability are the two main traits of Netbiter Remote Access. Data is encrypted both to and from Netbiter Argos and you can also choose a two-step verification method (you log in with a password and also get an SMS to verify your identity). This ensures secure data connection to your remote equipment. What you will gain As a device manufacturer or system

integrator, you can have immediate access to your machinery at any time and do remote maintenance from anywhere in the world. This saves travel costs and increases service levels to your customers. Scale up and use for other requirements The Netbiter solution is scalable, which means that you can easily expand your solution to also monitor the performance of your machine park. Get statistics and reports on energy or material consumption and get alarms whenever certain thresholds are reached (for example if the machine stops). By staying on top of your equipment, you will be able to make substantial savings in time and money. Benefits you can bank on from day one. Read more on www.netbiter.net

“The only software that we could find in the market that uses unique open SMS technology to manage all database updates and subsequent actions automatically.” Stephen Edwards, EMEA Project Manager at Agilent

AUTOMATING DATABASE WORKFLOWS FOR COMMUNICATION Just how do you manage a geographically disperse field force that works under huge time constraints and needs to send and receive time critical data immediately to databases? This was the challenge facing Agilent Technologies - a spin off from HP valued at $2bn and operating in 110 countries. Stephen Edwards, EMEA Project Manager at Agilent explains, “Managing the daily communications between the back office and the field engineers was a substantial task for some of our larger territories. It eventually became critical to automate this communication across Europe for reasons of practicality.” Agilent recognised that Boomerang was the solution they were looking for with its unique patented SMS messaging solution that correlates text messages irrespective of quantity or order of response. This means that database workflows can be fully automated and leads to increased productivity, reduced costs and ultimately improved customer experience.

BENEFITS The Boomerang service has enabled them to: Save time and money from having to manually send their engineers SMS messages delivering an ROI in excess of 300%. With the use of Boomerang’s Open SMS feature, engineers can now provide immediate status updates on each job. Improving customer experience by enable engineers to make the necessary follow-up calls whilst out in the field. The software empowers the database with the ability to send pertinent SMS messages to each engineer and manage subsequent messages based on the engineers’ responses. Edwards continues, “Using Boomerang’s open SMS functionality, a database is automatically updated with a live record so that all staff can see the status of each project on a daily basis. The open SMS also triggers the next action that needs to be performed within the database, meaning that our engineers receive the exact information required at precisely the time they need it, which has really improved the service we can offer our customers.”

Enquiries +44(0)207 224 5555 enquiries@boomcomms.com www.boomcomms.com Centa House 61 Birkenhead st London England WC1H 8BB

The only solution that can match multiple messages to automate your workflow process communications through SMS and Voice. Boomerang delivers improved efficiencies, reduces costs, saves time and delivers a richer customer experience. Enquiries +44(0)207 224 5555 enquiries@boomcomms.com www.boomcomms,com Centa House 61 Birkenhead st London England WC1H 8BB

Software & Systems ‘Time is Money’ - are you making the most of yours? Simplifi Solutions Ltd have just launched a new service called ‘Simplifi-a-register’™ especially for SHE professionals and consultants, to save them time and money. With ‘Simplifi-a-register’ a bespoke register of relevant and up to date legislation can be produced in minutes rather than days. ‘Simplifi-a-register’ is an on-line, profiling tool that takes all the effort out of trawling through the myriad of legislation in order to identify which is relevant to any specific business. At the heart of the Simplifi software is an extensive library of Health, Safety and Environmental Legislation that has been built up and refined over Simplifi’s 5 year history and contains in excess of 2600 pieces of legislation. This ‘one-stop-shop’ for legislation is kept up to date on a daily basis by a dedicated Legislation team.

Email: info@simplifi-solutions.co.uk www.Simplifi-Solutions.co.uk

Software for the Odd-Shaped Project Microsec has been working with non-standard and challenging software project requirements for more than 30 years, and was one of the very first software engineering companies in the UK to be awarded BS EN ISO 9001. We work alongside our clients throughout the bespoke software development lifecycle, aligning processes, disparate technologies, and software platforms, to produce a precisely-engineered Proof of Concept and finished solution. Whatever the environment or context - laboratory, shop-floor, office, mobile, or a mix of these – Microsec’s engineers can deliver a solution to your exact requirements, no matter what shape. Learn more at www.microsec.co.uk/what-we-do

PROCAD’s SpoolCAD software enhances business processes for Industrial Pipe Fabricators, EPCs, Owner-Operators and Independent Welders. With SpoolCAD’s comprehensive modules, users can setup projects, define pipe specs, draw spools, generate individual or projectwide BOMs, create weld lists and monitor fabrication Quality Control. To further streamline customer processes, global drawing data is exported to procurement and accounting databases. Best of all, users can learn this intuitive software quickly with PROCAD’s free online tutorials. For 25 years, PROCAD Software www.procad.com has supplied innovative 3D and 2D piping design solutions. With dedicated service through deployment and ongoing operation, PROCAD has consistently satisfied customer requirements.

The next major REACH registration deadline concerns chemical-substances manufactured in — or imported into — Europe in relatively small quantities, just 1 to 100 tonnes per year. This affects almost all manufacturers doing business in the EU. ECHA, the regulation management agency, is encouraging companies to prepare compliance processes now. For over a decade, Actio Corporation has been providing software to businesses for compliance with mandates such as REACH regulation, RoHS, and SDS / GHS — as well as with regional regulatory challenges such as current United States restrictions on conflict minerals. Visit www.actio.net for information.

Simplifi Solutions Ltd – Environmental and Health & Safety Legal Compliance Made Simple!

Do you spend hours trying to identify relevant SHE Legislation? Simplifi Solutions Ltd constantly update and review, new and amended Legislation and issue daily updates to customers. The Simplifi Legislation library now contains in excess of 2600 pieces of Legislation.

Do you know which legislation is relevant to your organisation? Simplifi Solutions Ltd offer a unique, tried and tested, web based profiling tool, that identifies relevant Legislation automatically and can build a comprehensive 'SHE' legal register in a matter of minutes. Are you trying to build your own management system to try and cope? Simplifi Solutions Ltd over the last 5 years have designed and built a range of software tools specifically to help you manage your Legislation compliance.


PECM Issue 11

Do you worry about the cost of managing your compliance? Simplifi Solutions Ltd offer a range of modulated software management packages that can be tailored to your needs and budget, starting with an web based pay to print service building to a complete fully modulated compliance management package. Are you hoping to gain ISO accreditation? Simplifi Solutions Ltd modulated software systems produce an industry recognised audit and reporting trail that will assist you in attaining ISO accreditation.

Who uses Simplifi Solutions Ltd? BAE Systems: "Our auditors were in recently and love the system they have recommended it and at least 4 other sites are now using it. Plus I think that the Prosecutions and more importantly legal updates are great." Paul McCullough, HSE Systems Manager, BAE SystemsSubmarine Solutions.

Evonik Goldschmidt UK Ltd: "We have found Simplifi a superb tool to identify all Environmental legislation and to measure our compliance against it. The ease with which documents can be uploaded means that compliance can be easily demonstrated. Setting up of the aspects register was straightforward and linking this to the legal register meant that there was a complete audit trail. When there were technical problems, help was always available and problems were quickly resolved. The whole system was given some very positive comments during our recent re-certification audit." Jayne Thompson, EHSQ Department.

Lafarge Tarmac: "I have found Simplifi invaluable in both identifying all relevant legislation as well as our compliance against it. The simple and quick way in which the software works means that updating and progressing

plans associated with ever changing legislation are effectively brought into day to day management of the business. The team are always helpful and timely in their responses and are very keen to work with customers in order to develop the process to meet changing demands and thus keeping the package current to the modern needs of business." Dave Shenton, Senior Environment Manager Cement and Lime, Lafarge Tarmac.

To name but a few, why not join them, Simplifi Solutions Ltd will save you money and make your life easier! Visit us at: www.simplifi-solutions.co.uk Contact us at: info@simplifi-solutions.co.uk

Just as the conventional model of managing data in our hypothetical petroleum processing plant was inadequate, so the higher level database model in discrete manufacturing operations fails to meet modern needs, with data being generated at a rate that far exceeds any ability to use it.


rom simple batch processing to the most sophisticated real-time processes, effective data management is the key to boosting efficiency, increasing productivity and reducing costs in industrial applications. Nigel Rozier of Raima explores the role of data management solutions embedded within industrial automation systems. Managing data effectively within industrial automation systems has become one of the key challenges of the 21st Century, as companies across all sectors of industry strive to improve efficiency and boost output. This may mean managing a switch from manual data collection and analysis to automated systems; it may mean making better use of existing batch or alarm information; or it may mean managing the ever higher amounts of live data generated within today’s increasingly sophisticated automation products. Common across all of these applications, regardless of their levels of data generation, is the requirement to make better automation and control decisions that will address issues such as the need to reduce downtime, increase availability, boost productivity, eliminate waste, reduce maintenance costs, and ultimately increase profitability. Making improvements in any of these areas requires businesses to look at how they collect and process data, and what they do with that data once it has been collected. At one end of the scale, consider a petroleum processing plant where many automation systems are still manually monitored and sensorgenerated alarms are passed on to responders in the form of a phone call or radio communication. These systems may well have been designed at a time when data management and dataflow solutions were still in their infancy. Because of this, alarms can often be delayed in their delivery to responders and many of them can be inaccurate or even false. This could result in frequent and unnecessary maintenance, costly production stoppage or, in rare cases, catastrophic failure.

DATABASE MANAGEMENT FOR INDUSTRIAL AUTOMATION SYSTEMS In this environment, the ability to make pro-active decisions is nearly impossible. Because of the lack of a real-time aggregated data system, operators may wait for scheduled batch updates before re-configuration decisions can be made, perhaps postponing tasks that could have increased the overall production. At the other end of the scale, we can look at high throughput discrete manufacturing applications, with automation systems that are generating more and more data, as increasing numbers of sensors and control outputs provide ever more detailed feedback on processes and production lines. That raw data may well hold the key to improved overall equipment effectiveness, reduced energy consumption and vastly improved productivity, but it’s more than traditional data management systems at the higher levels of the enterprise have been designed to handle. In these high data throughput applications, although the need for database systems has been identified, the database solutions that have conventionally been deployed have been slow and bulky, requiring an interface like SQL to access data. The interfaces have been difficult to set up, often representing a bottleneck between the plant floor and the higher level enterprise systems, both in sending data up from the plant floor to be analyzed, and down to the plant processes to be acted upon. Just as the conventional model of managing data in our hypothetical petroleum processing plant was inadequate, so the higher level database model in discrete manufacturing operations fails to meet modern needs, with data being generated at a rate that far exceeds any ability to use it. An alternative data management approach that meets the needs of all levels of industrial automation is the embedded database, which can be tightly integrated with real-time automation processes, and which can manage live real-time data streams. These data management systems can take captured live data, process it (aggregating and simplifying the data as required) and then distribute it to deliver visualization

and analytics that will enable meaningful control decisions to be made. The ability to do all of this locally within embedded systems – acting on data that may be of real value only in the moment – has a huge impact on the performance of plant and assets. Complete accuracy in events and alarms allows the operational system to be much less prone to unnecessary maintenance and production stoppage. Real-time decision making capabilities allow system operators to optimize total production and reduce risk by reducing the reliance on human capital. Business managers will have up-to-date information regarding the state of the system and accurate and reliable data for reporting and trend analysis. Raima’s RDM database technology is implemented in numerous industrial automation systems, ranging from simple batch processing systems to complex turnkey power plant systems. Common across many of these systems is the requirement for live real-time data management performance at the controller (device) level with automated data movement to upstream shop floor management systems and beyond to corporate management systems. RDM Embedded provides a rugged, scalable and local solution for the handling of large amounts of productionspecific data, directly on the plant floor. Platform independent, it can run on everything from popular OS options such as MS Windows, Linux and iOS to real time systems such as Wind Rivers’s VxWorks, QNX Neutrino and Green Hills INTEGRITY, as well as many others. As well as supporting multiple processor and multi-core architectures, the RDM data storage engine provides a set of data organisational features that you can use to control in-memory, disk-based or remote storage to provide the best possible performance in an embedded systems application. For more information on RDM or to download the SDK for evaluation visit: www.raima.com

Issue 11 PECM


Storage, Handling & Distribution Niplast Tanks Take it Lying Down Niplast has supplied two storage tanks to Suretank Ltd, the world-leading manufacturer of CCUs (Cargo Carrying Units) for the Offshore Oil and Gas Industry. The tanks, to be used to store sodium bromide and hydrochloric acid in the Caribbean, were commissioned by the customer in polypropylene rather than their usual steel construction, due to the highly corrosive nature of these chemicals. An unusual, but key, design request from the customer was that the Niplast tanks would be able to be transported horizontally within a purpose built mild steel frame based on an ISO container specification. To facilitate shipping from location to location, the empty tanks will be held in the horizontal position via a flanged bolted base and a polypropylene lined cradle. Fabricated in Niplastâ&#x20AC;&#x2122;s manufacturing plant in Stockport, the tanks were designed and constructed to the CEN standard BS EN 12573, with a 50 degrees Centigrade working temperature and a 20 year design life.

Tel: 0161 477 6777


Part-system build service for OEMs MiniTecâ&#x20AC;&#x2122;s full service (supply chain management) capability beneďŹ ts Cobalt Light Systems. Abingdon-based Cobalt Light Systems develops products and technologies for non-invasive subsurface chemical analysis and produces its INSIGHT100 table-top screening device for evaluating the chemical composition of liquids, powders and gels in glass or plastic containers. Used widely at airports, high security establishments and other passenger hubs, it employs an exclusively developed technology called SORS (Spatially Offset Raman Spectroscopy) which was invented at the STFCâ&#x20AC;&#x2122;s Rutherford Appleton Laboratory and through technology transfer initiatives has successfully found its way into very beneficial use. The machine is part of a range of screening, analysis and characterisation products that Cobalt Light Systems market for security, pharmaceutical and biological applications that rapidly and accurately measure materials without touching or altering the sample.

Tel: 01256 365605


Workplace ergonomics: MiniTec workstation features height-adjustable assembly table and material storage shelves MiniTecâ&#x20AC;&#x2122;s modular aluminium profile system has been made full use of for a technical product assembly workstation where the customer requirements included individual height-adjustable assembly bench and material provisioning shelves. This ergonomic solution allows assembly technicians to set-up their most productive working environment by maintaining a neutral standing or sitting working posture - with the aid of electric actuators and a simple control console that includes a multiple memory function to store and recall their preferred table and shelf heights.

Tel 01256 365605 Email: g.livingstone@minitec.co.uk www.minitec.co.uk

Intelligent IP69K drives for pumps and conveyors in the chemical, pharmaceutical, and food industries

NORD DRIVESYSTEMS supplies efficient drive units for dynamic speed control and automatic process control in applications that need to be regularly cleaned with high-pressure steam jets. Developed for strict hygiene requirements and featuring IP66/IP69K ingress protection, smooth-surface motors with an integrated frequency inverter are available for the 0.37..1.1 kW performance range. Common applications include conveyors, pumps, mixers, and agitators. Sensor data such as pressure or flow rate values can be directly communicated to the drives, enabling them to automatically adapt to current demand. If partial load operation is frequent, an automatic energysaving function decreases the running costs by a significant share. In conveyor applications, light barriers can be used for contact-free or gapless accumulation. A soft start function reduces the starting current and results in less stress on the mechanical system and the transported goods.

Email: info@nord.com


As world leaders in our field we recognize that our people are a key factor in our success. Due to year-or-year growth, plus a recent ÂŁ1.7 million further investment in additional machinery at our impressive UK Headquarters, we currently have a number of factory and office based vacancies in Milton Keynes plus some additional field based sales engineering vacancies in various locations throughout the UK. We need: Skilled CNC Machinists (Milling and T41-(-&;22$,!+7/$1 3(5$2;echnical Sales Support Engineers (Electrical and$"' -(" +;1.#4"3(.- + --$12; "(+(3($24//.13/$1 3(5$2;-3$1- + +$2$./+$;$2(&--&(-$$12;1.#4"3(.--&(-$$12 -#//1$-3("$2;($+# +$2-&(-$$12;$7 "".4-3 +$2-&(-$$12;(231(!43(.-4//.13-&(-$$12;/$"( +1.#4"3 +$2-&(-$$12"($-3(%(" 1."$22 1(5$2$36.1*2;1 #4 3$ +$2-&(-$$12 So, if youâ&#x20AC;&#x2122;re looking for a career in an environment that rewards its employees for their skill, hard work and reliability, weâ&#x20AC;&#x2122;d love to hear from you. With a commitment to help grow and develop our people through on-the-job training - to help career advancement and job satisfaction â&#x20AC;&#x201C; we also offer competitive benefits packages including performance based bonuses. To find out more, send your CV to: recruitment@smceu.com or visit our web site: www.smpneumatics.co.uk


PECM Issue 11

Extra Coldspace Where You Need it, When You Need it For maintenance and breakdown cover, project work or peak manufacturing times. Companies that rely on refrigeration often have a fluctuating need for cold storage. However many don’t know that portable refrigeration is the perfect solution to these changing requirements. You don’t need to invest your capital in building coldrooms that aren’t often in use, nor do you need to manage your processing around your existing capacity. A portable refrigerated unit will give the capacity you need, when you need it, where you need it and it can be taken away when it’s no longer required. Whilst undertaking a major piece of work, The National Composites Centre needed to keep pre-cured components at a steady specific sub zero temperature but were short of refrigerated storage capacity. A call was made to refrigeration experts Team Refrigeration and a 20ft refrigerated container was delivered which was kept on site for 10 months until the project was completed. “Hiring a refrigerated container was the perfect answer for us” said Rob Ludford, Operations Director of the National Composites Centre. “It provided us with the flexibility we needed during an important project and Team Refrigeration were great to deal with providing a really responsive service.” Portable refrigeration units vary in size from towable trailers with a capacity of 9.5m3 that will hold up to 3 pallets right up to 40ft containers with a capacity of 68m3 capable of holding 18 pallets. They provide the following additional benefits: • They are readily available and could be delivered within hours • They can maintain a stable temperature of -40⁰C to +20⁰C • They provide full traceability using data loggers • They can be located conveniently close to the building

Refrigerated containers provide extra cold space either short or long term.

Team Refrigeration have even provided breakdown cover to the AA and to an F1 team. “In both the cases we received calls from facilities managers who were worried about the refrigeration. “ says Tim Edwards, Managing Director of Team Refrigeration. “The AA had a refrigeration unit that had broken down and needed immediate an replacement so the catering department could continue to function. The F1 team had a freezer full of pre-preg and the unit was starting to falter” In both cases backup refrigeration was on site within hours and continuity of cold storage was maintained. If you find yourself scheduling projects or production around your available cold space or have some maintenance planned for your refrigeration, a portable refrigeration unit could be just what you need. And if you have a breakdown and need some backup refrigeration in a hurry, just give us a call and we’ll do what we can to help out. Contact: Tel: 01934 245020 Email: tim@teamrefrigeration.co.uk www.teamrefrigeration.co.uk

Refrigerated trailers can be delivered at very short notice – perfect backup for refrigeration breakdowns.

The Right Material Matters Do you remember the story of The Three Little Pigs?


he first little pig made his house out of straw, which was a bad mistake because it offered no serious longterm protection against big bad wolves (it was, you’ll recall, blown over by a passing wolf in five seconds flat). The second little pig made his house out of sticks – another serious design flaw resulting in another flattened house. Disaster. But the third little pig? He made his house out of bricks and this one stayed up, despite the alarming amount of huffing and puffing going on outside. The moral of this fairytale is fairly obvious and can be applied to real life. When it comes to workable, safetyconscious design, making products from the most suitable materials isn’t just desirable. It’s vital. After all, there’s no point in getting the form just right if the function is all wrong, because your creation might look good, but it won’t work properly – like a chocolate fireguard, or inflatable dartboard. Incredibly, though, products in the real world are sometimes made from precisely the wrong materials, yet still end up in the hands of consumers; although it’s often easy to recognise this in hindsight, because times change and so do health and safety standards. Asbestos, for example, is a very effective and economical fire-retardant material with excellent thermal and acoustic insulating properties.

Incredibly, though, products in the real world are sometimes made from precisely the wrong materials, yet still end up in the hands of consumers; although it’s often easy to recognise this in hindsight, because times change and so do health and safety standards.

Unfortunately, as we now know, prolonged exposure to asbestos fibres can cause serious and sometimes fatal lung diseases. Asbestos was duly banned as building material in the UK at the end of 1999. Even wood can be unsuitable as a material. Back in the day, tennis rackets used to be made from wood but, trouble was, they were really heavy, which is why some bright spark started making them from aluminium, then lightweight graphite and carbon fibre. It was the same with car bumpers. Not so long ago, cars were fitted with steel bumpers, because steel was presumed to be the best material to absorb impact in a collision. These days, however, that presumption has been roundly quashed. Now, in automobile bumper design, vintage steel is out and Thermoplastic Olefins (TPO’s) are, largely, in. Times, standards and materials change in the world of industrial workplace barriers, too. Well, almost. Steel barriers are still widely used in industrial environments because, mistakenly, they are believed, just like those steel car bumpers, to be the best protection against vehicle collision. In actual fact, steel simply dents or crumples when a vehicle such as a forklift truck hits it – and, for an encore, it rips up the floor because all the force of impact dissipates downwards.

Yet there is a barrier material that simply springs back into shape after a collision, because it has a built-in memory. This is called Memaplex, a flexible polyolefin blend of eight materials and rubber additives that has been exclusively developed by Yorkshire company A-Safe (UK) Ltd. A-Safe make a full range of Memaplex pedestrian guardrails and vehicle check systems, including Traffic Barriers, Rack Leg Protectors and Rack End Barriers, all tested and certified to British Standards, and the results have been startling. Instead of having to replace barriers that have come into contact with a moving vehicle, workplaces with Memaplex protection report no substantial damage, even after a few bumps. And because a Memaplex barrier is strong as well as flexible, the force of impact is dissipated, with just 20 per cent of shockwaves reaching the floor. Of course, it can take time for some products to go the way of the dodo and others to take their place. But people will always question the status quo and ask how things can be improved. Ultimately, that starts and ends with what a product is made from. Steel barrier producers can huff and they can puff all they like but, in the end, materials really do matter. To contact A-SAFE call +44 (0) 1422 331133, email sales@asafe.com, or visit asafe.com for more information.

RAISING THE BAR IN REDUCING YOUR WAREHOUSING COSTS With class-leading residual capacities, high efficiency and superior ergonomics, the new Cat® NR14-25N2 range achieves the next level in performance and operation. And with eleven models to choose from including high performance, compact and straddle versions, you’ll be spoilt for choice. Whatever materials handling equipment you need, we can provide the level of service to match your expectations. From a wide choice of quality, durable products, to flexible finance packages, comprehensive after sales service and maintenance, we pride ourselves on making it easy for you to put the right truck into the right application.

Contact Impact Handling, your Cat® lift trucks dealer today on:

0800 169 9789

or email: sales@impact-handling.com





Impact Handling - the UK’s sole distributor of Cat Lift Trucks equipment New and Used Sales  Finance and Rental  Servicing and Parts www.impact-handling.com | sales@impact-handling.com ©2014. CAT, CATERPILLAR their respective logos, ‘Caterpillar Yellow’ and the ‘Power Edge’ trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Storage, Handling & Distribution Demag V-type a new generation of industrial cranes Terex Material Handling has launched the new generation Demag V-type crane, which sets new standards in the industry. The V-type design uses less material, helping to reduce the depletion of raw materials. V-type girders weigh, on average, 17% less than comparable box-section profile girders. This reduced crane deadweight produces less wheel pressure, minimising the forces transmitted to the existing building structure and increasing the maximum load capacity. Consequently, the new Demag V-type crane provides architects with greater freedom in planning new factory buildings. The design is also suitable for companies, who wish to employ additional lifting equipment in existing assembly and production bays. The patent pending design, which features diaphragm joints, also cuts oscillation of the crane girder by up to 30%. The reduced oscillation characteristics cause lower loads to be transmitted to the crane, its components and the building structure, doubling the service life of the crane to more than 500,000 load changes. In addition, the improved oscillation characteristics enable heavy and sensitive loads, such as glass panels, fluids or aluminium shell sections for aircraft, to be positioned more precisely and quickly.

Email: bnb-help@demagcranes.com www.demagcranes.co.uk

Reduced Cost per Label on Primera’s Digital Label Press Primera now offers 10% more toner for the same price Primera Technology has increased the capacity of its cyan, magenta, yellow and black toner cartridges for the company’s popular CX1200e Digital Label Press and CX1000e Color Label Printer. Toner cartridges for the CX-Series previously were rated for 15,000 ISO pages. Now, all new shipments of toner cartridges are rated for 16,500 ISO pages – an increase of 10%. The price of the cartridges remains the same as before. “We’re pleased to be able to offer 10% more toner in each toner cartridge for the same price,” said Mark D. Strobel, Primera’s vice president of sales and marketing. “When we surveyed our users and asked what we could do to improve our best-selling CX1200e Digital Color Label Press, a reduction in the cost per label was the number one request. We listened and reacted as quickly as possible.”

Phone: +49 611 92777 0 Email: sales@primera.eu Web: http://primeralabel.eu

DUO PLAST presents Trend-Setting Stretch Film Going under the slogan “Double Edge – Double Strength!” DUO PLAST presents the DDK film as a pioneering innovation in the stretch film market. The film has already won several awards and signals a new trend in the field of load securing according to DEKRA. UO PLAST has dedicated itself to optimise cargo securing for years. The development of the worldwide patented stretch film DDK is trend-setting for load unit securing. The special feature of this film is the double edge (for example a 15 micron stretch film has a thickness of 30 micron at the edges).

very stable, while enormous material savings can be realised. A reduction of material consumption of more than 30 - 35% is not uncommon when using the DDK-film. Consequently lower packaging costs and lower disposal costs are the result. Conservation of resources and protection of the environment are further advantages of the unique film innovation.

The innovative double edge surrounds the pallet like a net and makes it

Security with comprehensive expertise A further innovation of DUO PLAST is the business segment DUO LAB. The German Technology Centre for Load Unit & Cargo Security checks, develops and audits load security concepts for dispatchers, logistics companies and institutions. Real transportation loads are simulated by using latest testing technologies. The goal is a neutral and individual optimization of load securing concepts, which can be recorded in a report and also certified on request.



PECM Issue 11

The resulting holistic, professional customer support is completely new to this extent. The focus of the analysis is always the perfect load securing concept for the customer. So not only packaging costs, but also the entire total cost of ownership are reduced. At the same time safety on European roads rises. More information and videos on DUO PLAST’s new concept are online at www.duoplast.ag/en


PECM Issue 11

Issue 11 PECM


“The Right Connection ” for all Industries ®

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

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


TEFSA Filter press technology and spares

Flottweg centrifuge technology

Belt filter technology

Euroby Ltd New Dawn House, Gorse Lane, High Salvington, Worthing, Sussex BN13 3BX T - 01903 69 44 00 F - 01903 69 44 77 E - sales@euroby.com www.euroby.com

Advanced SAF technology

Water & Effluent Treatment WES DosingCube™ Hampshire based dosing system experts, WES has been developing the DosingCube™ since 2006. This as a key product within WES’ product range. The principle of a pump within a bunded enclosure as a standalone unit provides a well-engineered safe and simple pumping solution for chemical dosing.

WES Hire Division WES’ Hire division operates a dedicated fleet of chemical dosing products for temporary and emergency requirements. Ranging from our DosingCube™ through to fully-integrated dosing systems, this rapidly expanding division of WES is highly reactive and geared towards quick deployment.

It has many applications from emergency dosing from an IBC to integration within a permanent system. It follows the plug and play principle, simple to install, inherently safe and easily inter-changeable when maintenance is required. At under 25 kg the DosingCube™ is easily portable.

WES continues to invest in expanding the hire fleet to meet increasing demand from existing and new customers. WES’ customers consider this a key service, in particular, to meet emergency chemical dosing requirements and also to provide continued process operation during main plant maintenance, asset replacement or chemical trials etc.

For more details visit www.wes.ltd.uk

For more details visit www.wes.ltd.uk

Blue-White Peristaltic Pumps

Coating protects header boxes

WES is the exclusive European Distributor for the Blue-White range of peristaltic pumps. These pumps are an excellent alternative to traditional solenoid and diaphragm pumps. Equipped with the latest control and motor technology, they offer great dosing characteristics on viscose and high solid content liquids. Maintenance is very simple and can be undertaken in minutes and requires no training. The tube assemblies are inexpensive and can operate for up to 12 months in many applications. These pumps are particularly suited to hypochlorite dosing as off-gassing has no effect on their performance. For more details visit www.wes.ltd.uk

Innovative project in wastewater screening management Wastewater screenings are a difficult waste stream posing a challenge for resource recovery. To meet their zero waste aspirations, water companies wish to identify a viable route to utilise some, or all, of the wastewater screenings produced at wastewater treatment works. To meet this objective WRc have been commissioned by the UK Water Industry Research (UKWIR) to undertake a review of ‘Wastewater Screenings Management Options’. This will develop a technology/solution evaluation framework to help drive screenings management further up the waste hierarchy. As part of the project, WRc will assess current and developing technologies to identify their suitability for treating, and ideally recovering value, from this waste stream. Please contact the project team (Paul Eades: paul.eades@ wrcplc.co.uk or Line Poinel: line.poinel@wrcplc.co.uk) if you are a developer or supplier of a technology that could be used to treat screenings – we look forward to hearing from you.


PECM Issue 11

Universal Heat Transfer Ltd (UHT) of Atherston,Warwicks, is a heat exchange and transfer specialist. supplying equipment and services to industry. One of its latest projects involved the manufacture of header boxes and channel heads for the refurbishment of four hydrogen coolers for a power station generator cooling system. UHT’s customer specified WINN & COALES (DENSO) LTD’S Archco-Rigidon 403D said to give “fit and forget” corrosion protection of the carbon steel substrate from the coolant inside the header boxes for a minimum of ten years. Winn & Coales checked the specification for both the suitability of Archco—Rigidon 403D and also for the method of application, given that the coating had to be applied in normal engineering workshop conditions. UHT say that the coating arrived in a timely manner, which was appreciated due to the tight deadlines they had to meet.

Tel: 020 8670 7511 www.denso.net

Email: mail@denso.net


visit www.imo.org/publications for your local distributor

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PECM - Issue 11 2014  

PECM - Issue 11 2014