PECM - Issue 20 2016

Process

Manufacturing

Control &

Engineering

PECM

Global Success Through Innovation Issue 20 2016 ÂŁ3.95 www.pecm.co.uk

Meeting the DeManD - 70

Safety anD health expo - 24

planetary gearheaDS - 38

Process control systems are becoming more complex; they are subject to greater scrutiny due in part to the demand for improved efficiency,

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Connect with us

Process

Engineering Manufacturing

Sections Editors Choice News & Events Drives & Controls Health & Safety Expo IFSEC International PDM Show Utility Week Live Air, Gas & Odour Control Boilers & Maintenance Calibration Software Control & Automation Drives, Gears & Motors Electrical & Electronics Facilities Management Fluid Handling Health & Safety Hydraulics & Pneumatics Lifting & Handling Equipment Machining & Machinery Measurement & Monitoring Process Technologies Pumps Software & Systems Storage, Handling & Distribution Tools Training & Recruitment Valves & Flow Control Water & Effluent Treatment

6 18 22 24 26 29 32 34 35 36 40 50 52 66 68 77 85 86 87 94 107 114 115 123 124 125 127 129

Control &

Inside...

Inside Issue 20 100 Years of Engineering Expertise From the largest forging press, to the latest ‘smart’ stadium, or even the hardy plant vehicles found at your local quarry; hydraulic systems keep vast swathes of industry moving.

Customized Protective Coatings Meet the Challenge of Extending Service Life for Rotating Equipment Achieving an acceptable service life without excessive maintenance can be a challenge for rotating equipment that is used in the processing and delivery of hydrocarbon products.

Brand Engineering: Your brand is your everything.

In a noisy complex world, we need clarity more than ever. With ever shorter attention spans, your

business needs to cut through with a succinct, compelling, and unique brand promise: a simple statement of what your brand stands for.

Meeting the Demand for More Complex Process Control Systems Process control systems in almost every industry are becoming more complex; they are subject to greater scrutiny due in part to the demand for improved e ciency, regulatory compliance and higher levels of automation and plant integration.

Partnership of Stieber with Twiflex Simplifies the Specification of Industrial Braking Systems for Customers Stieber GmbH, specialist for backstops, brakes and clutches, and a company of Altra Industrial Motion Group, now offers the entire industrial brakes assortment of the world’s leading brand Twiflex.

DELIVERING STRAINERS & FILTERS TO YOUR PROJECT WITHOUT DELAY

Y-type strainers • Basket strainers • Duplex strainers • T-type strainers • Radial fin cartridge filters (to 1 micron) Filter separators and demister pads • Quick release closures Materials available include: Carbon Steel & LTCS • Stainless Steel 304/316 • Duplex and Super Duplex Stainless Steel 6Mo • Monel • Aluminium Bronze • Cunifer • Hastelloy • Incoloy 625 & 825

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

Partnership of Stieber with Twiflex Simplifies the Specification of Industrial Braking Systems for Customers Stieber GmbH, specialist for backstops, brakes and clutches, and a company of Altra Industrial

The company supplies the brakes under

Motion Group, now offers the entire industrial brakes assortment of the world's leading brand

a comprehensive offering that includes

Twiflex. Moreover Stieber can support its customers locally through application engineering

support for the design and selection of

and mitliefern to customer specifications customized installation and additional components

the brake components and the supply of

in the package.

wheels, hubs, fasteners and other parts for

H

eavy-duty disc brakes

For the designer, the specification of these

include many industrial

brakes often means an extra level of effort

equipment of cranes and

and complexity of design and engineering

elevators to mills and

process. At the retail level makes the

conveyor belts to the main functional

wrong choice, the maintenance and the

components.

modernization concept. Stieber has now partnered with its sister company Twiflex

When integrated into the final machine

closed in order to offer a range of popular

design of the customer a careful selection

models brakes from stock in Heidelberg

process is therefore required.

can.

4

PECM Issue 20

complete brake solutions.

The new service will facilitate in the German market, the procurement and installation of brakes. Moreover Stieber can support directly from the manufacturer by the close relationship with Twiflex even the most complex and exceptional braking applications by order-made solutions.

Twiflex also benefits from the extensive

"With this new offering we are responding

service and support for its customers,"

international distribution, logistics and

to the needs of our customers in Germany,

adds Tony George, product manager

service capabilities of the parent Altra

who are constantly striving to optimize

at Twiflex. "Our customers in Germany

Group, the world's largest manufacturer

their procurement and to increase

benefit in the future from a shorter supply

of clutches and brakes for industrial use.

the flexibility and adaptability of their

chain and improved access to product

For customers, this ensures continuous

businesses," says Uwe Walter, CEO of

expertise locally."

support, regardless of the final destination

Stieber in Germany.

of its products.

"We are also very pleased Products of Twiflex come for more than

that we can enrich the

70 years in some of the most demanding

production in Germany

drive solutions in the world to use.Here,

by such a meaningful

Twiflex has not only made a name for

technical function and

quality, but also integrates a number of

securing high-quality

innovations in its products, which serve

jobs."

the reliability, and simplify installation and maintenance. In the series of modular

"This new agreement

brakes facilitates example the Park

with Stieber is a good

function installation, adjustment and

example of how the Altra

maintenance of the component without

Industrial Motion Group

hazard by spring tension, with separate

working towards to

hydraulic.

improve the worldwide Issue 20 PECM

5

Erodex

is the only company to stock every wire diameter in every reel size, with all tensile strengths and with every coating option.

Coated wire that performs out of this world

With an extensive stock of filters, electrode blanks and other consumables, the staff at the company are always willing to share their knowledge and experience with EDM users looking to improve productivity.

A

s the UK’s largest supplier of EDM consumables, Erodex is the only company to stock every wire diameter in every reel size, with all tensile strengths and with every coating option. That amounts to around 70 line items that can be sent to customers for next day delivery. “We have enough wire in stock to reach the moon and back; and we regularly ship 30 to 40 orders a day for customers looking for reliable service and support. We provide everything for EDM users, except the machines, using a full service approach,” explains Sales Director, Steve Rolinson.

With an extensive stock of filters, electrode blanks and other consumables, the staff at the company are always willing to share their knowledge and experience with EDM users looking to improve productivity. One of the greatest performance

improvements comes from using coated wire rather than plain brass during the wire cutting process. Erodex supplies the complete Bedra range of high performance coated wires that can provide an increase of up to 50 per cent cutting speed performance while maintaining the quality of the cut.

Steve Rolinson says: “For the efficient application of the wire EDM process Bedra has contributed significantly to the development of technology and production processes. With the functional coatings for wire electrodes it has developed, an enormous increase in material removal performance, and hence in productivity, can be achieved. Moreover, a reproducible high precision and surface quality is attained.”

Erodex are keen to promote the high-tech, universal Topas Plus wire

cutting range that has been developed as a high speed cutting wire.

Combining an excellent price-performance ratio for applications on all standard EDM machines, this range can significantly improve productivity compared to brass wire.

Erodex provide EDM users with a cost comparison spreadsheet that will calculate the savings that could be achieved by using these new generation coated wires. Steve Rolinson concludes: “Of course the coated wire is more expensive initially.

However, if you can increase the throughput of the machine tool by between 20 and 50 per cent the business efficiency gains far outweigh the additional cost of the consumable wire.”

Tel: 01384 892011 Email: sales@erodex.com www.erodex.com

Process

The leading source for innovators in Technology, Manufacturing and Maintenance within the Engineering & Processing industry worldwide.

Published bimonthly, a subscription to PECM magazine is essential for Process Engineers, Chemical Engineers, Instrumentation Engineers, Mechanical Engineers, Plant Engineers, Precision Engineers, Environmental Engineers & General Engineers, Companies and Organizations in the Food, Dairy, Beverage, Brewing, Semiconductor, Pharmaceutical, Biotechnology, Chemical, Oil & Gas, as well as all UK's major manufacturing units.

Every issue of the magazine contains the latest news, in-depth features, together with product innovations and case studies showing how process engineers are implementing new technologies to reduce costs and impact on the environment.

With over 300,000 readers worldwide the publication is widely read, recognized, and well respected within the Process, Engineering & maintenance industries.

A subscription to PECM magazine is the industry's 'must have' publication.

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Please mention Process Engineering Control & Manufacturing when responding to items in this issue.

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No part of the publication may be reproduced or transmitted in any form or by any means, mechanical, electronic (including printing), recording or stored in any information retrieval system without the prior written consent of the publisher.

Brand Engineering: Your brand is your everything.

In a noisy complex world, we need clarity more than ever. With ever shorter attention spans, your business needs to cut through with a succinct, compelling, and unique brand promise: a simple statement of what your brand stands for.

Applying lean principles to branding we deliver real commercial value that pervades the organisation from the inside out.

your brand. Everyone involved needs to understand what your brand stands for and what it means to their role. Your brand will bring your people together and help build belief right through the organisation. Engaged employees can often mean the difference between success and failure.

STARTING WITH THE RIGHT REASONS LET’S BE CLEAR Branding can have a significant impact on your people, sales, growth and business performance.

B2B branding in the engineering space is no different from any other when it comes to communicating effectively.

The traditional definition of a brand is a name, sign, or symbol used to identify products or services of the seller(s) and to differentiate them from goods of competitors.

It’s clearly not enough anymore to operate with this narrow viewpoint.

Your brand is your everything, from your people, products, place of work, your culture through to your tone of voice. All have a cumulative effect on how your customers perceive and experience your brand. It is through these touch points that they build a relationship with you rather just conduct a transaction.

BRANDS ARE BUILT FROM THE INSIDE OUT Brands are built on relationships and trust: between your leaders and your people, and between your people, your customers and partners. Your people are

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PECM Issue 20

Starting a branding project includes finding the right reason, commitment, and strategy; analysing brand equity; and uncovering insights and opportunities.

Fundamentally, there are two reasons a business needs branding. Either a new product or company has been created or there is a desire to change an existing brand to better reflect new business objectives (most often called a “rebrand”).

There must be a solid business reason to change, or refresh, a brand and a brand idea. Without a solid business objective and brand idea, the judging of brand change becomes purely subjective.

Suffice it to say, when you embark on a rebrand it is critical to ensure that you are rebranding for the right business reason, and if there is a desire to alter some visual or verbal elements, a clearly defined brand idea is essential for guiding this change.

making tough decisions about the market you are in. Get this clear and your nearly there.

Who is it intended for?

The more specific and targeted the answer to this question, the better.

What is the benefit to customers?

A company should be able to articulate clearly, in a few words, the unique aspect that differentiates its product from the competition and provides a benefit to its customers.

Start with the right focus: Customers One of the most important first steps in a branding project is to create a framework that identifies and compares all possible interaction points where a customer experiences the brand.

Uncover insights and identify opportunities As an agency, the process of creating a new brand or a rebrand always starts with a situation analysis or brand audit.

This process can uncover issues that you can exploit to your business advantage.

NAMING IS CRUCIAL

Follow these signposts and you won’t go wrong:

Naming is increasingly an important element to a brand’s success. Ideally, a name should be the pure encapsulation of the brand idea and, along with this audacious goal, should meet other key criteria:

Start with the right business strategy

t #F FBTZ UP QSPOPVODF JO FWFSZ MBOHVBHF

Good branding cannot save a poor product or business.

t #F NFNPSBCMF CFJOH CSJFG BMTP IFMQT

What are we selling?

In a very practical sense, selling involves

t )FMQ QFPQMF VOEFSTUBOE XIBU UIF business or product is about

t #F BCMF UP TUSFUDI JOUP PUIFS DBUFHPSJFT and areas in the future t )BWF OP OFHBUJWF DPOOPUBUJPOT JO PUIFS languages t #F PXOBCMF BOE QSPUFDUBCMF BT B trademark in all countries in which you want to operate t )BWF BO BWBJMBCMF EPNBJO OBNF By example, these case studies exemplify the power of effective branding.

TUROLLA MOVES UP A GEAR As a member of the global Danfoss Group, Turolla engineer, manufacture and supply Gear Products and Fan Drive Systems.

For many years Turolla had exclusively used blue in its communications, reinforcing perceptions of it being too cold and corporate. In our redesign we expressed the brand through the energy of orange, allowing the brand to communicate to its audiences their innovative products and solutions.

At launch, the vivid contrast between the old and the new was exciting and dramatic, serving as an instant and powerful signal of change—from old to young, and from corporate to personal.

With a new, vibrant expression, Turolla made a visible commitment to connecting with its customers.

GKN DRIVELINE REBRAND As part of the GKN group of companies,

GKN Driveline is the world’s leading supplier of automotive driveline systems and solutions. A global business serving the world’s leading vehicle manufacturers, GKN Driveline develops, builds and supplies an extensive range of automotive driveline systems.

Clarity helped GKN Driveline to consolidate fourteen separate brands and organisations under one united brand. GKN Driveline.

This consistent identity was extended across 30 countries and 24,000 employees. As a brand development programme guidelines, signage, literature, website and exhibitions were are developed.

SHHARK NAMING A product brand that needed to shout.

In this noisy complex world, every new product needs to stand out.

As a naming specialist, Clarity was central to creating the name and branding for Turolla’s revolutionary ‘quiet technology’ gear pumps to launch at Agritechnica in Germany.

GET CLARITY

We deliver global brand, rebranding and naming projects specifically within the engineering sector.

So when you need help to define and communicate your brand locally or globally, we’re here to talk your language. +(0) 7940 916759 more@engineeringclarity.com

www.engineeringclarity.com Issue 20 PECM

9

Editors Choice Hinge d e every ap sign for plication

# conti nuous # lift-o ff # butt a nd bac kfl # speci al purp ap ose # heavy -duty Quality hinges for over 200 years

01827 63391

www.goldwassallhinges.co.uk

SMALL PARTS. BIG IMPACT. Optimas Components Cable Management Optimas Components is a leading global supplier of C-class components, including fasteners, cable management and finishing products We provide innovative supply chain management solutions to reduce the total cost of production and implementation incurred by our customers. Our portfolio of services also includes kitting, bagging, dying, enclosure customising and on-site inventory management.

Optimas prides itself in being the exclusive Heyco® partner in the UK and Ireland. Heyco® is the leading manufacturer of moulded wire protection products and stamped electrical components. The product range includes cable glands, cable clips, locknuts, grommets, bushings, conduits, washers and plugs.

Products are continuously being introduced. Recent additions include the Heyco®-Tite Snap –In-2® Liquid Tight Straight Thru cable glands. These come in either nap n ubs or Fle rotect versions and offer a ma or advantage as no tools or locknuts are required for installation. Unique fingers securely snap into a range of panel thicknesses of up to mm They are perfect for low clearance installation where locking nut access is limited.

OPTIMAS SOLUTIONS - COMPONENTS DIVISION Tel: +44 (0) 1202 865222 Web: optimascomponents.com

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PECM Issue 20

Our growing team now also includes dedicated applications engineers to help customers develop tailored solutions suited for their specific application needs as ell as offering standard off the shelf solutions To see our full range of products or to get in touch, please visit optimascomponents.com.

Visual Identity I Brand Guidelines I Literature I Exhibitions I Advertising I Design I Web Design I Product Branding Visual Identity I Brand Guidelines I Literature I Exhibitions I Advertising I Design I Web Design I Product Branding

specialists in the engineering sector Is Is your your brand brand firing firing on on all all cylinders? cylinders?

We We deliver deliver local local and and global global brands, brands, rebranding rebranding and and naming naming projects specifically within the engineering sector. projects specifically within the engineering sector.

Taking Taking a a lean lean approach approach to to brand brand communications, communications, Clarity Clarity helps helps to minimise wasteful communications whilst maximising to minimise wasteful communications whilst maximising brand brand reputation reputation and and value. value. www.engineeringclarity.com www.engineeringclarity.com

Editors Choice

Leaders in surface engineering Increasing the performance and life of critical components

O Shot peening O Peen forming O Thermal spray O Engineered coatings O Anlytical services O Approvals: AS9100 Rev C O NADCAP O ISO 9001:2008 O FAA

www.cwst.co.uk/aerospace | eurosales@cwst.com | +44 (0) 1635 279621 Rapidox 2100 oxygen gas analyser Additive Manufacturing (AM), also known as 3D printing, refers to a manufacturing process, which creates ob ects by adding multiple layers of material to form components, parts or products.

Ecotile help Paxton take access control to the next level

Selective laser sintering and laser melting are processes which can be used with a high-powered laser to form ob ects from metal po ders, such as titanium, aluminium, stainless steel and others.

Paxton are one of the European market leaders in electronic access control.

They have achieved this through 30 years of innovation; creating simple yet intelligent products to provide reliable security to small and medium sized buildings. Their USP in this competitive market is the exceptional level of support and service they offer to their customers days a eek eeks a year so hen they needed an oor at their manufacturing facility in astbourne they naturally chose cotile interlocking oor tiles

The AM process requires an inert atmosphere to be used within the laser forming chamber. The Rapidox 2100 oxygen gas analyser has proven to be a reliable instrument for providing the low ppm analysis required for such an application.

a ton s paramount criterion as e ibility as they are gro ing so fast that they need to be able to change their production layout to accommodate new lines on a regular basis. Of the options suggested Ecotile was the only ooring that met this ob ective

www.cambridge-sensotec.co.uk

Tel: 01582 788 232

Speed marries quality with Kemppi mechanised MIG systems

Pain relief for your welding documentation process..

emppi ne and ystems offer welding mechanisation equipment for straight line OR orbital MIG/MAG welding applications.

Kemppi has released the latest version of their welding documentation software solution that streamlines and relieves the pain points of the welding documentation process.

The A3 MIG System is an excellent, durable and simple straight rail solution. Powered from a reachable battery, the A3 torch carriage is an ideal and low cost solution to mechanise longitudinal welding and cutting process. he ystems offer integrated elding carriage solutions for either straight rail or orbital MIG welding, incorporating a weaving unit, remote control, plus either straight rail or guide ring sets for orbital MIG welding.

For more information and/or site demonstration contact Kemppi (UK) Ltd Tel: 01234 832620 or email sales.uk@kemppi.com www.kemppi.com

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PECM Issue 20

www.ecotileflooring.com

anaging and compiling elding pro ect documentation can be a complex and time consuming process. Everything from welding procedures, personnel ualifications, prolongations, and elding uality records, must be managed in compliance with the latest standards and clients requirements. o one can escape the process, but there are ays to make it less e hausting and much more accurate. Standard documentation tools are not integrated, can increase pro ect costs and cause unnecessary delays in pro ect delivery emppi elding management solution resolves all of these issues by offering an integrated soft are solution, streamlining the elding documentation process, and reaching significant benefits and production improvements

Tel: 01234 832620 www.kemppi.com

Email: sales.uk@kemppi.com

Editors Choice Nutromex Biopack boosts Anaerobic Digester performance and stability OMEX Environmental Ltd. are introducing their new powder additive for the anaerobic digestion and biogas market, Nutromex Biopack. Nutromex Biopack is a unique solution of bio-available trace elements and specially selected bacteria which is used to supplement the existing microbial populations in Anaerobic Digesters and Biogas plants. This addition improves overall plant functionality, leading to optimum performance.

Nutromex Biopack has an advantage over current products in the market due to its’ easy application. It is a water soluble powder available in 250g biodegradable bags which are administered directly into the digester on a daily basis.

Each individual digester needs essential metals to create the perfect balance for microbial populations to thrive and break do n feedstock effectively and its performance and cost effectiveness is highly dependent on the microbe strains present. Nutromex Biopack provides both bacteria and trace elements in one hit.

Tel: 01553 770092

www.omex.co.uk

New Product Literature from Thermaset Leading powder coatings company, Thermaset Limited, based in Tamworth, taffordshire, has launched a ne suite of product brochures.

The new range of individual A4 size publications covers Thermaset’s specification brochures for its pectra range and ipple Finishes, a description of its Hygienilac Antibacterial powder coatings and a Stock ange brochure he specification brochures include four pages of product samples demonstrating the e tensive ranges of colours and finishes available The Spectra range from Thermaset is new to the market and is a collection of diverse finishes hich are an e citing alternative to standard and BS colours.

For further information please contact en ennens at hemaset on 01827 55777 or email: ben@thermaset.co.uk. Web: www.thermaset.co.uk

Issue 20 PECM

13

Editors Choice SuperCORR A protects and lubricates Contacts on the new Charge/Sync Cable from Lifedge uper lubricant and protective coating idely used by the military, electronics and aerospace industries for critical applications is used to protect contacts on the ne ifedge lightning connector to cable to offer the protection needed in e treme conditions uper deposits a dry protective film ith e cellent corrosion protection and lubricant properties plus the added advantage of a hydrophobic surface re ecting ater that ensures the easiest and best connection for the very close spaced connectors ifedge is the orld s first aterproof, rugged ightning to cable for charging and mobile connections hatever the eather or conditions eveloped for use in all outdoor activities including sailing, hiking, military, naval, surveying or other challenging uses ith an ultra durable outer coating that ill never fray and double moulded, super tough plugs, charging, do nloading and data transfer is improved even in the most e treme and difficult conditions

Tel 0208 281 6370

www.envirotech-europe.com

Engineering Utilities provides revolutionary equipment to leading machine components manufacturer eading supplier of metal finishing e uipment and consumables, ngineering tilities, has supplied a revolutionary surface finishing machine to precision machined component manufacturers, urner Following a competitive tender process, Engineering tilities on the contract to supply urner, based in eicestershire ith an innovative oe er deburring and edge finishing machine, hich as sourced e clusively from ngineering tilities team

ermany by the

he installation of the ne machine has resulted in a much uicker turnaround in the deburring process at urner, hich as previously conducted by hand his freeing up of capacity has allo ed the urner team to focus its efforts in other areas of the business, as ell as saving valuable man hours and associated costs

Tel: 0113 255 8887

www.engineeringutilities.com

ESTA’s newly designed FILTOWER series

GWR Colourfast® Is Capturing Industry Imagination

ith almost percent filtration efficiency, s ne ly designed F series helps significantly improve room air uality sed especially for those orking in manufacturing areas, contributing significantly to health protection

Fasteners imited, a multi a ard winning company, developed an innovative process to colour stainless steel fasteners and precision components olourfast® ince its initial development for the motorbike customisation market, it has attracted various industries such as food manufacturers, oil & gas, defence, electronics, military, dentistry and more

he filter to ers are suitable for supplementary orkplace ventilation ith e uipment for either elding fumes, fine dust or oil mist hese can also be used any here here direct e traction is not feasible, such as processing large ork pieces that involve constant changes in ork location

his process runs alongside Fasteners standard range of fi ings e g nuts, bolts, scre s, ashers hich are on their ebsite, ho ever, it can also be applied to stainless steel special fasteners and precision components hich the company has the capability of manufacturing at their facility based in s estry, hropshire

Email: enquiries@mccarthy-environmental.co.uk www.mccarthy-environmental.co.uk

For more information, visit the company s ebsite www.gwr-fasteners.co.uk or contact ude obinson, ommercial irector via email jude@gwr-fasteners.co.uk or telephone 01691 654979

FlyMarker® mini: Most likely the lightest, battery operated hand-held marking unit in the world

Securikey works the room with its new Modulprim features

arker®

he ne hand held marking system Fly mini is already the fourth generation of the mobile dot peen marker e t to its attractive price price performance ratio, the system for durable markings is characteri ed by its light eight of only kg and its high uality construction he marking unit convinces ith fast marking times and an intuitively to operate soft are haracters, numbers, logos or ata atri odes can be marked into nearly any material – from plastics, aluminum, stainless steel up to hardened steel ubse uent processing such as sand blasting, coating etc mean not a problem in most cases he marking remains visible

Email: mtaylor@lasersystems.ltd.uk www.lasersystems.ltd.uk

Eurotherm Online Tools for Trouble-Free Audits in Process Industries

he ne ompact emperature alibrator from ensors, est alibrations are engineered for “advanced simplicity , incorporating a number of useful features that greatly e tend the range and functionality of their popular temperature calibrator

rot erm nline er ice o er better management of compliance and calibration records.

he crisp, full color display, ith improved navigation, provides easy access to the ne features he no contains an auto step function ith up to preset temperature points, an optimi ed s itch test ith automatic up and do n test runs, assisted manual calibration using pre defined temperature points, and memory to store up to calibration processes n addition to the ne features, the includes improved accuracy ith as much as , and a broader temperature range from to ike other high end ofra temperature calibrators, the also no includes an optional input for a reference temperature probe, to increase the accuracy even more

14

PECM Issue 20

ecurikey s odulprim components have no been adapted, using ne materials, to provide further options, ease of installation and accessible space e light eight panels combined ith reduced steel ork decrease the eight of the original odulprim by up to For further information contact ecurikey td tel no 01252 311 888, email –enquiries@securikey.co.uk eb www.securikey.co.uk

New Compact Temperature Calibrator brings a new user interface and increased accuracy to Ametek STC

For more information on the full line of calibration products, contact est alibration hone +45 48 16 80 00, e mail Jofra@ametek.com, ebsite www.ametekcalibration.com

eading physical security specialist, ecurikey, has made innovative modifications to its range of odulprim security rooms he odulprim is a bespoke modular vault solution for both ne builds and e isting buildings and is a convenient and cost effective method of adding a high security strong room to a building he odulprim offers a complete storage facility for money, documents and pharmaceuticals and is adaptable to most building specifications, even those ith limited space or those located on upper oors his impressive level of adaptability has no been increased further ith the introduction of ne lighter eight materials to offer even further convenience and more storage space

e t month urotherm by chneider lectric launch urotherm nline ervices n integrated online platform and management tools for overseeing calibration records and regulatory status “ he tools are completely scalable and relevant to small manufacturing and large, multi site businesses, says hristopher sh orth, anaging irector, “ hey offer a more efficient ay of handling plant ide process information, enabling users to convert data uickly into the information re uired and that is hat the ndustrial nternet of hings is all about

ensors,

Eurotherm.co.uk

Frustrated by conflicting CAN Protocols refusing to communicate with each other? ommunication standardisation for lift-truck control can seem like wishful thinking, but savvy engineers can make devices from different manufacturers all speak one common control language, thanks to the capability of urtis controllers aving selected their ideal set of devices, frustrated engineers regularly find some on t communicate ith others, forcing them to approach manufacturers for e pensive and time consuming modifications to be performed void this scenario entirely by selecting a e uipped urtis motor controller that acts as an “interpreter for devices on the bus, translating different protocols into a single new common language without delay and fuss his simple, lo er cost solution can be done without assistance from urtis although support engineers are available for assistance with customisation if preferred

a configurations, so electronic y by ire control of all vehicle functions is preferred he vehicle developer was insistent that the steering had to simulate the feel of a hydrostatic steering system his limited the devices for the man-machine interface forcing the developer to choose a device that only ran a custom version of bit Curtis enGage VII colour LCD instrument as chosen to provide battery status and heel position indication plus on vehicle diagnostics, real-time monitoring of critical vehicle information and speed he final selection of control devices meant three different protocols ere on board re uiring a separate and e pensive system master module ould be re uired to pull all three into line, and asked for Curtis UK’s customer support engineers for help ithin an hour of arriving on-site, the Curtis engineer had set the odel traction motor controller as the system aster controlling all different protocols imple, yet efficient

ecently, a developer orking on an electric long load forklift pro ect re uired a remote seating position ithin a rotating cab, providing the operator ith a safe, clear vie of operations facing the direction of travel echanical linkages or hydraulic hoses are problematic in such

Fle ible and reliable is ust one of several interesting functions that characterise the urtis motor controllers hey utilise an advanced indirect field orientation F vector control algorithm that provides the ma imum possible tor ue and efficiency

C

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PECM Issue 20

across all loads and speeds and the comprehensive logic allocation is enough to handle the requirements of almost any application or operator command control devices, regardless of the communication standards they use In summary, Curtis Low voltage nduction and motor controllers give vehicle designers an easy opportunity to use ne vehicle configurations, or fully optimise the energy efficiency of their vehicle, at the same time as reducing the overall comple ity of their control systems presents endless options to create a virtual system controller by integrating all control devices for hydraulic and electric drives and manmachine interfaces into one system that accommodates differing protocols, even IC engines or transmissions can be included ngineers can e plore the benefits of easily implemented custom functionality, safe in the knowledge that e pert urtis customer support engineers are ready and aiting to help out if re uired For further details contact Curtis UK on 01604 885201 email: info@curtisinst.co.uk or visit www.curtisinst.co.uk

Temperature Monitoring makes Sense!

LumaSense’s E2T QUASAR family of detection systems are built for continuous duty monitoring of pilot flame (PM), flared gases (FM), and smoke particulate (SM) from flare stacks.

Professional Infrared Monitoring equipment helps to keep valuable assets efficient and safe

L

umaSense Technologies, Inc.® has developed a wide range of specialized products and solutions for the most critical temperature and gas applications in the Petrochemical industry.

The Company’s temperature solutions utilize single spot infrared radiation pyrometers as well as thermal vision and imaging systems to accurately monitor processes and provide accurate temperature readings. Their Gas solutions consist of analyzers, monitors, and detectors using the accurate and proven Photoacoustic pectrometry and on ispersive nfrared technology

LumaSense’s E2T PULSAR products solve your furnace temperature measurement requirements with sophisticated infrared technology.

Flare Stack Monitoring ilot ame detection must be monitored to assure ignition of ared gases during are operation ontinuous monitoring of pilot ames and ared gases is critical to ensure that the gases will be ignited and to confirm compliance ith government set pilot status recording requirements. hermocouple failure, ame movement, varying luminosity and adverse climatic conditions are ust a few of the obstacles which have to be overcome to gain long-term monitoring

make it nearly impossible for traditional temperature-measurement methods to monitor every critical point or to obtain complete temperature data. The lack of accurate and early detection of temperature changes increases the likelihood of failurerelated problems, which create safety and reliability issues.

LumaSense thermal imaging cameras and uma pection systems accurately measure temperature and operate by using reliable infrared technology. These high-tech instruments can operate remotely and can precisely determine the ob ect temperature and temperature distributions, even on small ob ects These systems also have the ability to see through ames and detect weak parts before they lead to critical damage.

Sulfur Recovery Unit (SRU) Monitoring Optimal operation of Sulfur Recovery Units (SRU) requires measurement and control of a complex sequence of processes. Of particular importance is control of the reaction furnace temperature to prevent damage to the refractory at high temperatures and ammonium salt from plugging the converters at low temperatures.

Installations that use the reaction furnace to incinerate waste gases like ammonia and hydrocarbons must maintain an adequate temperature to assure their destruction. Advanced processes, such as O2 enrichment, normally involve even higher temperatures and demand close monitoring.

reliability without false alarms.

Contact: Gerard Ames, LumaSense Technologies BV Tel: +31 165 381 800 Email: info@Lumasenseinc.com Web: www.lumasenseinc.com

LumaSense’s E²T QUASAR family of detection systems are built for continuous duty monitoring of pilot ame , ared gases F , and smoke particulate from are stacks.

The sight through optical system and choices of fields of vie allo the QUASAR to be positioned up to 400 m from the are stack Monitoring of Critical Assets Critical vessels and manifolds in refineries operate at high temperatures and high pressure and are at risk of failure as oints and refractory degrade. Extreme temperatures and non-uniform temperature gradients

LumaSense’s E2T PULSAR products solve your furnace temperature measurement requirements with sophisticated infrared technology.

News & Events Altus Successfully Showcases Solutions at the Southern Manufacturing and Electronics Exhibition Leading distributor of capital equipment for electronics assembly, Altus Group, welcomed many visitors to the annual three-day Southern Manufacturing and Electronics exhibition in Farnborough from 9-11th February by showcasing its latest range of ”state of the art” manufacturing and inspection equipment, for the SMT assembly industry from world leading manufacturers.

The latest industry trends and developments have centred on intuitive 3D AOI and SPI inspection equipment, which advances the imagery capabilities of its 2D counterpart to provide high quality and accurate measurement, with minimum escapes and false calls.

Altus presented Koh Young’s Zenith full 3D AOI System at the exhibition, enabling visitors to get a first hand look at ho the system inspects and provides uantitative measurements of components.

www.altusgroup.co.uk

Teconnex clamp onto JET PRESS

Onsite Calibration Nationwide oung alibration offer on site calibration services for Flow, Temperature, Pressure, Electrical, Mass and Humidity type sensors.

Independent, and providing cost effective and uick turnaround calibrations for a range of industries, their field based engineers are able to visit your site on daily terms and minimise your operational interruptions. The company also holds ISO 17025 UKAS accreditation for onsite calibration of electrical and pressure instrumentation and UKAS accreditation for air velocity anemometers returned back to the laboratory.

For more information visit www.youngcalibration.co.uk To book a calibration, contact Young Calibration on 01273 455572 or email ay@youngcalibration.co.uk

“Far more than a Thermal Fluid Firm” TFS Hits 20 and Shares Secrets of Success

Fasteners and components distributor JET PRESS have teamed up with UKbased world class manufacturer of pipe and hose ointing solutions econne to supply their range of clamping products.

Parts are utilised by engine and vehicle manufacturers in a wide range of applications. These include turbo chargers and exhaust after treatment applications, plus aerospace, marine, power generation, oil and gas production as well as the pharmaceutical, petrochemical, food and beverage filtration processes

Pioneering technology and a service predicated on risk-management lie at the heart of the success of the first company to bring thermal uid reconditioning to process industries worldwide, according to UK system support and maintenance provider, Thermal Fluid Solutions Ltd, in its 20th anniversary year.

F as the first firm to offer thermal uid reconditioning, facilitating the maintenance of vital uid safety parameters such as minimum ashpoints uick, cost effective, environmentally sustainable alternative to replacement, uidfit e tends uid life by a factor of at least , saving customers up to of their thermal uid costs ince its launch as eat ransfer ystems in , erbyshire based F has reconditioned over 10 million litres of thermal oil across 150 systems in 15 countries, saving customers in excess of £20 million in the cost of replacement oils, excluding the cost of disposal and downtime. “One of the things we’ll be doing in our anniversary year is developing our riskmanagement offer further, and e look for ard to sharing details of this with the industry

A standard size range of Teconnex 304 grade Stainless Steel Hose Band Clamps (these include V Band Clamps, Slip Joints and Flange Assemblies) are available from stock and can normally be shipped on the same day from JET PRESS.

later in

www.jetpress.com

www.t erm lfl i

SWINDON Silicon Systems launches its new website

Axion Polymers presents recycled engineering grades at PDM Event 2016

ne , informative and intuitive ebsite has been launched by Silicon Systems, one of the world’s leading designers and suppliers of mi ed signal pplication pecific ntegrated ircuits s he ne ebsite has been designed to re ect s position as a global leader in ASIC design and supply for industrial and automotive sensor interfaces. As well as including information on the solutions offered by the company, it is set to become a valuable resource for design engineers and decision makers providing valuable information to support their decision making process when sourcing an ASIC supplier.

ol tion .com

eturning to vent on tand , plastics recycler ion olymers ill be presenting its range of Axpoly® high quality recycled engineering polymers suitable for in ection moulding Created from a fully-integrated recycling process for end-of-life vehicles (ELV) and WEEE materials, all grades are fully traceable from the end user polymer grade back to the origin of the source material.

he ebsite has been optimised to be e tremely user friendly avigation is no intuitive and users can uickly and easily find information on their specific industry solutions ver mindful of the increased use of tablets and mobile phones for surfing the internet on the move , the site is also completely scalable and can be viewed comfortably on all devices.

ion s control of the entire process means it can offer a consistent polymer supply and price stability because its cost of incoming raw material is not linked to volatile oil markets. Manufactured to strict quality standards, all Axpoly grades are REACH-ready and RoHS-compliant. On display will be the HIPS (High Impact Polystyrene), ABS, polypropylene (PP) and polystyrene (PS) grades, all of which can be customised to satisfy the demands of customers’ application requirements.

www.swindonsilicon.co.uk

For more information, contact Axion Polymers on 161 737 6124 or visit the website - www.axionpolymers.com; @axionpolymers.

Reference manual of best practice for operators of FRP

Campaigning for product traceability

JMC Composites Ltd. has published a reference manual of best practice for operators of F fibre reinforced plastics assets such as pipes, tanks, dual laminate tanks, access structures etc. used within industrial sites such as power stations, water distribution, waste water treatment, chemical process plant etc.

The manual is designed to enable the managers of FRP assets to adopt best practice for the specification, installation, operation, maintenance, inspection and repair of tanks, pipes and access structures fabricated from FRP.

Hot on the heels of announcing the stamping of CE Marking on their leaf chain range, onghua has confirmed that all leaf chain will now come with a DEKRA certificate, here applicable Donghua Limited, the UK arm of one of the world’s largest chain manufacturers, CE Marking plate is available either in black or silver for ID purposes. announced recently that they are stamping CE marking on all their leaf chain products sold across the European Economic Area (EEA). CE Marking reassures customers that the manufacturer takes responsibility for the conformity of their product to applicable EC safety directives.

The manual is written and compiled by specialists with many years experience in the use of fibre reinforced plastics

he company is supporting this move even further by issuing a certificate alongside their usual product test certificate provides an independent review of whether the product complies with relevant European criteria.

Email: info@jmccomposites.co.uk

For more information visit www.donghua.co.uk/leaf-chain, email sales@donghua.co.uk or call 01902 866 200

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PECM Issue 20

www.jmccomposites.co.uk

News & Events

Schwer Fittings lead the way in stainless steel connection technology. Manufacturers and suppliers of high precision stainless steel tube components and hose fittings, with a technically trained sales team and a BFPA authorised training centre.

With most products available from stock in Warrington, Schwer can supply a next day service throughout the UK. Threads available include BSPP, BSPT, NPT, Metric and JIC; hose tails include standard and interlock; DNV certified compression fittings in single and twin ferrule; LP and HP valves.

Schwer enjoys an enviable reputation in the stainless steel industry for unrivalled service levels, components built for longevity and guaranteed 100% traceability across all products. In addition to holding German Lloyds classification for more than ten years, Schwer also holds DNV, ABS, GOST and RINA certification.

Schwer Fittings Ltd, Warrington Tel: 01925 639006 t Fax: 01925 639007 t Email: Info @schwer.co.uk t www.schwer.com

Process

SuBScriBE nOW Every issue of the magazine contains the latest news, in-depth features, together with product innovations and case studies showing how process engineers are implementing new technologies to reduce costs and impact on the environment.

Process

Engineering Manufacturing

Control &

Manufacturing

Control &

Engineering

www.pecm.co.uk T: 01843 830249

PECM

Global Success Through Innovation Issue 20 2016 ÂŁ3.95 www.pecm.co.uk

6 Issues For Only

ÂŁ27

Meeting the DeManD - 70

Safety anD health expo - 24

planetary gearheaDS - 38

Process control systems are becoming more complex; they are subject to greater scrutiny due in part to the demand for improved efficiency,

The only place in the UK where all key associations, manufacturers and distributors come together with industry leaders.

As industry becomes more automated and robotised the need for high precision gearboxes in machinery and plant engineering grows.

Call Us On 01843 830249 NOW Issue 20 PECM

19

Protection & Management Series Colonel Tim Collins OBE, Kate Adie OBE And James Cracknell OBE To Headline A Stage Of 300+ Speakers At Protection & Management Series

I

FSEC International and

safety, facilities and service management,

International and FIREX International

FIREX International,

taking place at London’s ExCel from 21-23

are part of UBM EMEA’s Protection &

organised by UBM EMEA,

June 2016.

Management Series, the UK’s largest event

have today unveiled the

dedicated to protecting and managing

speaker line-up for the Protection and

Headlining a programme of more than

Management Series 2016, Europe’s leading

300 speakers will be keynote addresses

events for security, fire, safety, facilities

from Colonel Tim Collins OBE, Kate Adie

The series incorporates major events

and service management, taking place

OBE and James Cracknell OBE, truly

Safety & Health Expo, IFSEC International,

at London’s ExCel from 21-23 June 2016.

inspirational speakers who have shown

FIREX International, Facilities Show along

Headlining a programme of more than

grit and determination in the face of

with Service Management Expo and

300 speakers will be keynote addresses

adversity. Further speakers will cover

attracts more than 40,000 attendees

from Colonel Tim Collins OBE, Kate Adie

sector specific case studies, best practice,

annually over three days to ExCeL London.

OBE and James Cracknell OBE, truly

training and legislative updates, click here

The series of events will run from 21-23

inspirational speakers who have shown

for the full IFSEC International line-up or

June in 2016 at ExCeL London.

grit and determination in the face of

click here for the full FIREX International

adversity.

line-up.

property, people and information.

Colonel Tim Collins OBE will speak on Tuesday 21st June from 11.30 – 12.30,

Commenting on the line up, Charlotte

Kate Adie OBE will speak on Wednesday

Wright, Senior Content Manager for

22nd June from 11.30 – 12.30 and James

Protection & Management “A wealth of

Cracknell OBE will speak on Thursday 23rd

18 month research with the security, fire,

June at 11.30 – 12.30.

safety, facilities and service management

The Inspirational Speaker Series will be

communities has resulted in the most

hosted in the Keynote Theatre at ExCel

focused programme that the Protection

London.

& Management Series has ever seen.

Stages this year will welcome a mix of

To register to attend and hear from these

inspirational stories from our headline

great speakers plus much more, please

speakers with practical and insightful

visit:

sessions from top speakers and trainers. We can’t wait until June!” IFSEC

IFSEC International –

International and FIREX International,

www.ifsec.co.uk/keynote-release

organised by UBM EMEA, have today

FIREX International –

unveiled the speaker line-up for the Protection and Management Series 2016,

Commenting on the line up, Charlotte

Europe’s leading events for security, fire,

Wright, Senior Content Manager for Protection & Management “A wealth of 18 month research with the security, fire, safety, facilities and service management communities has resulted in the most focused programme that the Protection & Management Series has ever seen. Stages this year will welcome a mix of inspirational stories from our headline speakers with practical and insightful sessions from top speakers and trainers. We can’t wait until June!” IFSEC

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PECM Issue 20

www.firex.co.uk/keynote-release

Access to leading global technology, solutions and knowledge to ensure life safety Driving global expertise and guidance in life safety 3 Learn best practice in life safety from industry leaders in the FIREX Theatre 3 Explore and learn about competency best practice at the FPA Infozone 3 Get the best advice in fire stopping from the ASFP 3 Learn about the latest legislation and how it will affect you @FIREXIntl #FIREX2016

REGISTER FOR YOUR 2016 BADGE TODAY AT WWW.FIREX.CO.UK/PECM In association with

Partnered with

Organised by

Part of

UK Manufacturing Excellence Highlighted at NEC Extravaganza

B

ritish manufacturing and

tasking culture of today’s design engineer,

machines. Vanda Jones, BCAS’s executive

engineering excellence

covering critical areas such as energy

director, commented: “Air-Tech was a

was said to be ‘well and

efficiency, machine safety, drives, motion

great show for BCAS. BCAS hosted its

truly alive and kicking’

control, robotics and automation all under

spring conference at Air-Tech, which was

one roof.

attended by members from both the

according to the organiser of the recent co-located of events; Drives & Controls, Fluid Power & Systems, Plant and Asset Management, European Offshore Energy, and Air-Tech Exhibitions, which returned to Birmingham’s NEC last month (12-14th April), alongside MACH 2016 and National Electronics Week 2016.

Collectively the exhibitions made up the

For the first time the show also included a dedicated area where some of the latest industrial robot technology were demonstrated. Interest in robotics is growing rapidly as the significance of smart factories continues to rise, and prices come down and capabilities increase.

largest manufacturing and engineering

procurement and energy generation.

discussions. Speakers offered expert views, information, guidance and advice on a

The demo attracted many big names

wide range of important and topical issues

including: ABB Robotics, Applied

relevant to each show.

Engineering, B&R, Harmonic Drive AG, Mitsubishi, Universal Robot, RA Rodriguez, Staubli, Active8 Robots Ltd. There were several examples of the new generation of “collaborative” robots – or “cobots” – designed to operate safely alongside human workers, without needing a protective cage.

the industry sectors represented by these

Show organiser, DFA Media, explained that

exhibitions.”

SM&F will drive the technology revolution

attracted a mix of first-time exhibitors and established regulars, and brought together key suppliers of state-of-theart equipment representing the multi-

22

PECM Issue 20

right audience. All in all a very successful

production, design, maintenance, upgrade,

more than 50 technical seminars and panel

Drives & Controls Exhibition & Conference

impartial expert advice to exactly the

offshore energy marketplace – exploration,

in the hundreds of delegates attending the

market strength and optimism felt within

an excellent opportunity for us to provide

service providers for the entire upstream

optimism. The success was also reflected

we believe reflects the continuing overall

traffic was brisk on all three days and it was

one roof, suppliers, manufacturers and

to date, and highlighted industry

alike has been highly encouraging, which

knowledge base on the website. Show

also returned to bring together under

the 2016 co-location the most successful

we received from exhibitors and visitors

survey, our technical guide and the new

European Offshore Energy Exhibition 2016

official attendance figure of 13,115 made

yet for the co-located shows. The response

use the platform to launch our end user

contacts and existing members.”

Show organiser, DFA Media, said the the

Atkinson, said: “This was the best outing

For the end users we were also able to

three days; it enabled us to link with new

events of 2016.

DFA Media managing director, Ian

manufacturer and distributor sectors.

in factories where they become more

Ryan Fuller, commercial director at DFA Media (Energy Division), commented: This year’s event came at a time of significant challenge for the offshore industries, and it is why as organisers of European Offshore Energy 2016, we were heavily focused on helping visitors find ways bringing costs down and improving efficiency through the latest technologies and services in the offshore industries.”

The biennial co-location of events returns to Birmingham’s NEC alongside MACH between 10 – 12th April 2018.

automated, IT driven, proficient, smarter,

www.maintenanceuk-expo.com

safer and sustainable and simulate the

www.drives-expo.com

greater use of automation, efficient data

www.fluidpowersystems-expo.com

exchange, new technologies, processes

www.europeanoffshoreenergy-expo.com

and the networking of products to

www.airtech-expo.com

Drives & Controls Review

TransDev is the Power in Motion at Drives & Controls 2016 ransDev exhibited at the bi-annual Drives & Controls 2016 Exhibition at the NEC in April.

Their stand at 40 square metres provided them with the perfect platform to showcase what they do and how they help a wide audience of OEMs, trade, distributors and endusers.

T

This was the first time for several years that TransDev have exhibited and they enjoyed meeting customers old and new, as well as those who wished to learn more about their 50 year old business. New branding and comprehensive literature redesigns were on show alongside exciting hands-on product displays, including an exclusive Continental belt driven electric bike as well as a six axis robot from ST Robotics featuring SYNCHROCHAIN pulleys and belts.

As the UK member of MULCO (the organisation representing major PU brands) visitors saw world class PU belt technologies from German

manufacturers, such as BRECO and ContiTech. They also showcased new brands such as BRECOFLEXmove®, CONTI-V® FO Pioneer and their own Transflex rubber belts.

Their Special Belts were on display and took centre stage on the stand. These are manufactured at their factory in Poole and cover everything from special profiles and flights to backed belts, draw-down belts, jointed and extra wide belts. The possibilities, like some of their belts, are endless and they are experts at delivering the most complex belting solutions, within microns of pitch accuracy.

Chain brands such as Wippermann, TYC and Witra® plus hardware, gears, sprockets and pulleys all ensured that customer’s power transmission and conveying needs were fully covered in one place. As a major pulley, gear and sprocket manufacturer they can discuss standard and custom requirements and can work with customers to develop drive solutions for a vast array of applications.

Request the NEW TransDev Range Catalogue at www.transdev.co.uk/ catalogue

Email: sales@transdev.co.uk www.transdev.co.uk

8. 0DQXIDFWXUHUV

P Issue 20 PECM

23

afety and Health Expo is

As well as unparalleled sourcing

Bringing together 1000 successful women

the only place in the UK

opportunities, the show will provide

working in health and safety, security,

where all key associations,

visitors with over 80 hours of free theatre

fire, facilities management and service

manufacturers and

content across 7 theatres. Topics range

management, #SHE1000 will include

distributors come together with industry

from engaging the board, to CDM and

a presentation on networking from

leaders, giving visitors access to all the

sentencing guidelines, and seminars

expert Heather White, followed by the

expertise and networking they need.

will be presented by experts such as

opportunity for attendees to practice their

John Green from Laing O’ Rourke, David

new skills over prosecco.

S

Showcasing THE largest collection of

Snowball from HSE and Emma Head from

health and safety products in the world

HS2.

Safety & Health Expo is proud to be

under one roof, Safety & Health Expo 2016

partnering with the Professional Clothing

will host over 300 exhibitors providing

Show in 2016. This dedicated exhibition

solutions across every area of the industry,

and catwalk presentation will provide

from PPE to asbestos control, and more.

more PPE options than ever before

Visitors will also be able to visit the

allowing visitors to source the latest

co- located shows in the Protection &

developments in clothing and equipment.

Management Series - IFSEC International, FIREX International, Facilities Show and

The BSIF Safety Awards will take place

Service Management Expo - providing

on the first day of the show, recognising

access to a further 1300 exhibitors and

excellence within the safety industry,

over 20,000 solutions across security,

excellence in customer service and in

fire, facilities management and service management.

The show will also welcome three keynote speakers to the stage – Kate Adie OBE,

product innovation, with the key goal of improving occupational health and safety.

To ensure that visitors and exhibitors

James Cracknell OBE and Colonel Tim

The RoSPA Occupational Health and

maximise their time at the show,

Collins will share lessons for success from

Safety Awards will also host a prestigious

the Meetings Service will provide

their illustrious careers.

presentation ceremony at the show, recognising individual’s commitment

a bespoke and tailor-made hosted buyers’ programme bringing together

Safety and Health Expo is a celebration

to maintaining and improving safety

manufacturers and distributors from the

of the great work health and safety

standards.

exhibitor base with visitors to Safety &

professionals do. 2016 will see the launch

Health Expo. Visitors and exhibitors will be

of a number of new initiatives including

To attend the UK’s largest health and safety

able to search for and request meetings

The Rising Star in Health and Safety

event please visit

with others, and will also be given

Awards Ceremony which will celebrate

www.safety-health-expo.co.uk/PECM/

suggestions from the organising team

the future leaders of the profession, and

who can broker meetings with potential

#SHE1000, promoting the many women

prospects on their behalf.

protecting and managing people and buildings.

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PECM Issue 20

Be part of the transformation 3 Be part of the transformation driving health and safety in your organisation from compliance to engagement 3 Evaluate THE largest collection of health and safety solutions in the world under one roof 3 Boost your CPD points with over 80 hours of free theatre content across 7 theatres 3 Celebrate excellence with events recognising up and coming talent in the profession and #SHE1000 celebrating the many women protecting and managing people and buildings

DON’T MISS OUT. SAVE YOUR PLACE AT SAFETY-HEALTH-EXPO.CO.UK Your badge also gives you entry to:

Partners

Supporters

Official Media Partner

Organised by

Part of

Get the best products in the industry at the leading security exhibition and be secure The global stage for security innovation and expertise

3 Pre-book 1-2-1 meetings with the suppliers you really want to do business with the “Meetings Service�

3 Learn from experienced security professionals and develop your knowledge by attending free seminars 3 Grow your network through connecting with over 27,000 of other leading security professionals 3 See the evolution of security systems in the Smart Zone, looking at Home Automation & Smart Buildings 3 Addressing the demand in physical and perimeter security, visit the dedicated zone to find the right product for your business

REGISTER TO GET YOUR BADGE TODAY AT IFSEC.CO.UK/PECM Your badge also gives you entry to:

Supported by

Organised by

Part of

IFSEC International

Restoring a classic S

ince its inception, David Marks Garages has built up a reputation for competent and attentive servicing, with expertise in complex diagnostic procedures of the main electrical systems found within cars.

Reviving the Lagonda In 2003, the business expanded into repairs of the Aston Martin Lagonda.

As Lagonda’s were electronically advanced when they launched in 1978, the electrical systems, such as their multi-tactile switches, can need a lot of attention. It was therefore important that David Marks found a specialist manufacturer who was prepared for the challenge of replicating electrical dashboard panels and switches that could be up to 40 years old.

Aston Martin Lagonda Membrane Keypad

David Marks Garages and Fascia David Marks Garages first started working with Fascia Graphics 10 years ago, and they have since worked on eight different projects, which have all been electrical system related.

Fascia encountered a variety of challenges when developing these products. These varied from having to match the exact texture, colour and translucency of the original panel, while also ensuring that the heat from the backlighting would not degrade the panel over time. All while working with components that are no longer widely available. For instance, Fascia needed to source special connections so that the original Aston Martin ribbon cables could plug-in to the new panels.

The most recent and complex project was for an Aston Martin Virage. David Marks said: “Fascia Graphics had to get this multi-layered panel right and ensure it was as true to the original as possible. They also had to reverse engineer the complex electrical matrix that appeared underneath the touch button panel. But no challenge has seemed too big for Fascia Graphics.”

David Marks with an Aston Martin Lagonda

“In the ten years that we have worked with them, I have found them unbelievably accommodating and flexible. They quickly understand what needs to be done, and they have consistently demonstrated an ability to always meet timeframes.”

Fascia Graphics Bath Road Industrial Estate Chippenham Wiltshire SN14 0AB sales@fasciagraphics.co.uk Tel: 01249 460606 Issue 20 PECM

27

StuvEx Safety Systems Abbey Studio, Church Walk, Chertsey, Surrey KT16 8RE - United Kingdom

Tel: +44 (0)1932 571303 - Fax: +44 (0)1932 570548 E-mail: info@stuvex.com - www.stuvex.com

Axis introduces the first of a new generation of smaller, more cost-effective modular cameras for exceptionally discreet surveillance xis Communications, the market leader in network video, today adds a high performance HDTV 720p camera to its AXIS P12 Series of complete modular cameras for highly discreet surveillance. Compared with its predecessors, AXIS P1244 is smaller in size for easier, more versatile mounting. It offers better image quality in low and varying lighting conditions, provides improved video compression and analytics capabilities, and is affordably priced.

A

“The combination of better performance and a smaller size and price makes AXIS P1244 an attractive product for customers who are looking for a cost-effective, highly discreet surveillance solution,” says Erik Frännlid, Director of Product Management, Axis Communications.

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PECM Issue 20

Modular concept The modular concept divides a camera into different parts: a sensor unit comprising a lens and an image sensor, a main unit that houses the processor, network and power connections, and a cable that connects the sensor unit to the main unit. The modular concept allows for the discreet installation of a small sensor unit where needed while the main unit can be placed elsewhere where there is space.

Compact design AXIS P1244 comprises a sensor unit with a 102° horizontal field of view. It can be mounted in tight places, or in walls or ceilings with the included flush mount kit.

Optional accessories enable the sensor unit to be tilted in a surface or recessed mount.

The sensor unit comes with an 8-m (26 feet) cable for connection to the main unit.

The main unit of AXIS P1244 is three times smaller than previous AXIS P12 main units.

High-performance AXIS P1244 supports full frame rate HDTV 720p videos, Zipstream technology for lower bandwidth and storage use, Power over Ethernet (PoE) for easy installation, and a microSD card slot for local storage. It has built-in Active Tampering Alarm and Video Motion Detection, and has a greater capacity to support additional video analytics that are compatible with AXIS Camera Application Platform.

AXIS P1244 is supported by the industry’s largest base of video management software through the Axis Application Development Partner (ADP) Program as well as AXIS Camera Station and AXIS Camera Companion. ONVIF support allows for easy integration with a wide range of video surveillance systems. www.axis.com

Innovation and Opportunities in Plastics Design & Moulding

T

he latest scientific

Rotomoulding will then become the focus,

discoveries, ground-

with a session on alternative materials

breaking new technology

presented by Matrix Polymers, and advice

and innovative approaches

on preventing “creep” – a cause of plastic

to design feature at this year’s PDM Event,

product failure – presented by Dr Nick

taking place at the Telford International

Henwood, Rotational Moulding Expert,

Centre from 14 to 15 June 2016. A true

Rotomotive.

showcase of the UK’s dynamic plastics sector, the free-to-attend PDM Event

Scott Crowther, Innovation Manager at

offers an all-encompassing exhibition and

Warwick Manufacturing Group will present

conference for plastics design, moulding,

on Industry 4.0, outlining what it is, why it

packaging and recycling.

is important and how SMEs can embrace it.

Robin Kent of Tangram Technology follows

This year’s PDM Event features two free-

him with an overview of energy efficient

to-attend conference programmes. The

equipment, which will show how real

PDM conference covers moulding, design,

savings that can be achieved by updating

materials and industry innovation across

or replacing existing machinery.

the medical, automotive, packaging and construction sectors. The parallel PRE conference focuses on plastics recycling.

PDM Conference Injection moulding will be covered in depth on the first day of the PDM

Moulding experts from British Plastics Federation (BPF), Engel, Helix Polymer Technology Ltd, Stratasys, Arburg and Amtek Plastics will all participate in a panel discussion on recent innovations.

conference. Martin Neff, Team Manager

Jason Lessard, European Patent, Trade

Technology Consulting – Plastics

Mark and Design Attorney and Patent

Freeforming will give Arburg’s perspective

Director, HGF Ltd will provide valuable

on freeformer additive manufacturing

guidance on patenting strategies in

versus conventional additive

injection moulding and plastics design,

manufacturing and Murdoch Crawford,

and explain how costs and risks should be

Category Director, Plastipak will provide

evaluated.

Day Two opens with a number of new perspectives on design. Andy Ditchburn, Creative Director, Perro Design and Communications will explore how integrating design with social media and marketing can be used for predicting future design and market trends.

The PDM Event exhibition and conference is free to attend. Register now at: www.pdmevent.com

an overview of SprayPET technology developments.

Issue 20 PECM

29

PDM Show

Not sure who to go for Technical Support?

t Independent t Impartial t 'SFF BTTJTUBODF Try the RAPRA Polymer Helpdesk We are attending the PDM event – visit us on stand C002 to discuss your technical problems in person RAPRA Limited Business & Technology Centre University of Wolverhampton Priorslee Campus Teford TF2 9FT Tel: 01952 288 367 www.rapra.org

30

PECM Issue 20

Pentagon Plastics is a pro-active plastic injection moulding business based in Horsham, West Sussex. As a family run business that enjoys over 43 years of trading, we provide a depth of knowledge and skill to our diverse customer base.

Services offered here at Pentagon Plastics include Design Assistance, Development, Toolmaking and Injection Moulding.

As an experienced manufacturer of bespoke thermoplastic products we provide both mould tooling solutions and repeat production of injection moulded components to a wide range of industries.

We have experience in processing most types of thermoplastic materials including high engineering grades. We are able to provide low volumes in single figures up to batch sizes in the region of 150,000.

From design assistance at an early stage through to repeat production of your component including development options and complete manufacture of your mould tool you will benefit from a full in house service.

Email: gabby@pentagonplastics.co.uk www.pentagonplastics.co.uk

Discover hundreds of essential new engineering and operational products and solutions plus the very latest gamechanging technologies from hundreds of exhibitors and innovators. t

Discover new kit and cutting-edge supplier solutions

Explore the innovations that are

and industry leaders. 2016 content

transforming your industry, share

themes: innovation, skills, data &

knowledge with your network, and

analytics, customers, totex and resilience.

discover what’s driving engineering change in your industry.

The stellar line up of speakers and workshop leaders includes senior

Taking place 17-18 May 2016 at the

representatives from Energy Innovation

NEC Birmingham, Utility Week Live is

Centre, Energy Systems Catapult, Gas

the UK’s utilities event. With product

Industry Safety Group, E.ON, Future

demonstrations, exhibitions, seminar

Cities Catapult, RWE npower, National

sessions, technical pitches and

Joint Utilities Group, Ofgem, Gas

innovation zones, it brings the sights and

Industry Safety Group, Energy Networks

sounds of the utility industry workplace

Association plus many others.

to the show floor.

Get inspired in the CPD-accredited seminars and technical talks featuring the UK’s key innovators, game-changers

32

PECM Issue 20

2016 show theme: Innovation.

Book your free tickets today at www.utilityweeklive.co.uk.

t

Touch and feel hundreds of innovative new products

t

Fresh ideas and practical workplace tips

t

Experience the latest engineering and operational technologies

t

Hear from the innovators and game-changers

t

See tomorrow’s smart technologies today

t

Link up, socialise and network with your peers and colleagues

t

Inspiration from expert speakers and workshop leaders

t

Live demos, pitches and product launches

The essential show for essential services Explore the innovations that are transforming your industry, share knowledge with your peers, and discover what’s driving change in 2016.

Book your free ticket today

ESSENTIAL INFORMATION Hall 12, NEC Birmingham, B40 1NT 17th May 2016: 9.30 - 5.30pm 18th May 2016: 9.00 - 4.00pm

www.utilityweeklive.co.uk

Air, Gas & Odour Control As they are stackable, less storage space is taken up, and large handles enable effortless manoeuvrability. Anti-skid rubber feet ensure steady operation, and the rugged build of the machines means they are durable and weather resistant.

The Professional Choice for Portable Fume Extraction and Confined Space Ventilation T

he combination of dependable power and practical design makes the Miniveyor Air VAF series fans and ventilators the professional choice for portable dust and welding fume extraction.

As they are stackable, less storage space is taken up, and large handles enable effortless manoeuvrability.

Anti-skid rubber feet ensure steady operation, and the rugged build of the machines means they are durable and weather resistant.

Designed with a twin wall, rotationally moulded fan body, made from high density polythene, means the products can absorb bangs frequently experienced with industrial use, eliminating costly maintenance procedures. Compare this with conventional metal bodied fans that typically don’t last very long in the workplace, as the sheet metal bodied fans tend to dent easily when knocked, so they will need replacing. The plastic moulded fans from VAF Air are highly resistant so they can last a much

longer time. Additionally, all of the parts are replaceable so if anything does get damaged then they can be changed easily.”

The portable and reliable fans and blowers are both safe and suitable for use in confined spaces. Where fumes, smells or dust occur, the axial fans can extract contaminated air out of the building, and blow fresh, clean air into a workspace.

The VAF series range has recently been extended with the introduction of the VAF-200C Canister blower. Based on its popular VAF-200, the compact VAF-200C is ideal for confined space ventilation and fume extraction and benefits from a, simple to attach, Duct Canister that neatly clips onto the fan body and houses 7.5 metres of flexible duct. Designed for manhole work, It is great for telecoms of utilities contractors that have limited storage space in service vehicles and can be carried to the job site with ease.

Visit us online at www.vaf-air.com

Designed with a twin wall, rotationally moulded fan body, made from high density polythene, means the products can absorb bangs frequently experienced with industrial use, eliminating costly maintenance procedures.

34

PECM Issue 20

Boilers & Maintenance Babcock Wanson provides new boiler house & plant for Stolthaven Terminals

Handing over the torch at G P Burners

abcoc Wanson has desi ned a ne thermal fluid system to accommodate its hi h e ciency hermal Fluid eaters at tolthaven Da enham td bul li uid terminal situated on the river Thames in Dagenham, Essex.

Swindon based combustion equipment manufacturer, G P Burners (CIB) LTD, has appointed Daniel Goulding to the post of Managing Director. He replaces Jim Spearing, who is retiring after nearly 40 years in the post, during which he oversaw the acquisition of the company by Italian manufacturer, CIB Unigas S.p.A.

The site has been operating for many years, handling chemicals, petroleum, pharmaceutical and agricultural products, but more recently has added a bitumen facility to its portfolio. Originally operating at 134,000 M³, Stolthaven Dagenham has no expanded its capacity to 0,000 and is home to 20 tan s ran in from to 11,000 M³.

Babcock Wanson worked closely with Stolthaven Dagenham’s consultants to provide the final desi n of the boiler house and then install and fit it out ith its C and TPC B Thermal Fluid Heaters. A large proportion of the thermal design was also carried out by Babcock Wanson with the supply of all the system valves and ancillary equipment to provide a complete system with single point of responsability. The system also incorporates a secondary circuit to provide lower temperature thermal fluid for the bitumen pump casin heatin . he pro ect as a fast movin one ith tight deadlines, all of which Babcock Wanson met.

Babcock Wanson Tel: 020 8953 7111 Email info@babcock-wanson.co.uk www.babcock-wanson.co.uk

Large Scale Rotational Moulding Installation benefits from Lanemark Process Heating Technology he heatin e ciency of process as burner systems from Lanemark Combustion Engineering, and the company’s ability to work closely with customers to meet specific applications needs, have been clearly demonstrated through a ma or pro ect underta en by rotational mouldin specialists, Rotomech Engineering.

Daniel (33) has a BA in Business Management from the University of Gloucestershire. After graduating, he retrained as a commercial electrical en ineer, before oinin urners in 20 . Durin his time with the company, he has acquired a broad range of industry experience in a number of roles, most recently as a commissioning engineer.

Email: info@gpburners.co.uk

www.gpburners.co.uk

WTS Benefits from Economic Upturn Wellman hermal ervices, are benefitin 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 su cient ro th or stability for manufacturers to invest in new capital plant. Therefore the additional production demands must be met by existing plant.

Lanemark FD (forced draught) burners have been specified as a ey element in a lar e-scale roc -and-roll system – the latest facility to become operational at Etills, who produce a wide range of water storage tanks, vessels and containers for both public and trade markets across Europe and are well known for the ‘Ecosure’ brand.

Running and maintaining industrial heating plant, in some cases as much as sixty years old, re uires a lot of time and effort especially iven ne 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.

Email: info@lanemark.com

Tel: 0121 543 0000

www.lanemark.com

www.wellman-group.com

Issue 20 PECM

35

Stand Number P486 Fluid Power & Systems 2016

Implementing a calibration system?

Our calibration and IT expertise helps you face calibration process improvement projects that are typically complex and consume a lot of time and resources.

Only 20% to 30% of a calibration system upgrade is tools and technology, the rest is business culture and process. Therefore, the success of a new calibration system depends especially on the implementation of the system and the ability to define and adopt a new calibration process. We are the experts in both technology and implementation, so you can focus on the opportunities, while we support and guide you in the evolution of your calibration system and successful implementation of the calibration process change.

Learn more at: beamex.com/CalibrationProcessImprovements

www.beamex.com info@beamex.com

Calibration Solutions Leaders in bespoke calibration & test systems As Chell approaches 40 years experience of designing and building high integrity test and calibration systems, our engineers are ready to design complete solutions for your production calibration needs. + + + +

Pressure, Vacuum & Gas Flow

Automated Product Calibration All Cal. Standards to ISO17025 All Design & Build to ISO9001

Ask your engineers to call our engineers, they almost certainly speak the same language.

Chell Instruments Ltd www.chell.co.uk info@chell.co.uk +44 (0) 1692 500555

36 channel smart gas meter calibration system

Instcube

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Issue 20 PECM

37

Planetary Gearheads â&#x20AC;&#x201C; Their Time is Now A

s industry becomes

characteristics and advantages, so will

more automated and

know, for instance, when to specify

robotised the need for high

a servo motor rather than a stepper

precision gearboxes in

or which type of coupling to use in

machinery and plant engineering grows.

Ian Carr, Managing Director of Drive Lines in Bedford, explains how planetary gearheads have precision and power designed into them.

given situations.

It is fair to say that precision drive system designers make regular use of planetary gearheads. In fact they are used almost exclusively as the

Machinery and systems such as robots,

major joints in both articulated arm

packaging machines, pick and place

and delta robots, are ideal for many

units, tool changers in machine tools,

bespoke machines and are a firm

printing presses and welding systems

favourite for medical scanners. So let

all rely on precision motion. Likewise,

us look first at how they work, then

medical equipment, navigational aids and

at why they are good for precision

astronomical telescopes also need cutting

drives.

edge motion systems.

While at first glance some of these applications may seem to have little in common, in fact their power and motion systems are based on similar fundamental principles. Looked at as a drive system, the main requirements are in fact very similar: high torque must be provided, whilst low backlash is essential.

Operating principle Planetary gears are also called epicyclic gears or sun-and-planet gears, the latter being useful for helping visualise - their operating principle. Dismantle a planetary gear and at first it looks complicated, but you can soon identify a central sun gear, surrounded by, and meshing

To achieve this, torsional stiffness is

with, some planet gears. (Typically

required, and high acceleration and

there are three or four planet gears,

braking are often demanded. More often

but it could be fewer or more.)

than not, there is also the need for a

Holding the sun and planet gears

compact design, or the need to fit within a

together are an outer ring gear with

demanding space envelope.

internal teeth that mesh with the

Such drive systems have a high design content. Many are truly bespoke, one-off designs, while others may be customised variations of a standard design. However,

planets. There is also a planet gear carrier, but this does not transmit power rather being a structural element that keeps the gears in place.

like all drives systems they are typically

Significantly, while the sun gear

made up in large part from standard

rotates relatively quickly, the outer

components, servomotors, gearheads,

ring gear rotates more slowly. In

couplings etc.

fact the ratio of their two speeds is

Thus a precision drive system designer will select components, optimising one with the next with the ultimate goal of achieving each projectâ&#x20AC;&#x2122;s performance specification. They will also be aware that each type of component has certain

38

PECM Issue 20

derived from the ratio of their two diameters â&#x20AC;&#x201C; the planet gears act as idlers, their role being to transmit power between the sun and ring, in other words their diameter does not affect the overall speed ratio between input and output.

This configuration offers some very

Tilting and torsional stiffness are high,

significant advantages over other gear

leading to precise positioning and high

layouts. For instance, all the parts fit inside

repeatability. In fact the Melior Motion

the ring gear making it a compact unit.

was designed with robot applications very

Because there are a number of planet

much in mind, hence its compact size, low

gears, there are many teeth meshing with

maintenance, and high performance.

one another, each pair transmitting power

In conclusion we can say that planetary

and adding together to give a high torque

gearheads are enabling more and more

capability in a compact unit.

potential users to think about adopting

The multiple meshing of teeth also helps

precision servo drive technologies for their

to significantly reduce backlash compared

machines and systems. First time users

to a gear system where there is only one

in particular may appreciate technical

meshing pair. Also, because the power

support from a company like Drive Lines,

transmission is spread equally across each

which not only supplies gearheads and

planet gear, there is an innate symmetry

associated equipment but also has a

which helps prevent the gearhead from flexing under load.

Thus it can be seen that planetary gearheads have a lot to attract designers of precision drive mechanisms. They are

wealth of expertise and experience in Now to look in more details at a particular

specifying precision drives for a wide

planetary offering, letâ&#x20AC;&#x2122;s take the Melior

range of applications.

Motion range, again from Premium Stephan.

Established over 30 years ago, Drive Lines has worked on applications as diverse as

compact, powerful, accurate and robust.

This has many design details that help

hot drape formers, golf buggies, lifting

In order to make planetary gearheads

ensure performance is as precise and

systems, laboratory equipment, cement

even more attractive to potential users,

reliable as possible. For instance, the

mills drives and a door closure for a

manufacturers such as Premium Stephan

gear teeth have a unique profile that

medieval cathedral.

make them in a range of formats, so that

guarantees backlash is less than 0.6

individual requirements can be met from a

arcmin and will not change by more

standard model or one that has been only

than 10% over the nominal operating

slightly modified.

lifetime of 20,000 hours. This reduces the

Premium Stephan can supply their gearheads as sub-assemblies, enclosed

costs associated with initial set up and subsequent servicing and replacement.

If the sun gear is turned, the

gearboxes or fitted to a motor to form a

Further, the Melior Motionâ&#x20AC;&#x2122;s torque

meshing teeth cause the

unitary component. They are available in

capacity is exceptional for such a small

planet gears to turn, which

a range of sizes and can be supplied with

footprint, so energy efficiency is high. Thus

then cause the ring gear to

either solid shafts (with shaft length to

heat generation is low, allowing standard

turn. It sounds complicated

match the application) or hollow shafts,

lubricating oils to be used rather than

and looks hypnotic, but in

the latter allowing a feed-through of

expensive specialist ones. It also leads to

fact is very simple. It is also

cables. Generally they are designed for

low starting torque, inertia and braking

notable that the ring gear

use with standard mineral oils, although

loads, and therefore smooth and reliable

turns in the same direction

specials are available.

operation.

as the sun gear.

Control & Automation

BEHIND EVERY SATISFIED CUSTOMER

THERE’S A DISTRIBUTOR YOU CAN COUNT ON

uk.rs-online.com Power Bayonet Connectors These new power connectors are designed for industrial cable connections with IP67 protection. Bayonet locking allows a quick, simple and robust connection in harsh environments. 2 and 3 pole versions are available within the IP67 power bayonet connector series. The 2-pos. version is designed for DC use up to max. 48 V DC and the 3-pos. version utilises a premating contact for AC up to max. 250 V AC with protective earth contact (PE).

Crimp contacts are available for wire cross sections 12 to 10AWG or AWG10 to 8 for the 2 pole plus AWG14 to 12 for the 3 contact version. Crimp connections ensure easy, safe and quick mounting of the contacts, which are included in the connector kit.

These power connectors can be used to replace other types like the IEC C13, Neutrik PowerCon or CEE Norm and have the added benefit over some of bayonet locking to ensure safety and continuity of supply in an industrial environment.

The connectors are also available in readymade cable assemblies.

Skype Name “In2Connect” Tel: UK 01962 773004 Fax: UK 01962 600034 Email:sales@in2connect.uk.com

40

PECM Issue 20

Risk Assessment Services

Risk assessments are the key to machinery safety, they pave the way for a level of risk reduction thatâ&#x20AC;&#x2122;s both effective and economical. With years of technical comptence and knowledege Pilz is your partner for Risk Assessments.

( &(

( &! " ( #" # ! " ! ('

Pilz Risk Assessment Includes 0 "( / ( #" # $$ '( " & ' & ) ( #"' " '( " )'(&- $& ( ' 0 ( ( ! "( # ! " ! (' 0 , ! " ( #" # . & ' ( &#) #)( ( & * "( ! " &- - $ ' ' 0 '( ! ( #" " * ) ( #" # & ' & #!! " $$&# #& & ' &eduction

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"

Control & Automation

Chancellor Angela Merkel and President Barack Obama visit Rittal Stand at Hannover Messe 2016 US President Barack Obama and German Chancellor Angela Merkel paid tribute to the extraordinary innovation and commitment to future talent development shown by the Rittal company during a state visit this week.

B

oth the corporation’s new “Blue e+” generation of cooling units - which set new standards for energy efficiency - and its ongoing investment in young trainees impressed the President and Chancellor Merkel on the opening day of the Hannover Messe 2016. The USA was selected as this year’s partner country for the Hanover expo, which is now the world’s leading trade fair for industrial technology.

Chancellor Merkel, meanwhile, appeared particularly enthused by the Friedhelm Loh Group’s commitment to training young, up-and- coming, talent

and she also spoke warmly of Rittal’s determination to integrate refugees into its regular training programme – a first in Germany.

Rittal currently equips some of the largest data centres in the world.

“We are Europe’s number one provider of engineering software, and we want to keep on growing,” says owner and CEO Dr. Friedhelm Loh, who also highlighted to both leaders the importance of software and data in future industrial production.

The US President showed considerable interest in the new Blue e+ cooling unit, commenting at one point; “This is a fine company!”

Box smarter with Rittal

Superior quality Extensive size range Comprehensive product options Instant availability Competitive pricing

ENCLOSURES

POWER DISTRIBUTION

CLIMATE CONTROL

Control & Automation

Even more room for manoeuvre!

Space is precious – especially when it comes to high packing densities in electrical engineering. pace limitations mean that panel builders and switchgear manufacturers have to accommodate more and more mechanical and electrical components in enclosures.

S

Now, a smart new enclosure accessory from Rittal can provide far greater scope for the interior configuration of compact enclosures.

The planning and configuration of interior installations within compact enclosures can be both time consuming and complicated.

It can also lead to actions which compromise the integrity of the enclosure and add to the cost of installation.

Additional holes often have to be drilled in areas such as the side panels to fasten components outside of the mounting plate. This not only lowers the enclosure’s protection category, it is also adds significantly to the settingup costs.

The limited available installation space inside the enclosure can also cause

IT INFRASTRUCTURE

problems around the best use of the existing mounting surfaces.

In response, Rittal has developed an interior installation rail. The rail can be easily mounted to the side, oor or roof areas of the E compact enclosure, without any need for additional drilling through the enclosure panels.

This neat solution saves time and preserves the enclosure’s protection category. It can be placed wherever it is needed in the enclosure and is easily fi ed with a screw) and it will support static loads of up to . dooroperated switch can also be fitted to the rail using an adapter supplied .

This means that rail mounting is easy even if the mounting plate has already been installed.

mounting surface for items such as punched sections, enclosure lights, the afore-mentioned dooroperated switches, door stays, cable conduit holders and a range of other components. Use of the rail can easily double the available mounting surface inside an E compact enclosure.

And because it has also been designed to use the accessories for the triedand-tested modular TS enclosure system, there is no longer any need to keep a duplicate stock of accessories.

The rail has two rows of system punchings to create an additional

SOFTWARE & SERVICES

www.rittal.co.uk

Control & Automation

Your dedicated specialist for factory automation.

For the last 60 years the world’s No. 1 in factory automation has been at the forefront of innovation, continually pushing back the boundaries of automation to increase productivity and drive down costs across a whole range of industries. Boasting 99.9% reliability, a customer-centric approach, world-class service and infinite solutions for industrial robots, CNC systems and purpose-built machines for wire cut EDM, electric injection moulding and milling and drilling, we’re there to help you make the most of your automation. All you need is yellow.

www.fanuc.eu

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/

Drives for process technology applications At the ACHEMA exhibition in Frankfurt, Germany, NORD DRIVESYSTEMS recently presented distributed drive concepts that meet the typical demands of the process industry.

Variable-speed drives with IP66/IP69K ingress protection are suitable for applications that require regular cleaning with high-pressure steam jets. All components are manufactured in-house: gearboxes, smooth-surface motors, and frequency inverters. The nsd tupH anticorrosion treatment – developed by NORD and FDA-certified (Title 21 CFR 175.300) – gives the aluminum housings a smooth and durable surface.

Even blows and scratches do not impair the corrosion resistance. Since no coating is applied but the surface itself is hardened, there can be no pollution of products or process media as for instance with chipping paint.

Email: info@nord.com

44

PECM Issue 20

www.nord.com

Safe machinery, step-by-step P

recise knowledge of what is technically feasible and what is permitted from a legal perspective is a prerequisite for designing safety technology that will offer the greatest possible potential for productive machine operation.

The Machinery Directive is concerned with the standardisation of European safety requirements on machinery; it has the status of law and has been incorporated into respective domestic law by EU member states. It specifies a standardised level of safety for machinery placed on the market within the European Economic Area, so guaranteeing the free movement of goods. Machine builders use the CE mark to document that the product complies with the applicable directives.

Machines that are joined together, such as robot cells and production lines, are also subject to mandatory marking. However, operators are also responsible if “significant changes” made to a machine during a retrofit, for example, mean that the risks need to be re-assessed and the Performance Level (PL) determined.

Step 1: Risk assessment as the key to machinery safety Machine manufacturers have an obligation to supply only safe products to customers in the internal European market. For this reason, they must calculate all the hazards associated

46

PECM Issue 20

with the machine in advance and assess the resulting risks. That’s why the first step to machinery safety under the terms of the Machinery Directive is always the risk assessment.

The contents and scope of risk assessments are not specified in any directive, but EN ISO 12100 describes the general procedure. All relevant hazards must be identified, based on the intended use – taking into consideration all the lifecycle phases prior to the machine being placed on the market. All the various groups who come into contact with the machine, such as operating, cleaning or maintenance staff are also considered.

The risk is estimated and evaluated for each hazard. Risk-reducing measures are established in accordance with the “state of the art” guidance.

For example, there is a risk of crushing and shearing when operating a mechanical press. The risk is described in detail and the severity of injury and frequency of exposure is estimated and assessed. Afterwards the risk reduction measures are presented, if possible using fixed guards. Following on from these considerations, the potential reduced risk is presented as part of the risk assessment.

The quantitative approach of Pilz’s “Hazard rating numbers” (PHR) makes sense when it comes to

The quantitative approach of Pilz’s “Hazard rating numbers” (PHR) makes sense when it comes to also determining those risks that cannot be reduced through control measures, but only by using covers or fences also determining those risks that cannot be reduced through control measures, but only by using covers or fences for example. The PHR procedure introduced by Pilz, with its corresponding assessment figures, is used for a strictly objective and practicable estimation of a plant’s risk.

The machine manufacturer must then design and construct the machine to take account of his assessment.

Risks are calculated from the frequency and severity of potential injury and damage to health or material damage, combined with the possibility or otherwise of technical, organisational or personal measures to avert or protect against the hazard. The residual risk is calculated at the same time: if it is too high, additional measures are required. This iterative process is continued until the necessary safety is achieved.

The result of the risk assessment ultimately determines the requirements of the technical protective measures. It also refers to the reliable performance of the guard function. The challenge is to examine and assess the overall process as well as estimate the individual risks correctly.

Pilz offers a wide range of safety services including risk assessment, for more information contact services@pilz.co.uk or call 01536 460766

Control & Automation

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Issue 20 PECM

47

100 Years of Engineering Expertise

F

rom the largest forging

Oilgear is one of the world's leading

It's no secret that hydraulic equipment,

press, to the latest 'smart'

suppliers of hydraulic packages for

like all industrial components and systems,

stadium, or even the hardy

industrial and plant applications.

needs servicing from time to time. Often

plant vehicles found at your

local quarry; hydraulic systems keep vast swathes of industry moving. Hydraulic fluid is the life blood of many industrial power systems, pumps and valves are to a larger extent the heart of this process.

Designing and manufacturing a complete range of components including pumps, valves, manifolds and power units, as well as ancillary components such as electronics, control panels and software solutions, it is able to deliver projects of any scale

maintenance engineers wait until the scheduled shutdown period and call in their local service engineer or original installation engineer â&#x20AC;&#x201C; depending on the best quote â&#x20AC;&#x201C; to see what work needs to be done.

Just like our heart, a good hydraulic system

using its own in-house expertise. It's this

While this maintenance method keeps the

will last for years if it is cared for correctly.

manufacturing expertise that provides

system ticking over, it offers very little in

Oilgear Service contracts take the

it with a unique insight into hydraulic

the way of flexibility, nor does it offer the

guesswork out of hydraulic maintenance

technologies and allows it to offer a unique

opportunity to improve your system or

by preventing unplanned downtime and

aftermarket service.

regulate maintenance costs.

costly repairs.

48

PECM Issue 20

Oilgear are able to deliver projects of any scale using Oilgear's own in-house expertise.

Oilgear's aftermarket service offers a

For example, it is able to offer substitute

everyone can benefit from it. Where a

pro-active maintenance campaign that is

pumps or valves from stock to keep

component or system has reached the end

scheduled to provide ongoing care, all year

a system operating while the client's

of its useful service life, if the parts are no

round. A service engineer will conduct

equipment is taken to the workshop. This

longer available, Oilgear is able to reverse

regular site visits to monitor the condition

offers multiple benefits to the operator

engineer a solution which will match the

of the complete system and recommend

as the work is performed outside of peak

original footprint â&#x20AC;&#x201C; often with improved

action to solve potential issues before they

season, reducing engineering costs as

performance.

become a problem. This makes it easier to

well as the burden of work during the

plan activity around scheduled downtime

traditional shutdown.

so maintenance is planned rather than

Keeping your hydraulic system healthy is essential to keeping your entire

With almost 100 years of expertise,

production process moving. By investing

Oilgear has experience servicing almost

in a service contract you are able to rely on

In fact, in some cases, Oilgear can use its

every conceivable application in any

100 years of knowledge and experience to

experience as a manufacturer to provide

industry around the world. Its aftermarket

make sure you never have to worry about

maintenance services outside of the usual

service extends beyond its own product

a cardiac arrest.

shutdown period.

and hydraulic packages, meaning that

reactive.

Issue 20 PECM

49

Drives, Gears & Motors

ROTEX® SH with T-PUR®

Reduce Your Downtime

ROTEX ROT RO OTEX O OT TEX E X® G GS S& S SY SYN YN Y NTE TEX T EX E X®-NC -N SYNTEX

It’s a known problem with electric motors; bearings fail prematurely due to misalignment and vibration, causing downtime and increased maintenance costs. Choose quality to reduce these failures by half……

Insist on a KTR coupling. Any pump to any motor, we’ve got a coupling to suit the job and our split hub ROTEX® and BoWex® designs offer one of the quickest maintenance turnarounds in the industry!

www.ktr.com

KTR: Backlash-free shaft coupling with integrated clamping system I

n cooperation with the Swedish company ETP, KTR developed a backlashfree servo coupling with an integrated clamping system. The highlight is that the coupling can be mounted with one screw only which is completed within a few seconds.

ROTEX® GS with integrated ETP clamping system ROTEX® GS has been integrated with the ETP clamping system in a collaborative effort between KTR and the Swedish company ETP Transmission AB, specialist suppliers of shaft-hubconnections utilising Blaise Pascal’s principle of pressure propagation in liquids. The new backlash-free and highly accurate ROTEX® GS ETP is made entirely of steel and specifically suitable for applications involving highspeed drives.

The clamping system of this new coupling type consists of a doublewalled, hardened steel sleeve that is filled with a pressurizing medium. The flange comprises a piston with a gasket and a screw which is tightened on the piston for pressure generation.

on a two-part type which will allow for the use of other coupling types and materials.

Email: mail@ktr.com www.ktr.com

The screw is tightened radially, while no axial space for assembly tools is required. When under pressure, the sleeve expands generating a uniform surface pressure against shaft and hub. This principle of just a single screw allows for assembly within a few seconds and ensures a continuously variable positioning of the coupling.

The uniform stress distribution in the basic body of the hub results in an accurate concentricity of the ETP system while achieving a very smooth running result.

Currently KTR and ETP are working Issue 20 PECM

51

Advanced decoupling protection for renewables offers easy set up and safe grid connection VMD460 delivers external network and system protection by continuously monitoring phase sequence, voltage and frequency.

to a PC or other device to set up and commission, or change operating threshhold parameters. All of the required information can be displayed and customised using the illuminated liquid crystal multi-line graphic display on the device itself.

T

he new VMD460 Interface Protection System from Bender UK makes it easier than ever to set up advanced decoupling protection for the critical link between renewable power electricity generating equipment and the National Grid.

The new system simplifies commissioning with a wide range of flexible settings and related parameters saved in pre-set basic programs, all accessed through the on board screen display and push button controls.

That enables VMD460 to easily to accommodate the limits dictated by the DNO (District Network Authority) or plant-specific requirements which typically include voltage, frequency, ROCOF (rate of change), and phase angle etc.

The new system is compliant with the latest UK and European standards for the G59 Mains Protection Relay for photovoltaic systems, CHP (combined heat & power), wind and hydroelectric power to provide a comprehensive solution to the needs of renewable energy installations.

52

PECM Issue 20

VMD460 delivers external network and system protection by continuously monitoring phase sequence, voltage and frequency. If there is an infringement beyond the pre-set limits the relay isolates the connection between the public grid and the power generation system - instantly disconnecting the generator from the grid for total protection and peace of mind.

A key advantage of the system is the fact that it does not require connection to a PC or other device to set up and commission, or change operating threshhold parameters.

A key advantage of the system is the fact that it does not require connection

The device incorporates an RS-485 interface for data exchange and software update via BMS bus, and settings can be password protected.

Other features of the system include a test function for the determination of the shutdown time, memory of the last 300 events and faults with real-time clock-calendar time stamp, continuous monitoring of phase voltage and line conductor voltage, and separate switching conditions after a threshold infringement. The device incorporates an RS-485 interface for data exchange and software update via BMS bus, and settings can be password protected.

Bender UK Managing Director Steve Mason explains: “Bender has a very strong track record in supplying mains protection relay systems and the VMD460 represents a step change in terms of functionality and ease of use. It is, however, competitively priced against the previous generation products and therefore represents outstanding value for our customers, delivering total safety and programming capability in a single compact unit.”

For more information on the VMD460 and other electrical safety equipment designed for the renewable and power generation sectors visit us at www.bender-uk.com

THE POWER IN ELECTRICAL SAFETY© LINETRAXX® VMD460 G59-3/G83-2 decoupling protection relay X

Independently certified to G59-3 & G83-2

X

Suitable for solar, wind & other distributed generation applications

X

Simple to install & commission with pre-configured settings & test simulation

X

High quality, reliable, German manufactured solution

X

Cost effective, competitively priced

X

Password & padlock security with history of up to 300 events

X

Vector shift and ROCOF in a single unit ANSI 27 59 81U 81O 81R 78 47 86

PROTECTION FUNCTION Under Voltage – 2 stage Over Voltage – 2 stage Under Frequency – 2 stage Over Frequency – 2 stage ROCOF – Rate of change of Frequency Vector Shift Phase Sequence Voltage Asymmetry/Phase failure Lockout

www.bender-uk.com

BENDER UK Low Mill Business Park, Ulverston, Cumbria, LA12 9EE Tel: 44(0) 1229 480123 Fax: 44(0) 1229 480345 Tel ROI: +353 1 5060611

Electrical & Electronics

New ETA Enclosures 2016 Product Overview Brochure Hot off the press for 2016 is a new 44 page product overview brochure from ETA Enclosures UK Limited.

Including new products:

This new, easy to navigate publication shows ETA’s range of ex-stock enclosure products and thermal management solutions and it is the ideal user friendly tool from which to select in stock products for quick no delay delivery.

• EGRAN Stainless Steel Terminal and Push-button boxes

Products featured are: • Boxes in Mild Steel, Stainless Steel and Polyester • Cabinets in Mild and Stainless Steel • Desks/Consoles in Mild and Stainless Steel • PC Cabinets in Mild Steel • Outdoor Cabinets in Mild Steel and Aluminium

• ERAM Stainless Steel Suspension Arms and Enclosure Systems

• Die-cast Aluminium Boxes All products are available in standard format to a comprehensive range of sizes but custom modifications to the customer’s specific requirements are also available on a quick turn round basis.

For further information or to request your free copy of ETA’s new 2016 Product Overview Brochure call our sales office on 01709 386630, E-mail info@eta-enclosures.co.uk or log onto www.eta-enclosures.co.uk

IP65 Weatherproof Distribution Boxes – New from ETA Enclosures ETA Enclosures UK Limited have launched a new range of IP65 rated Weatherproof Distribution Boxes suitable for both indoor and outdoor applications.

Produced from high quality ABS material these enclosures offer a durable modern stylised look whilst incorporating many user friendly features.

• IP65 Protection • Sizes from 4-72 Modules • Tinted Grey hinged lid • Complete with fitted Din-rail • Suitable for indoor & outdoor applications • Manufactured from high quality ABS

54

PECM Issue 20

ETA’s new Weatherproof Distribution Boxes are designed to reduce cabling times as well as allow total integration with modular DIN-Rail MCB’s, MCCB’s and other front panel devices. With an aesthetically pleasing new modern look these units are well suited for both indoor and outdoor installations especially where an attractive finish to the application is desirable.

For further information or to request your free product brochure call the ETA Enclosures UK sales office on 01709 386630, Email info@eta-enclosures.co.uk or log onto www.eta-enclosures.co.uk

Product Overview - 2016 Mild Steel

Stainless Steel

Polyester

Aluminium

Boxes

Boxes

Boxes

Out Door Cabinets

Cabinets

Cabinets

Junction Boxes

Desks/Consoles

Desks/Consoles

Suspension Arms

PC Cabinets

Suspension Arms

Out Door Cabinets

Standard | Modified | Special

www.eta-enclosures.co.uk

ODU-MAC

ÂŽ Compact modular connector system

THE ALL-ROUND SOLUTION FOR MANUAL MATING AND AUTOMATIC DOCKING The intelligent path to individual connection: ODU-MAC â&#x20AC;&#x201C; our versatile modular connector solution enables signals, power, high current, high voltage, coax, high-speed data transmission, fibre optic and other media such as air or fluid. For your individual connection.

Fail-safe performance thanks to high level of contact reliability

30 different high-speed inserts in the field of data technology

6 standard docking solutions

> 100,000 mating cycles

High packing density

Stable low contact resistances

ODU-UK Ltd. Phone: +44 1509 266433 sales@odu-uk.co.uk www.odu-uk.co.uk

Electrical & Electronics We develop electronic products from concept to manufacturing At Ricco we provide individuals and organisations with a complete electronic’s design and mechanical design capability in which to develop their customised electronic products. Whether all or parts of these elements of the electronics design, design of enclosure, electronics prototyping, apps development, testing, certification and manufacture are required we have all the skills, experience and resources at hand to successfully undertake your project.

FISCHER CORE SERIES STAINLESS STEEL

Chris Coates Ricco Associates M: 07747 879212 T: 02476 980930 E: ccoates@ricco-uk.com W: www.riccooutsourcing.co.uk

For further information call 0800 432 0301 or +44 23 9245 9600

Electronics Product Development, Manufacturing Services and Apps Creation

Panasonic MINAS A6 servo drives: Faster, more compact, more precise Panasonics new MINAS A6 series follows in the footsteps of the highly successful predecessor, the MINAS A5 series.

The A6 series has been improved further. At the same time compatibility with the A5 series has been maintained.

Thanks to the split core structure and a new housing we have been able to reduce not only the length by 30%, but also the weight by up to 10%. Even the encoder design has been made more compact.

An open serial communication protocol (RS232 or RS485) The 20-bit MINAS A5 encoder (1048576 pulses per revolution = ppr) has been upgraded to 23 bit (8388608 ppr). Consequently the resolution of the new A6 series has been improved eightfold.

The new servo motors come with an even faster velocity response (3.2kHz), which means that the driver can react even faster. In addition, micro vibrations have been reduced considerably thanks to an improved reaction of the current regulation and linearity.

Info.pewuk@eu.panasonic.com

www.panasonic-electric-works.co.uk

TRUMPower Launches UPS-Ready Medical Grade 550W ATX Power Supply with Built-in 24V Battery Charger

Premium grade 316L stainless steel

High corrosion and radiation

resistance

TRUMPower introduces the Intel’s Haswell™ compatible TMPC-550U, which is a medically approved 550W ATX PC power supply equipped with a built-in 24V battery charger. A single 24V or two 12V lead-acid batteries in series can be connected to the TMPC-550U to be used as an interruptible power source, with the backup power being 400W. The battery charger in conjunction with a built-in DC to DC converter ensures that all connected equipment will receive a stable supply of power with the correct corresponding voltage in case of a blackout or temporary power loss.

Easy decontamination and

The TMPC-550U comes with DC voltage outputs and maximum loads of +3.3V/20A, +5V/20A, triple +12V/16A, -12V/0.5A, and +5Vsb/3A for standby purposes. The TMPC-550U is designed to meet the 3rd edition of IEC/EN 60601-1, ANSI/AAMI ES 60601-1:2005, CSA C22.2 No. 60601-1: 2008 and IEC/EN 60601-1-2:2014 (4th edition) EMC standards.

Wide range of body styles and

For detailed information on the TMPC-550U, please visit http://www.trumpower. com/library/tmpc-550u.pdf or email sales@trumpower.com.

sterilization

Easy handling with gloves

sizes IP68 sealed solutions

Martindale produce new series of short information videos Martindale Electric has created a ten-part series of short videos detailing the benefits of choosing the correct equipment for the job.

Presented by industry personality Dave Austin, the new collection of videos from Martindale Electric looks at the five key areas; 17th Edition Testing, Voltage Indication and Safe Isolation, Fuse Finder and Cable Detectors, PAT Testers and Sockets testers; and has been designed to help electricians and maintenance personnel perform safer, faster and smarter testing on-site.

Focusing on key products from the Martindale Electric range, the new collection of video includes valuable information on the ET Series of Multifunctional Electrical Installation Testers, which have been designed to simplify testing to the latest Amendment 3 changes to the 17th Edition Wiring Regulations. The first two videos are available to watch now on the Martindale Electric You Tube channel https://www.youtube.com/ user/MartindaleElectric

Martindale Electric Email: sales@martindale-electric.co.uk Tel: 01923 441 717 www.martindale-electric.co.uk

THE RELIABLE EXPERT

www.fischerconnectors.com Issue 20 PECM

57

Electrical & Electronics

Fischer Connectors FiberOptic Series gets smaller and smarter F ischer Connectors has launched its new single ďŹ bre optic connector (FO1) within its Fischer FiberOptic Series.

Designed speciďŹ cally to ensure premium performance in harsh environments, the FO1 is a miniature, lightweight, rugged connectivity solution that is easy to use and is ideally suited for applications such as instrumentation, sensing, defence and broadcast.

This new connector fulďŹ ls the growing market need for higher data transmission rates over long distances while reducing space and guaranteeing performance.

This is achieved through Ultra Physical Contact (UPC) and Angled Physical Contact (APC) polishing which reduces insertion and return losses. IP68 sealing provides device protection while the push-pull locking system allows quick and easy connection and disconnection for outdoor environments. A removable sleeve holder (monobloc mate adapter) enables inďŹ eld cleaning of the end faces, ensuring electronics can be kept in top condition wherever you are.

â&#x20AC;&#x153;Weâ&#x20AC;&#x2122;ve extended our FiberOptic Series bearing our customersâ&#x20AC;&#x2122; needs for ďŹ&#x201A;exibility and eďŹ&#x192;ciency in mindâ&#x20AC;?, says Christopher Martin, FiberOptic Product Manager at Fischer Connectors. â&#x20AC;&#x153;The product lineâ&#x20AC;&#x2122;s main beneďŹ ts â&#x20AC;&#x201C; high optical stability in harsh environments, robustness, and ease of use, cleaning and maintenance â&#x20AC;&#x201C; remain the same. But weâ&#x20AC;&#x2122;ve designed this smaller product to be even lighter and more ďŹ&#x201A;exible so that itâ&#x20AC;&#x2122;s easy to integrate into existing solutions, saving time and money for our customers.â&#x20AC;?

The Fischer FiberOptic Series already includes two versions: a rugged ďŹ bre optic connector with two or four ďŹ bres, and a rugged hybrid connector with two ďŹ bre channels and two electrical contacts.

These can be pre-conďŹ gured with Fischer FiberOptic Series reels of any required length to oďŹ&#x20AC;er a convenient and ďŹ&#x201A;exible turnkey solution.

FISCHER CONNECTORS LTD Tel: 0800 432 0301 or +44 23 9245 9600 sales@ďŹ scherconnectors.co.uk www.ďŹ scherconnectors.com

YOUR ULTIMATE SOLUTION FOR DIELECTRICS AND CONDUCTIVE MATERIALS

www.taiyo-america.com

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0 ax [775] 885-9972

Issue 20 PECM

59

“The protector of electronics” pursues Ambitious visions!

STEGO Filter Fan Plus expels more air from an enclosure.

A

fter merely 26 months of research and development ‘the protectors of electronics’ STEGO, launch a filter fan series that will create a sensation. Its new air-flap technology achieves considerably more efficient air circulation which is a big plus in operational terms.

through the filter at the base of the enclosure. The air then is actively drawn upwards by the fan and expelled through the flaps.

The filter fan series comprises five enclosure cut-out sizes from 92 x 92 mm to 291 x 291 mm. ‘We cover all relevant fields of application with these sizes. A very customer-oriented approach!’ - STEGO CEO Elmar Mangold declares. But this is by far not all that is to be marveled at. Users can take delight in the totally novel ratchet mounting mechanism, improved access protection and lots more.

But back to the core of the product: the air-flap technology. Elmar Mangold describes it as a suggestion of ‘German inventive spirit’.

Because it reached maturity at STEGO’s R & D through trials in manual model making.

Contrary to the filter mats, the flaps allow for noticeably more air to exit. Consequently a smaller filter fan suffices to achieve the same airflow output than a bigger device did before. Thus saving cost and installation space! Positive sideeffect: In idle mode of the fan the recessed flaps stay closed and dirt stays out.

Due to additional product variations the Filter Fan Plus system gives its buyers further freedom to choose between two principles that differ in direction of air flow. The FPI-principle (‘in’) actively imports fresh air through the filter fan and exports it as warmed up interior air passively through the exit via flaps. The FPO-principle (‘out’) brings in the air passively

Users can benefit quickly and easily from more air in enclosures. Due to a STEGO in-house development of mounting ratchet braces the Filter Fans Plus can be inserted and mounted tool-free into the cut-out of the enclosure. By pressing of the ratchet braces the Filter Fan Plus is drawn to the cut-out, clicks into place and is firmly sealed. Even

Left

Above

Mounting rachet system

Above

Flap technology

On the other hand the hood of the Filter Fan Plus is deliberately designed to be opened with a screwdriver only. This allows for better access protection and consequently for more safety.

PECM Issue 20

Below

FPI System Drawing EN

FPI FPO 92x92

60

without additional gluing the slim filter fan fits perfectly.

Conclusion: The German manufacturer STEGO ‘the protector of electronics’ introduces a powerful product series to the market with the Filter Fan Plus and resumes its position as innovation leader. ‘The Filter Fan Plus series is distributed by our twelve locations worldwide.

We thereby serve customers in over 90 countries. With this product launch we once again want to live up to our role as global player’, reports Elmar Mangold, who anticipates numer-ous customer requests in the near future.

The market introduction of the Filter Fan Plus is accompanied by an atten-tion-grabbing advertising campaign that intentionally presents the power of the filter fans in distinct exaggeration. Are you curious?

You will find the advertising theme under www.filterfan-plus.com

Safe Isolation saves lives Stay safe, prove dead and lock off with Martindale VIPDLOK kits

NEW

VI-15000

CAT IV 1000V

The VIPDLOK kits include everything you need to ensure safe isolation / )) %*! # &( &$'#! % -!* # *(! !*. * &(" +# *!&%) &( ) -&("!%

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The simple solution to safe maintenance

Available from your wholesaler and online www.martindale-electric.co.uk Call:

email: ) # ) $ (*!% # # *(! & +"

Electrical & Electronics

Weidm ller Presents FreeCon Contactless Contactless power transmission - maintenance-free and up to 240 W with high power density, maximum efficiency. Thanks to FreeCon Contactless from Weidmüller, customers who employ industrial robots on their production lines can now avoid contact related failures and cut maintenance costs considerably.

the line can obtain a far higher degree of efficiency compared with comparable solutions that are available on the market.

Burnt, bent or dirty contacts can often be the cause of time consuming and costly production failures. This is all the more true of applications that require frequent plugging cycles. Certain models of industrial robots performing frequent tool changes are prone to suffering such system errors like this; the level of wear on moving parts can be especially high.

In some scenarios industrial robots can perform several hundred tool changes per day. In this regard, conventional contacts are subjected to high levels of wear. With FreeCon Contactless, customers will benefit from a reliable and maintenance-free connection. The process of charging driverless transport systems can now also be automated via FreeCon Contactless. High maintenance slip ring transmitters can be replaced too, since it securely transmits power even in the case of rotational movements.

FreeCon Contactless allows power to be transmitted via an ‘air gap’ by means of an inductive resonance coupling. This is a solution that’s completely wear-free and especially efficient. By doubling the power density,

Unlike conventional plug-in connections, which only provide IP 20 protection when unplugged and are therefore unprotected, FreeCon Contactless offers IP 65 - permanently. FreeCon Contactless also enables

reliable and contactless transmission of up to 240 W of power with compact dimensions and maximum efficiency. The transmission can even be controlled via PLC. It is therefore possible to switch 10 A directly via the PLC without the need for further contactors. FreeCon Contactless provides complete protection against humidity and dirt.

For further information and product specifications visit www.weidumuller.co.uk

One week, £65,000 saving with our Sinergy e-TRacKER The client – a manufacturer of heating products – installed a Sinergy e-TRacKER sub-metering unit to get an in-depth view of its energy usage over one week. When the stats were examined the company discovered its electricity meters were making incorrect readings. The matter was taken up with the power supplier and a refund of £65,000 issued along with an assurance that future bills would be correct.

The e-TRacKER, which took about 30 minutes to install between the Mains supply cable and the Main Distribution Board, was removed after one week and the statistics examined. The client, with the aid of the e-TRacKER, identified that its electricity meters were reading incorrectly. They questioned the billing data with their supplier and received a refund of £65,000.The Sinergy e-TRacKER is a portable kWh meter allowing users to monitor incoming power supply, specific circuits/equipment etc to show the pattern of demand over an hour, day, week or month. The unit utilises non-invasive clipon transducer (CT) clamps that are quick to install and do not require power being turned off. They are magnetic-backed so attach easily to switch boards making them perfect for temporary monitoring. e-TRacKER measures current from 10Amps to 2500Amps. The system offers 16 days of battery life or runs off mains supply. Other features include pulse input, optional voltage connections, CT amps range indicator and EV-Trac electrostatic phase identifier.

Sinergy Meters Unit 1, Union Road Estate Union Road, Macclesfield SK11 7BN E: sales@sinergymeters.com T: 01625 611808

62

PECM Issue 20

Please see our new website www.sinergymeters.com

Catchment Based Thinking to Industrial Wastewater Treatment

By Rich Matthews, General Manager, Siltbuster Process Solutions

A

s part of A P6 the water industry is already taking some steps towards catchment management. Indeed, when it comes to tackling diffuse pollution issues, that threaten the aquatic environment, water companies comfortably adopt such an approach. They adeptly identify the often local, root causes of any problems and mitigate or eliminate them accordingly.

Yet, when it comes to industrial wastewater treatment, an area which potentially puts a greater burden on infrastructure, this approach comes less naturally to the sector. Instead, investment decision-making is generally made at the end of pipe’. As a result, efficiencies are missed and problems are not tackled at source.

There are a number of compelling reasons why this entrenched way of operating should be over-turned and a catchment-based approach to industrial wastewater treatment should be considered.

Unpredictable Problems The first has to be industrial unpredictability and risk.

It is e tremely difficult for water companies to predict with certainty how demand from an area’s industrial and commercial base is likely to develop and grow, or to forecast the upside and downside of demand in a specific area.

This is a very real problem as, from an operational perspective, apart from storm ows, it is the uctuations in industrial contributions ows and loads that place the greatest stress on the wastewater treatment infrastructure.

It’s not ust the treatment facility that is impacted by this; conveyance systems are affected too by industrial demand.

Risk to Conveyance Infrastructure A purely centralised approach, where the problem is purely dealt with ‘at the end of the pipe’ also presents an increased risk to conveyance infrastructure in terms of the ows and types of e uents to be catered for. For e ample, significant trade discharges can have high loads that can affect pump stations and other sewerage infrastructure, leading to a greater risk of pollution events. The control of fats, oils and greases (FOG) is a particular focus area and contributor to this. o in essence water companies face a significant potential pressure from their commercial communities, and these communities can e and grow quite unpredictably The use of well-managed Trade uent Consents, and charging by Modgen formula, provide the tools to both control industrial discharges and implement a pricing strategy which ensures revenue for investing in wastewater services. However, where should that investment be best placed?

Investing Closer to the Customer This is where we would argue that catchment based thinking comes into its own. SPS has undertaken a number of pro ects with food and drinks companies seeking to improve their discharge compliance performance and / or to reduce their trade e uent charges. ften these systems can be installed as relatively simple retro-fits. ome have even the potential to provide a revenue income; e.g. feedstock for AD plants. Dissolved Air Flotation (DAF) technology has proven time and again to be a cost effective and robust process for reducing organic load into the sewerage system at source; particularly in relation to FOG applications.

As an example, the use of a DAF system complete with packaged chemical pre-treatment facility treating wastewater from a ready meals producer, typically achieved an 87% reduction in TSS, and a 70% reduction in of COD.

Furthermore, since this packaged treatment system has been installed it has treated ~120,000 m3, with a gross saving of circa £50,000 in Mogden charges since October 2014.

However, more importantly this has significantly reduced the demand on the existing conveyance and treatment infrastructure At present it is the proactiveness of industrial customers in managing their operation and expenditure that drives this approach. However, given the potential reduction in both the load and the associated stresses on infrastructure, water companies should perhaps themselves look at how some of their assets can be better deployed by treating at source.

Of course there may be scenarios where the traditional end of pipe solution is the right one. We also acknowledge that the catchment approach to industrial water treatment requires a significant shift in the water sector’s investment model. Primarily in the operational philosophy outlook and responsibility, by treating solutions on third party land and the additional interfaces. However, with engineering, construction and space constraints increasingly inhibiting the sustainable development of wastewater treatment sites, we really believe higher rate, smaller footprint, intensive treatment processes, working where the problem originates present a real answer. The change in approach will deliver enough significant benefits to merit this shift in thinking.

For further information on Siltbuster Process Solutions, please visit www.siltbuster.com, call 01600 772256 or email enquire@siltbuster.com Issue 20 PECM

63

Flammability Standards and 2L Refrigerant Introduction

B

y now we are all aware that

programs to thoroughly investigate the

a degree of flammability or to accept a

regulation of fluorinated

performance and reliability of these

higher GWP in order to maintain non-

refrigerants is here in

alternatives and to optimise system

flammability. Central to this choice is how

Europe through the

performance based on the properties of

to meet the GWP regulatory requirements

the new fluids.

whilst maintaining a high degree of safety?

Mobile Air Conditioning (MAC) Directive, for automotive air conditioning, or the F-Gas Regulation for all other refrigerant applications.

As with many of the higher GWP products they are to replace, for example R-404A, many of the new alternatives proposed

In some circumstances, the choice is made for us by the regulations. For example the MAC directive requires use of refrigerant GWP below 150 and with the exception of

Over the last few years, the chemical

are blended HFCs. The building blocks

manufacturers have been looking to

for these alternatives include the

develop reduced GWP products that are

hydrofluoroolefins (HFOs) as well as the

capable of meeting the requirements of

more familiar lower GWP fluids such as

Similarly looking ahead to alternatives for

these regulations and which maintain the

R-32 and R-152a.

R-410A in smaller (<3kg charge) single-

high levels of safety and efficiency we have come to expect from hydrofluorocarbon refrigerants. Here, Stuart Corr, techno commercial director of refrigerant gases manufacturer and supplier, Mexichem, discusses how the issue of refrigerant flammability relates to the use of reduced GWP products.

All of these components are flammable, falling into the ASHRAE 2 2L safety categories. Whilst they can be blended with non-flammable components in order to achieve non-flammability, for the majority of air conditioning and refrigeration applications, it is an unfortunate fact that the lowest GWP

We are in a position where the

products will tend to be flammable to a

refrigeration and air conditioning

degree, mostly falling within the ASHRAE

industries have a number of options

2L category.

available to them across the range of application sectors and many of the equipment manufacturers have active

64

PECM Issue 20

CO2, there are no viable non-flammable candidates.

split a/c systems, the F-Gas Regulation imposes a GWP limit of 750 and again there are no viable non-flammable candidates identified to date with R-32, and blends based on R-32, coming to the fore. The first step towards introduction of a refrigerant is to determine the flammability and toxicity classification for the fluid. This is most commonly through the internationally recognised ASHRAE classification system (figure 1). Whilst this process is essentially complete for the MAC

The industry is then faced with a choice:

sector, the stationary applications are more

to use the lowest GWP fluid and accept

complex.

Figure 1

Figure 2 In order to understand the range of

With the introduction of the 2L

EN378 is currently under revision to

applicability of a refrigerant, it is necessary

flammability category in 2010, it was

incorporate and provide new limits for

to consider a range of national and supra-

recognised that there was a group of

the 2L classification and is expected to

national regulations.

refrigerants that whilst flammable, had

issue in late spring 2016. If we are to

the potential for lower risk in use than the

exploit many of the low GWP fluids to their

more flammable hydrocarbons. Whilst

maximum extent, we need to understand

current standards and codes provide

how widely applicable they are, we need

safe boundaries for the use of flammable

to understand how regulations should

refrigerants, most do not yet recognise the

be amended to incorporate the new

2L category. Accordingly, if 2L refrigerants

classification whilst critically maintaining

are to be used in current equipment and

end-user and practitioner safety.

These regulations principally relate to the safe use of the refrigerant in a range of application sectors and govern aspects of equipment design, location and installation requirements. These regulations are generally based on the refrigerant safety classification or the data used to obtain that classification, for example flammability limits.

Whilst highly flammable hydrocarbon refrigerants and the less-flammable ammonia have been used for a number of years, most in relatively small domestic refrigeration applications or in industrial applications, the industry has generally relied on the use of non-flammable fluids to ensure a high degree of safety across a wide range of applications and operating environments. Many countries

environments, they must be treated as if they were category 2.

Figure 2 provides an overview of some of the regulations and codes that are either

Under the current EN378 the maximum

under current review or which may need

charge for propane in a wall-mounted

to be reviewed in order to address 2L

indoor split a/c unit in a 3m-square

refrigerants. Any amendment of standards

room is around 0.23kg whilst that for

and building codes must be undertaken

R-32 is around 3.08kg. Whilst this is still

with a significant degree of conservatism

potentially very attractive for 2L fluids in

with respect to safety. Furthermore, many

some application sectors, there are other

of these codes and standards are only

regulations, many of them at a National

reissued on a 3-yearly or so basis and with

level, that place more severe limitations on

a degree of interdependence. As a result,

their use.

it will be a number of years before the

have regulations that prohibit the use

For example both Italy and France

of flammable refrigerants in many

currently prohibit the use of flammable

applications.

refrigerants in room air conditioners.

potential for 2L fluids to provide low GWP solutions across a range of sectors will become clear.

Issue 20 PECM

65

Facilities Management

LIP SURFA IS HTWEIGH IG

T

L

AN T

CE

AN T

CORROS I ON

LIP SURFA IS

CE L

HTWEIGHT IG SPARKIN ON

N

G

G

N

N

VE

NO

CORROSI

VE

N

SPARKIN ON

Dura Composites & wnm limited Provide a Safe GRP Solution to Corrosion Issues for Nigerian Oil & Gas Company’s Brine Mixing Pit

D

ura Composites & wnm limited have provided a safe, durable and corrosionresistant alternative to traditional steel for a vital Brine Mixing plant at a major Nigeria based hub for West African deep sea oilfield operations.

Fabricated from glass reinforced plastic (GRP) profiles and grating, the resulting structure provides a safe working environment, and is designed for the future thanks to its inherent strength, durability and anti-slip properties.

Prior to installation, the mixing pit at the facility in Onne, Rivers State, Nigeria was found to have significant issues caused by the degradation of various steel components. Steel corrosion (rusting, or oxidation) is an electrochemical reaction that occurs when iron atoms lose electrons in the presence of oxygen and water. In this case, the effects of the salts being used within the mixing pit (calcium chloride and calcium nitrate) had led to severe corrosion, which is widely acknowledged as the largest single cause of plant and equipment breakdown in the process industries,

66

PECM Issue 20

and which results in an unsafe working environment that can lead to plant closures.

Dura Composites’ exclusive Nigerian distributor wmn Ltd (whose client owns the plant), were responsible for the supply and install of the materials.

Dura Composites’ industry leading GRP products are manufactured using high quality fibreglass produced from the latest pultrusion processes, and offer high strength, low weight, chemical and fire resistant properties. Dura Composites uses the latest CAD design techniques to produce a bespoke design using profiles which are delivered to the site in manageable sections for final assembly on location. Stairways, access platforms, walkways and step-over platforms can be fitted with fibreglass

floor grating to provide a gritted flooring finish which offers the highest degree of slip resistance ever measured for a walking surface, even in the wet and oily conditions found at the Nigerian oilfield.

For more information about Dura Composites, visit the website at http://www.duracomposites.com

Electricity Sub-Station Fibrelite Composite Covers Selected to Renovate UK Sub-Station Trenches Lightweight Covers, Making for Easy Removal and Still Maintaining Heavy Duty Load Rating Due to their composite make-up, Fibrelite trench covers are lightweight allowing for easy removal even at D400 (40 tonne) load rating. Coupled with the ergonomically designed lifting handle, all previous manual handling concerns and safety ris s are no longer an issue. his improves e ciency and productivity on site; making for a quicker, safer and more cost effective wor ing environment.

The installed Fibrelite heavy duty trench covers Fibrelite’s work replacing unsafe and damaged trenches at Sub-Stations continues. The Existing concrete and cast iron covers had begun to crumble and crack, causing health and safety issues on numerous sites. Trench covers manufactured by ibrelite do not suffer from such structural issues and are maintenance free.

Fibrelite composite trench covers and aluminium frame during installation

Further advantages include: • Corrosion resistant • No resale value to the scrap market so will not be stolen: A thermoset plastic, the composite makeup of the cover means it has no resale value • Non-metallic and will not spark • Composite is lightweight, strong and unlike concrete will not crumble or crack • Guaranteed structural performance: All covers are tested toEN124 D400 load rating • Colours and logos: Available in a vast array of colours and company logos available on request • Training for the installation team available • Range of sizes: From 800mm to 1600mm at D400 load rating, increasing in 50mm increments

Lightweight composite trench covers

For more information on Fibrelite's product range please contact us: UK Office:

US Office:

Malaysia Office (Asia Pacific):

Tel: + 44 (0) 1756 799 773

Tel: + 1 919 209 2404

Tel: + 44 (0) 1756 799 773

Email: covers@fibrelite.com

Email: covers@fibrelite.com

Email: covers@fibrelite.com

Facilities Management LED lighting rental aids cash flow

SEAMLESS

Using LED lighting with the latest in lighting management systems it is now relatively easy to achieve 50-80% energy savings on most projects. Aura Light has launched a Lighting as a Managed Service scheme which eliminates investment in equipment and reduces an organisation’s energy costs from day one. The scheme provides a full performance guarantee over the contract period. In Aura’s experience the lighting installation will continue to provide large energy savings into the future.

The scheme is ideal for all types of applications including offices, factories, warehouses and exterior lighting.

INDUSTRIAL FLOORING

Financing arrangements are entirely flexible with the rental payments adjusted to protected energy savings, making the project cash positive right from the start. Aura Light visits the company to conduct a survey of the existing lighting installation and energy consumption by a technical expert. This is followed with the provision of a new lighting design with a full financial calculation together with energy saving and CO2 saving documentation.

Tel: 01952 250800

www.aura-light.co.uk Resurfacing of badly worn floors and new build installations

Pirtek pioneers safety glove

Impact, abrasion and point load resistance Anti-static, anti-bacterial, slip resistant, chemical resistant & suitable for heavy traffic plus high bay category one and two

Hydraulic injection injuries are almost entirely occupational and sustained by male manual workers, both skilled and unskilled, with injuries mostly sustained to the palm or pads of the digits of the non-dominant hand. If untreated, hydraulic injection injuries can result in amputation or even death.

Fast installation for minimum downtime Integrate corporate colour schemes, colour matching and corporate logos into the same hardwearing and durable flooring For a complete Nationwide service from FREE survey and recommendations, to preparation and installation with single source, uncomplicated warranties…

Call 01952

The Pirtek Fluid Power Glove and its unique hydraulic injection resistant technology means it is the only glove available today that offers protection against hydraulic injection injury as standard. The lightweight design and dexterity make it a must have PPE garment for all personnel working on or around hydraulic plant or equipment.

Email: info@pirtek.co.uk

www.pirtek.co.uk

Fluid Handling PTFE Labware from Bohlender Bohlender offers a vast range of finished and semi finished products in technical and fluoroplastics.

A variety of different materials like PTFE, FEP, PFA, PEEK and others enable innovative products to be produced with excellent chemical resistance and high thermal resistance.

Screw joints and ground joint components, tubing and connectors allow an infinite number of combinations to create sophisticated systems of fluid transfer using standard laboratory bottles and containers.

For distillation of strong acids or alkaline products BOLA manufactures reaction vessels up to 6 litre capacity in PTFE or PFA. All parts exposed to the medium are either made completely of PTFE/PFA or jacketed like the thermometers.

The BOLA catalogue also includes a wealth of technical information on the materials used including physical properties and chemical resistance and the safe use and care of fluoroplastic labware.

Further advice on the pressure resistance of tubing and the correct choice for pressure or vacuum applications make the catalogue a useful reference. www.labtex.co.uk

68

PECM Issue 20

740400 or visit us online.

RESPOL - innovative flooring solutions GUARANTEED!

www.industrialflooring.co.uk

Meeting the Demand for More Complex Process Control Systems Process control systems in almost every

"The diversity of requirements and the

In practical terms this strategy can deliver

industry are becoming more complex; they

global appetite for these systems means

a number of improvements such as

are subject to greater scrutiny due in part

that manufacturers need to take a new

reducing supply chain management costs

to the demand for improved efficiency,

approach in order to meet demand.

while improving production agility and the

regulatory compliance and higher levels

Bürkert manufactures over 100,000

use of internal resources.

of automation and plant integration.

different products for example, typically

The need for bespoke or low volume

valves, actuators, sensors, controllers

Jens Fuhrmann, General Manager

system design is also growing as a result.

and combined devices. Applying these

at Bürkert's Dortmund Systemhaus,

Bürkert has addressed this challenge by

products to scenarios that require

comments: "Modern process control

developing the Systemhaus approach,

specialist assemblies requires skill and

systems can encompass a huge range

where regional technology solutions

experience as well as an imaginative

of parameters, deliver micron levels of

centres sit between the sales offices and

approach, but without the volume

accuracy and repeat millions of cycles, all

larger-scale manufacturing facilities,

constraints of large scale production runs.

the while recording data for standards

solving problems and building innovative

This is where we use our Systemhaus

compliance or historic analysis. However,

systems on-demand.

network."

designing, building and delivering a

Neil Saunders, UK General Manager for Bürkert, explains: "The market for small volume, specifically tasked control systems is certainly growing and the operational environments in which this equipment is working are complex and governed by a considerable amount of legislation such as ATEX or food and pharmaceutical safety and cleanliness standards for example.

End users realise that transferring the responsibility of meeting these demands to a trusted supplier can reduce costs and increase operational efficiencies.

The definition of a bespoke control system means that the designers have to start from the ground up, working closely with the client to establish what will be

new process control system requires considerable expertise and flexibility, as well as an in-depth knowledge of the industry standards and specifications.

delivered by the new system and how best

“These teams can procure all the necessary

to achieve it. Often existing technology and

components, both from our own product

components will have to be integrated with

lines and from external suppliers in

unique parts and custom designs in order

order to achieve the most effective

to achieve the best solution.

solution for the client. At the same time

The principle of outsourcing this type of project is considered by the vast majority of OEMs as an essential part of manufacturing strategy that allows them to remain competitive in a rapidly changing global market.

all the components must be seamlessly integrated and work together to deliver the required control structure and meet the necessary industry standards.”

"The most effective way of delivering a bespoke project is to assign a team that contains all the necessary skills and expertise to design, simulate, prototype, construct and test the finished product. Working closely with the client, this team has the ability to ensure the most efficient methods are used to develop an idea into the completed design.

Each industrial sector has its own

Similarly, components and systems

The completely in-house build programme

requirements and these must be adhered

operating in potentially explosive

will ensure that all the necessary

to if any new product is to be accepted

atmospheres must be suitably tested and

components, including HMIs, PLCs and

under the current certification scheme.

certified as safe for such an environment

their programming will be integrated and

There are statutory requirements of

using the ATEX and IECEx standards.

ready to connect with the host system. We

HACCP (Hazard Analysis and Critical

This is an area that requires considerable

continue to support all our customers with

Control Points) for the food processing

expertise and design knowledge in order

their own projects, however, sometimes

industry that set very precise standards

to deliver a packaged solution, typically

you need the scope and resource of an

with regards to cleanliness, safety and

on a skid or in a cabinet that is tested

original equipment manufacturer to

product quality. These standards are aimed

and guaranteed to operate safely once

deliver. The fact that we are using our

to protect the consumer and they are

installed.

Systemhaus resources more and more in

enforced rigorously in most countries by regulation.

Industries that are required to adhere to stringent hygiene regulations need process control systems that will seamlessly integrate into the existing, predominantly stainless steel process structure. B端rkert ensures that all pipework associated with a design is fabricated and welded by engineers that are ASME (American Society of Mechanical Engineers) coded for process piping.

Neil Saunders concludes: "The benefits of collaborating with an industry leader that has the resources and expertise to deliver bespoke or short run projects should not be underestimated. The potential to reduce manufacturing lead times and costs as well as providing a guaranteed fixed cost of ownership allows a client to concentrate on their core business and improve their own productivity.

"The depth of knowledge and experience within B端rkert ensures that the finished solution will fully satisfy the client's expectations.

the UK just serves to underline the fact that the market has changed and will continue to do so."

Fluid Handling

The Formidable Team of Guided Wave Radar and Non-Contact Radar R

adar technology has revolutionized level measurement in a variety of process industries since the introduction of 4-20mA loop powered, radar-based transmitters in the 1990s. Both guided wave radar (GWR) and non-contact radar have numerous advantages over older, more established level measurement technologies. In a recent article for Industrial Products Process and Technology Magazine (IPP&T), Magnetrol®Global Product Manager Bob Botwinski discusses the benefits of using these radar technologies versus traditional level instrumentation, and how guided wave radar and non-contact radar can work together to provide reliable level measurement. Here’s an excerpt from the article: Both guided wave radar and non-contact radar have the same general principle of operation (microwave time of flight) and no moving parts. Because of this, users can retrofit these radar transmitters into various process applications and see improvement in efficiency and accuracy, including applications that use these technologies:

• DPs, due to SG shifts, installation cost, and leak points • Buoyancy, due to SG shifts, moving parts, calibration issues, and cost • RF Capacitance, due to cumbersome calibration, dielectric shifts, and coating issues • Ultrasonics, due to vapor effects, turbulence, and foam Guided wave radar and non-contact radar are related technologies, and together they are a powerful combination that can cover the majority of your continuous level control needs. A very similar user interface and quick disconnect electronics means that, if you know how to use one, you’ll know how to use the other.

More Information The IPP&T article contains an overview of the two technologies, the best applications for each technology and information about what to look for when selecting a radar-based device.

In addition, MAGNETROL has created a radar solutions site with more information on both guided wave radar and non-contact radar level control technologies. radar.magnetrol.com

The IPP&T article

72

PECM Issue 20

Radar Solution Site

The Radar Punch

Magnetrol

ÂŽ

Total Radar Solutions Count on best-in-class Guided Wave Radar and Non-Contact Radar performance â&#x20AC;&#x201C; to knock out all of your level control application challenges.

radar.magnetrol.com

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Š 2016 Magnetrol International, Incorporated

Saving energy made easy.

Minimizing carbon footprint in pharma production has never been easier: A tube valve body is an innovative energy saver. It outperforms forged bodies by far. With less weight, it heats up and cools down much faster â&#x20AC;&#x201C; saving you steam, time and energy in CIP and SIP processes. Imagine that saving multiplied by every single diaphragm valve in your plant.

Tube Valve Bodies â&#x20AC;&#x201C; for more efficient processes We make ideas flow. www.burkert.co.uk

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Health & Safety JSP’s Press to Check™ Filters – Supreme Compatibility with Faceshields and Visors Wearing face-protection equipment such as faceshields and visors is no problem when they are used with JSP’s Press To Check™ filters on a half-mask. The low-profile, swept-back design of the Press To Check™ filters enables excellent visibility, allowing the filters to be worn effectively behind all types of faceshield and welding visor.

End users are now therefore able to achieve a truly compatible half-mask solution with their faceshields whilst also receiving the award-winning functionality benefits of the Press To Check™ face fit check system. The unique hinging system on JSP’s Press To Check™ filters enables the wearer to quickly determine whether a correct face-fit has been achieved every single time they put on their half-mask before entering a hazard area, without disturbing the fit to the face, so providing daily face-fit reassurance. This is one of the features that led to the product winning the BSIF Product Innovation of the Year Award in 2014.

Tel: +44 (0)1993 826050

Email: uksales@jsp.co.uk

Electrical Safety Assured with Rittal’s TS 8 Baying System Safety and security are two high priorities for installers and users of electrical switchgear. To prevent personal injury or property damage as a result of issues such as fault currents (short circuits), a number of industry standards and regulations have to be followed.

To help limit this risk, Rittal has developed an effective solution with the TS 8 bayed enclosure system. During the assembly phase, the side panels, enclosure roof, rear panel and gland plates are automatically connected to the frame conductively.

This means potential equalisation can be achieved without necessarily having to connect these parts with earthing straps (although the final decision as to whether to leave earthing strips out completely is up to the user).

Automatic potential equalisation with the Rittal TS 8 baying system offers the following benefits: • It saves mounting as many as seven earthing straps • It simplifies the assembly and disassembly of all the panels.

Further information at www.rittal.co.uk

Denso Void Filler Protects Anchor Head Caps on New Belfast Footbridge

Heavy duty floorings, coatings and tile linings from Prokem

Graham Construction of Hillsborough, Northern Ireland, used Winn & Coales Denso Tape and Denso Void Filler during the construction of the new £5million Lagan Weir 120m pedestrian and cycle bridge. Replacing the old footbridge, it improves the links between Belfast City Centre to the Queens Quay Development and the Titanic Quarter.

Prokem offers a variety of heavy duty floorings, coatings and tile linings to handle virtually any physical or chemical abuse found in commercial and industrial environments. Prokem install floors which are: • Aesthetic – a variety of colours and finishes are available • Tough – in addition to chemical resistance, Prokem can install floors which are highly durable and resistant to mechanical wear

The new footbridge consists of a cantilevered deck, built from structural steel enveloped in aluminium cladding. Denso Tape was used to protect anchoring bolt threads , with Denso Void Filler used to fill the anchor head protective caps on the rear tension support frame.

• Safe – Prokem can install level floor surfaces with anti-slip finishes and safely markings

Denso Void Filler is based on a microcrystalline petrolatum containing corrosion inhibitors and moisture repellents. It forms a permanently flexible medium for the encapsulation and protection of bearings, tendons, stay cables, among many other applications. It has been used on a variety of major civil engineering projects, including both Severn Bridges.

Based in Derbyshire, Prokem have a proved track record in projects across the UK and Worldwide. Projects include chemical-, corrosion-, acid- and oil-resistant flooring, tiling and coatings, including anti-slip, epoxy resin and synthetic resin coatings for tanker unloading bays, containment bunds, bund relining and recoating, pickle tanks, potable water tanks, sewage & effluent storage.

Email: mail@denso.net

Whatever you need, Prokem have a solution for you. Contact Prokem on +44 (0) 7713 856433 or info@prokem.co.uk www.prokem.co.uk

www.denso.net

Innovative Solution for the Prevention of Crevice Corrosion at Pipe Supports Corrosion at pipe supports is one of the leading causes of topside and above ground piping failures, which can have potentially catastrophic results. Traditional styles of pipe supports including beam, clamp and saddle create crevices where water is trapped and held in constant contact with the pipe surface. Once corrosion is initiated in these areas it can quickly undercut the paint film, resulting in rapid wall loss generally in the form of pitting. If these conditions are not addressed, entire sections of pipe can fail and require replacement.

I-Rod is a durable thermoplastic, extruded and cut into a half round rod. It is the key component in all of Deepwater’s I-Rod pipe supports. www.I-Rod.com

BSRIA Instrument Solutions applauds the BOHS Breathe Freely Initiative Instrument Solutions, a key supplier of products into the Health & Safety market has applauded the newly launched Breathe Freely collaborative initiative, designed to prevent occupational lung disease in the construction industry. Led by BOHS (The Chartered Society for Worker Health Protection) – in partnership with key organisations – it will provide guidance, tools and resources that facilitate the recognition, evaluation and control of workplace exposures leading to the implementation of a recognised management standard.

The TSI PortaCount Pro+ is part of a portfolio of instruments offered by Instrument Solutions to ensure users of RPE (Respiratory Protection Equipment) are safe in the workplace. It is complimented with instruments such as background dust monitors including the recently released TSI environmental DustTrak that can be used to monitor ambient levels of pollutants in external environments with information stored in the cloud for immediate access anywhere in the world.

The PortaCount Pro+ respirator fit tester is used for the testing of full facemasks, SCBAs, respirators including disposables (P1 and P2 versions).

www.bsria.co.uk

• Hygienic – Prokem floors are perfect for use in the food and dairy industries

New JSP EVO5® Olympus® ABS Safety Helmet offers the world’s highest levels of protection and ultimate comfort and fit As part of JSP’s commitment to improving occupational safety and health worldwide through innovation and intuitive products, the company has just launched the Global Standard EVO5® Olympus® safety helmet - the latest addition to JSP’s market-leading Evolution® (EVO™) industrial head protection range.

Conforming to multiple international standards including European, American, Canadian and Chinese, the EVO5® Olympus® helmet is the perfect choice for multinational companies with sites all over the world. This international helmet combines an extremely robust ABS shell and a specially designed Evolution® 3D adjustment harness offering the perfect fit and excellent levels of comfort and thus ensuring it can be comfortably worn throughout the working day.

Tel: 01993 826050 www.jsp.co.uk

Email: uksales@jsp.co.uk

KlenzGuard - The Safest Delivery Possible “Connecting Chemicals Correctly” Klenzan, one of the UK’s leading suppliers of hygiene solutions is excited to launch a unique innovation in the safe delivery of bulk chemicals – KlenzGuard.

The risks of delivering the wrong chemical into the wrong bulk tank are well documented with severe health & safety risks associated with mixing incompatible chemicals with the accompanying financial losses and costs.

Existing primary controls involve reliance on the delivery driver / operator ensuring that the correct transfer pipe is connected to the correct inlet pipe introducing the risk of human error, a risk that KlenzGuard removes.

Contact Klenzan for more information Klenzan Ltd: 2 Cameron Court, Winwick Quay, Warrington, Cheshire WA2 8RE T: 01925 234696 F: 01925 234693 E: info@klenzan.co.uk www.klenzan.co.uk

Issue 20 PECM

77

Staying on the Right Side of Legionella Law New rules on legionella risk assessment and control get tougher

R

ecent changes to legionella regulations by the health and safety executive (HSE) have put

greater responsibility on businesses to

Legionnaires' disease.

With symptoms resembling the common cold, this disease can be even more difficult to diagnose at first glance.

Government is keen to crack down on premises at risk. The Health and Safety Executive (HSE) has issued new guidelines called the L8 Approved Code of Practice (ACoP), fourth edition. These guidelines

actively manage the legionella risk in

Although everyone is susceptible to the risk

are accompanied by technical guidance

their water systems. Businesses failing

of infection, the likelihood is exacerbated

documents in three parts to make it easier

to meet the new regulations could face

with age and in people with weaker immune

for businesses to comply with the law.

prosecution as part of a concerted effort

systems such as diabetics, smokers and

to drive improvements in the sector. Here

heavy drinkers.

Dr. Simona Vasilescu, from the Water

While the concentration of legionella

Treatment Innovation Platform at NCH

specific people of responsibility within

bacteria is relatively low in nature, it can

Europe, looks at what businesses need to

them. 'Dutyholders' such as employers,

quickly multiply upon entering a business's

do to stay in control.

landlords and those in-charge of any

water supply. The warm, humid conditions

site, now have a legal responsibility to

Ingested, the bacterium Legionella

created by stagnant water in storage tanks,

identify and manage the risk of exposure

pneumophilia is relatively harmless. After

heat exchangers and miles of piping,

to legionella, develop preventative and

all, it exists in low numbers in natural water

provide a thriving breeding-ground that

control measures, ensure the process is

sources such as rivers, lakes and reservoirs.

can quickly harbour a breakout.

recorded using a regularly updated, 'living

However, trapped in a microscopic droplet

Regulatory reform

document' and appoint a competent

of water vapour and breathed into your lungs, it can lead to the potentially fatal

78

PECM Issue 20

To drive improvements in the health and safety of people at work, the UK

The new rules now increase the responsibility on companies and on

authority to implement the control measures.

A water system includes all the plant

The new rules are certainly clearer

equipment and installed components

in defining the responsibility

such as pipes, pumps, feedtanks,

of businesses when it comes to

showers, heat exchangers, quench

mitigating the risks of legionella

tanks, water softeners, chillers and

exposure. While at first this may

humidifiers to name just a few. These

seem daunting, with the right

kinds of setups are very conducive

help and use of control methods,

to stagnant water temperatures

businesses can not only comply

between 20-45 degrees Celsius in

with the law but also become

water sources, which can lead to spray

examples of best practice.

and legionella laden aerosols.

As a business, it's often easy to overlook the fact that although the mains utility has a responsibility to provide a bacteriafree water supply, once the mains supply enters the building at the ball valve, even small amounts of bacteria can quickly multiply. Pipes under buildings and facilities are often decades old, containing rust, slime and microbiological films. These are perfect environments for legionella to thrive.

Stress free Step by step So what do you need to do to make sure your system is not at risk? The first stage is to establish whether your site is low risk or not. If you're in a small building with no water storage tanks, where the cold water comes directly from the mains and hot water is fed directly from instantaneous or low volume water heaters at around 50 degrees Celsius, then there is very little risk of exposure to individuals. Here, the

For many companies it can become a nightmare to take control of this process.

Although temperature-based monitoring is straightforward, many businesses simply don't have the expertise to deal with the more complex control methods that include chemical dosing and water treatment. Luckily, the regulations make it permissible for businesses to appoint a competent authority to manage the assessment and control of legionella.

only source of risk is from toilets and hand

When it comes to water treatment, it's

washbasins.

important to select the right chemicals.

If you are low risk, you don't need to take further control action. You simply need to perform a regular risk assessment, document the process, and review it when changes are made to the system.

For businesses operating in anything other than a small building, for example if you're running a plant, the risk is much higher. Facilities that have more complex water systems need to create an asset register; a schematic diagram of the system highlighting deadlegs - lengths of pipework where water can stagnate - and identifying possible sources of contamination as well as assessing current

Whether it's chlorine, bromine or any oxidising biocide, understanding contact time, system water-turnover rates and half-life are essential in developing a sustainable long term treatment plan.

It's also more cost effective to outsource the sitesurvey assessment and monitoring to an expert that really understands how to keep your business compliant.

disinfection and treatment methods.

Issue 20 PECM

79

Computer Aided Engineering meets rupture discs EMBE is continually expanding its portfolio of products and services. The latest addition to its consulting and engineering services is currently REMBE CAE. Until recently any customers who needed strength certificates, tightness analyses or temperature profiles, had to get these separately from engineering firms. This is now no longer necessary. REMBE is the first company of its kind to offer CAE services, so that each customer receives not only high-quality products but also comprehensive solutions and

R

therefore genuine added value: lower costs and specialist calculations of explosion safety and pressure venting as a guarantee for highly dependable results.

“Originally CAE was used entirely for in-house purposes. However, we had such positive feedback from so many customers that we decided to intensify this service.”

“We’ve been more than product suppliers for a long time now. Our specialists are continually on the customers’ premises, viewing their systems and developing specially tailored, cost-effective safety systems, partly also with the help of our CAE tools,” says Stefan Penno, Managing Director of REMBE GmbH Safety + Control.

So far customers have mainly requested strength calculations and tightness certificates.

But REMBE’s CAE professionals are already working on a wide range of further options.

Contact: Email:- info@rembe.de www.rembe.de

Stress distribution in an assembly comprising flange, holder and rupture disc.

80

PECM Issue 20

T +49 2961 7405-0

Made in Germany

Your Specialist for PRESSURE RELIEF and EXPLOSION 6$)(7<

Consulting. Engineering. Products. Service.

Gallbergweg 21 | 59929 Brilon, Germany F +49 2961 50714 | info@rembe.de | www.rembe.de Š REMBE | All rights reserved

IP69K: FQ rotational speed sensors from RHEINTACHO The intelligent continuation of a success story

W

ith its high IP69K protection class, RHEINTACHO is set to introduce a complete new series of plastic sensors for detecting rotational speed and direction from the second quarter of 2016.

Thanks to different sensor lengths, cable outlet directions and connector options, this product line offers users a high degree of flexibility, enabling adaptation to entirely individual requirements. And even if none of the available models is suitable, RHEINTACHO will be pleased to draw on its recognised expertise in customised solutions to develop the right solution for you.

Why IP69K? RHEINTACHO Sales Manager Wolfgang Sexauer: “There are two main reasons why we were motivated to develop this new series.

Firstly, we see a tendency to specify higher IP classes in many applications for safety reasons, than was the case a few years ago. Secondly, the IP69K

protection class enables technical potentials to be realised even more efficiently today. This applies to both available materials and, of course, to intelligent constructions.”

The FQ product line is consequently a further development of the current FK product line, which fulfils protection class IP65. In recent years the FK sensors have developed into a genuine success model. Numerous electromotor applications would be inconceivable without these rotational speed sensors.

The basic geometrical data for the RHEINTACHO FK has meanwhile been adopted by significantly larger competitors too.

The electronic design of the FQ product line is successively complemented with different variants in order to fulfil different requirements. In detail: Frequency range, detection distance, EMC and temperature stability.

According to the current development plan, all versions will be designed as a two-channel sensor, enabling the

detection of rotational speed and direction of rotation.

RHEINTACHO wholeheartedly welcomes higher specifications from users in regard to its sensors. “Our experience has shown that specifying too low an IP class and putting the onus on users via operating or maintenance instructions, is not practical. This simply doesn’t work”, continues Wolfgang Sexauer.

“When a machine is to be cleaned with a steam jet for practical reasons, it is difficult to convince the operators otherwise – regardless of what is found in the operating manuals. Subsequent problems “in the field” are then inevitable. Whether in consideration of all actual costs a more cost-effective, lower-specified component is then the means of choice is at least doubtful.

And just for this reason we are expanding the proven FK product line to include the FQ series with its higher protection class. We always strive to offer the best technical and economic solution, tailored to the specific application.”

New rotational speed sensors of the FQ series from RHEINTACHO

Rheintacho UK Ltd. Enterprise Court, Pit Lane Micklefield, Leeds, LS25 4BU Tel: +44 (0)113 287 44 11 www.rheintacho.co.uk 82

PECM Issue 20

Health & Safety

StuvEx Safety Systems Abbey Studio, Church Walk, Chertsey, Surrey KT16 RE - nited Kingdom

Tel: +44 (0)1932 571303 - Fax: +44 (0)1932 570548 E-mail: info@stuvex.com - www.stuvex.com

Transparent Graphene Coatings for ATEX Handling Environments TBA’s new permanently conductive graphene coatings provide effective static elimination for electronics safe handling and explosive atmospheres.

Fully compliant with BS EN 61340-51:2007 and ATEX, the coatings contain carbon nanotubes and graphene.

Giving light transmission of around 85% and surface resistivity of <107 ohms/sq the acrylic coating, available in paint or aerosol form, can be applied to in-situ light fittings, windows, clear covers and lids to provide a permanently conductive surface.

For more flexible surfaces made of polyurethane, P C and rubbers such as flexible monitors, the clear flexible polyurethane coating eliminates static in sensitive areas.

For flooring applications the water based epoxy gives excellent mechanical properties which will withstand abrasion, impact and has good resistance to a wide range of chemicals including oils, fats, solvents, acids and alkalis. Permanently conductive, the paint is particularly suited to ATEX environments where the risk of explosion through static spark is high.

Contact:- Gail Campbell TBA Protective Solutions Unit 3 Transpennine Trading Estate Gorrells Way, Rochdale, Lancs OL11 2PX Tel: 44 (0)1706 647718 Email: info@tbaps.com www.tbaps.com

Issue 20 PECM

83

From Switchroom to Container The fully integrated factory-built container for industry and infrastructure

A

20 metre container

to plan, design, implement, test and

costs, because it reduces testing and even

could accommodate

especially maintain a containerised

building times significantly.

approximately 2,000 cases

switchroom, as long as the right

of wine, a small cafe or your

monitoring is in place.

company’s next switchroom. Industrial sectors are taking advantage of this versatility, and containerised electrical switchrooms are becoming a common sight. Here, Nick Boughton, sales manager at Boulting Technology, explains why the answer to complex electrical projects isn’t always adapting the system to fit the space.

Traditionally, systems integrators faced with a project would build the equipment in-house, transport it to site and spend time installing and testing it. Although this sounds like a relatively straightforward process, the reality is much more complex and there are plenty of opportunities for

Temperature is one of the most complex things to manage in any switchroom, especially when the space doesn’t allow natural air flow. With a container, it’s easy to install the necessary HVAC equipment in the initial stage of the project, along with remote temperature monitoring and alarms, which allow control engineers to identify a deviation from the normal parameters long before it becomes a risk.

Remote or difficult sites The containerisation approach works particularly well for remote environments, such as substations located in the middle of nowhere. The reverse is also true. In busy locations or areas of high risk or high security, it’s much easier to fit and test a switchroom when it comes neatly wrapped up in a “box” that doesn’t need any unwrapping. In nuclear projects, for example, where security, regulations and radiation can be significant hindrances for

For larger or more complex projects, the

contractors a kitted out container is the

container approach also means better

easiest, fastest and most reliable bet.

scalability, because as long as the client allows for some space next to the original container, it’s easy to get another one

A recent project saw Boulting Technology design, build and install a 20m containerised electrical control room for a nuclear site. The container housed power

logistic difficulties to rear their ugly heads.

distribution, MCCs, control panel suites

Safe transport is always tricky, especially

and stand-alone control panels. Boulting

when your “passenger” weighs a few

Technology built the MCCs and control

tonnes and remote locations can be

panels in its Warrington factory, integrated

difficult to reach, particularly when there

them into a prefabricated container at the

are only dirt roads going your way. Once

company’s St Helens mechanical workshop

on site, the equipment itself – usually large

and completed the electrical fit out,

power distribution boards or motor control

installation and testing even before the

centres (MCCs) - can be difficult to get to

container reached the site.

wherever the switchroom is tucked away.

Additional health and safety measures

No more headaches

also need to be taken if there are people

2,000 cases of wine would lead to one hell

working in the building.

Fortunately, there is an easier way. By

of a headache (to drink or to transport!), but containerised switchrooms are commissioned, designed and delivered.

exactly the opposite. They reduce the

the switchroom and building all the

Overall, the time it takes to design and test

overall project timescale and logistic

equipment, lighting, cabling and HVAC

a containerised switchroom is significantly

difficulties and they can be built exactly

into the room, companies can avoid most

shorter than a more traditional approach

to the requirements of a client. Boulting

of these logistic headaches altogether.

that fits a system to a room. It’s faster and

Technology has yet to come across a

The project is always client-led and

easier for the client, contractor and any

project it couldn’t tackle, so if you’re stuck

containerised switchrooms are highly

third parties to fit all the requirements in a

with a U-shaped switchroom with very

customisable, which means the approach

separate, controlled environment that can

small doors, don’t worry – a container

can reconcile even some of the toughest

be delivered to the site, plugged in and left

switchroom might be just the thing you’re

requirements in industry.

to run.

looking for.

Controlled environment

While it’s true that the capital cost of a

To find out more, get in touch with

containerised switchroom can be higher

Boulting Technology on +44 1925 720 090

than a traditional system, this approach

or visit the Boulting Technology website

usually results in lower overall project

on www.boultingtechnology.co.uk.

using an industrial container to host

The main advantage of containerisation is its controlled environment. It’s easier

84

PECM Issue 20

Hydraulics & Pneumatics

Tom Parker Ltd Introduce FasTest’s Pioneering Range ith over 40 years’ experience, Tom Parker Ltd is renowned, throughout the UK fluid power industry, as one of the leading distributors of pneumatic and hydraulic products. They have gained this reputation by focusing on supplying costeffective, innovative, global connection solutions. Their newly launched biennial product catalogue contains 34,000 high quality items from over 90 market-leading brands. Tom Parker Ltd is pleased to announce that they have secured an exclusive UK distributorship with US company, FasTest, further strengthening their already impressive portfolio.

W

Since 1985, FasTest has manufactured a wide range of quick test connectors and valves, designed for the industrial manufacturing, HVAC-R and compressed gas industries. They have secured more than 50 US and international patents for their state-of-the-art products, which improve testing and manufacturing processes whilst maximising efficiency, productivity and profitability.

FasTest’s ground-breaking FE and FI Connector Series were designed to improve automated product testing and provide fast, leak-free connections

for testing vacuum and pressure applications, fluid filling and flushing.

The connectors, suitable for use with air, gas or liquid, are manufactured with a superior performance seal material and are highly adaptable for pick and place robotic systems. They are easy to use, hardwearing, reliable and suitable for testing up to 500 PSI. Another of FasTest’s key product lines, the TwistMate Series, provides easy connection of internal and external threads and compression fittings, featuring a unique, hand tight twist to connect feature. It is suitable for vacuum and pressure test applications up to 10,000 PSI and provides seal vacuum to 5000 PSI. With a highly durable, stainless steel construction, these connectors can withstand demanding production environments, ensuring leak-proof sealing without the need for taping, thread sealants or wrench tightening. The TwistMate automatically seals when the main seal is pressed against the test piece and the system is pressurised with air, gas or hydraulic pressure.

This greatly reduces the number of test errors that lead to product loss, damage repair costs and time wastage. This

series is both safe and simple to use, with no risk of pressure build up in closed hydraulic systems.

As exclusive distributors to the UK, Tom Parker Ltd is delighted to now offer FasTest’s product ranges to their customers. Always a step ahead, Tom Parker Ltd can be counted on to source efficient, high quality, cost effective products for their customers. www.tom-parker.co.uk

Issue 20 PECM

85

Lifting & Handling Equipment

$u-7bŕŚ&#x17E;om bm Â&#x2039;m-lb1 mmoÂ&#x2C6;-ŕŚ&#x17E;om

& _-bmv |7

"r;1b-Ń´bv|v bm ;-Â&#x2C6;Â&#x2039; Â&#x2020;|Â&#x2039; b[bm] Ć&#x201D;Ć?Ć? b[bm] Ĺ&#x; -v_bm] obm|v =ou oŃ´ŕŚ&#x17E;m] Ĺ&#x; );Ń´7bm] o-7 1-r-1b|Â&#x2039; u-m]; Ć?ĺѾ |o Ć&#x2018;Ć?Ć? |omm; ) ŃśĆ&#x201D;Ĺ&#x160;Ć&#x2018;Ć?Ć? $omm; obv| ubm] =ou _;-Â&#x2C6;Â&#x2039; 7Â&#x2020;|Â&#x2039; Ń´b[bm] Ĺ&#x160;"! uo|-|;v Ć&#x2019;ŃľĆ?ĹŚ bm -Ń´Ń´ 7bu;1ŕŚ&#x17E;omv Â&#x2020;m7;u Ń´o-7 !& o@;u - Â&#x2030;b7; u-m]; o= ruo7Â&#x2020;1|v =ou _;-Â&#x2C6;Â&#x2039; 7Â&#x2020;|Â&#x2039; Ń´b[bm]

RUD Chains Offshore Lifting Applications Heavy Duty Lifting Capabilities 0.6 to 200 Tonne RUD manufactures a range of lifting and lashing applications that guarantee ultimate safety when lifting and moving heavy loads. OďŹ&#x20AC;ering over 500 diďŹ&#x20AC;erent tested and certiďŹ ed lifting/ lashing points for bolting and welding.

Their products have been increasing popular across the oďŹ&#x20AC;shore industry, due to their heavy lift capabilities of 0.6 to 200 tonne.

The ICE-LBG-SR super rotation load ring is one of RUDâ&#x20AC;&#x2122;s latest innovations

which possess an array of innovative designs. Firstly, the double SR ball bearing oďŹ&#x20AC;ers the ultimate solution for turning and ďŹ&#x201A;ipping at high working load limits without aďŹ&#x20AC;ecting the mounting bolt stability. It enables the load to rotate 360° in all directions under load. The advanced ball bearing technology is arranged in a double way which transfers the forces of the WLL into a rotation movement without jerks which avoids unintentional slackening of the fastening bolt.

RUD ICE Chain is widely used across oďŹ&#x20AC;shore, arctic oďŹ&#x20AC;shore and extreme materials handling projects due to its extreme resistance to temperatures operating from -60°c to +300°c. The chain is coated with RUDâ&#x20AC;&#x2122;s groundbreaking pink powder coating which acts as an overheating indicator, which shows the temperatures in which the chain can be safely used. If the chain reaches temperatures of 300°c or above it will turn from a pink colour to brown, then black which shows that the chain is unsafe to use and must be taken out of service.

As one of the worldâ&#x20AC;&#x2122;s largest manufacturers of lifting and lashing applications combined with their extensive range of products and knowledge in the market, RUD are continually innovating and developing their extensive product range to stay at the forefront of their customersâ&#x20AC;&#x2122; demands.

For more information call 01227 276 611, Email: Katie.crane@rud.co.uk or visit us at www.rud.co.uk

86

PECM Issue 20

Machining & Machinery

Solutions for safe & efficient working

Extraction & filtration (dust, fume, gas, oil mist) Cleaning (wet, dry, explosive) Production recycling (inc cutting fluid & coolants)

Systems to protect staff, reduce environmental impact and realise financial gains

Resource & waste management (metal, paper, wood) Workplace services (air, power, fluids)

Please contact us to arrange a free site survey

www.nederman.com

www.nederman.co.uk 08452 74 34 34

THERE IS SURE TO BE MAKA KNOW-HOW ON BOARD AGAIN. MAKA â&#x20AC;&#x201C; your technology partner for 5-axis CNC cutting systems from wood and composites to aluminium.

MAKA Machinery UK Ltd. C5 Horton Park IE., Hortonwood 7, Telford Shropshire TF1 7GX Tel: 019 52 - 60 77 00, Email: iy@makauk.com

www.maka.com

CNC Spezialmaschinen

Issue 20 PECM

87

Customized Protective Coatings Meet the Challenge of Extending Service Life for Rotating Equipment

A

chieving an acceptable

Long-term reliability is a common goal for

From there, the sources of degradation can

service life without

all plant operators, achieving it requires

be classified and specific coating systems

excessive maintenance can

a considered approach that takes into

can be used to increase efficiencies,

be a challenge for rotating

account a range of contributory factors

lengthen the interval between scheduled

equipment that is used in the processing

and makes use of the most appropriate

maintenance and reduce the occurrence of

and delivery of hydrocarbon products.

technology and manpower available

unscheduled maintenance events.

Thanks to the latest surface coating

to them. Rotating equipment that is in

technologies however it is possible to offer

direct contact with the process media and

Gas turbines example

massive improvements to the expected

under constant attack, presents a major

The flow path of air and fuel through a

service life of compressors, turbines

challenge; it is possible however to reduce

gas turbine presents a number of different

and pumps that are subject to surface

degradation to a minimum by selecting

conditions that can have an adverse

oxidation, corrosion, erosion and heat

the correct coating system.

effect on the performance of the turbine.

damage.

The combination of heat, microscopic Generally, turbines, compressors and

abrasives and a gradually increasing

Travis Cockrell, Component

pumps, are all subject to a variety of

concentration of corrosive elements

Superintendent of the Coating

environmental conditions that contribute

can cause significant damage to a once

Department at Sulzer's Houston Service

to corrosion, erosion, fouling and various

smooth airfoil surface. As the surface finish

Center, looks at some surface protection

temperature related issues. The first step is

slowly degrades, the efficiency of both the

processes and technologies that are now

to understand the operating environment

compressor and turbine is reduced.

being used to increase the durability of

of the machinery.

rotating equipment used in demanding operating environments.

88

PECM Issue 20

Compressor section This process can be arrested in the compressor section of the gas turbine,

Spraying (LPPS) or High Velocity Oxygen

Hot corrosion may take place between

Fuel (HVOF) - which one will depend

1450 and 1650 째F and it attacks the entire

on the coating thickness required and

surface of the component. Alternatively,

the sensitivity of the part to heat, as

corrosion at cooler temperatures is more

some processes are hotter than others.

localized and therefore tends to create

By applying corrosion inhibiting and

distinct layers of oxide and exposed metal.

surface finish enhancing coatings to

Further damage can be caused by erosion

the compressor section it is possible to

which involves repetitive mechanical

increase the efficiency and extend the

abrasion by particles in the air stream.

service life of the gas turbine.

Standalone High Velocity Oxygen Fuel Hot section

applied MCrAlY coatings are sufficient

Modern gas turbine hot section

to combat corrosion/oxidation at lower

components are made using nickel or

firing temperature gas turbines. For newer

cobalt based superalloys, which are

technology, higher firing temperature gas

designed to operate in high temperatures.

turbines, the combination of a MCrAlY

However, these alloy compositions are

bond coat coupled with a ceramic thermal

less well suited to providing corrosion

barrier coating will reduce the surface

and oxidation protection and need to be

temperature of the substrate and reduce

An aluminum base layer is typically used

supplemented with custom coatings that

the degenerative effects of oxidation and

in gas turbine compressors for corrosion

can deliver the hot corrosion and oxidation

corrosion.

protection of ferritic/martensitic steel

protection required for extended service

components in moist conditions. It

lives.

and the surface finish restored, by the application of suitable metallic coatings.

There is a range of options open to suit the specific duty of the turbine in question, but all include a type of metal deposition where a tough corrosion resistant surface is created.

provides galvanic protection, which means that small scratches to the surface layer are less likely to cause corrosion. It is produced by spraying a slurry of aluminum and an inorganic binder, rendered insoluble by a medium-temperature baking process.

This layer can then be covered by a harder layer that might include metals such as Chromium.

The harder layer is usually applied using a spray coating method such as Chemical Vapor Deposition (CVD), Air Plasma Spraying (APS), Low Pressure Plasma

The process of oxidation causes a layer of metal-oxide to form on the surface, which, in general, protects the underlying material.

Therefore the oxidation process slows down as the thickness of the oxide layer increases. This process can be replicated with the intentional formation of oxides that provide a protective layer preventing further atmospheric attack.

Corrosion of a gas turbine component usually occurs in one of two ways.

Issue 20 PECM

89

Tsubaki has the Answer for Automotive Coating Applications

A

utomotive manufacturers

large size chain and ancillary equipment

array of sizes and shapes and are used

put incredible emphasis

designed for carrying different vehicle

in all sorts of specialized equipment,

on the paint finish of their

types and models. These chains are very

including multi-axis robots. They are made

new vehicles. Not only is

durable and highly efficient to ensure

from a flame resistant certified material for

smooth, accurate, slip-free conveyance.

peace-of-mind use in areas that require

immaculate paintwork essential for that 'showroom appearance', it is also a vital

inflammability.

element in the long term environmental

The bodies are then transferred to a cart

protection of the body panels. Therefore

and delivered to a second coating station,

The top coat is sprayed on by special

paint shop plant and equipment must be

where a robot spray paints them with an

coating robots and reciprocating

of the highest calibre, and even the drive

intermediate grey coat which ensures they

machines, whose combined motion

chains must be of a quality that ensures

are smooth and ready for the top coat.

ensures the body panels each have a

smooth operations and reliable long term

(The grey coat also prevents the top coat

beautiful, even finish. The reciprocating

performance in harsh working conditions.

from fading over time.)

coating machines typically use drive chains such as lube-free Tsubaki Lambda

Chain and associated ancillary products

chain, which has special oil impregnated

are used throughout many major

bushes and is available in a wide range of

automotive plants, in just about every

sizes. Lambda is highly resistant to seizing

section of the production and assembly

and is not susceptible to excessive wear

process. Many plant engineers have opted

and therefore trouble-free, reliable and

for Tsubaki chain because of its reputation

long lasting, even in raised temperature

for smooth operation and reliability over

environments.

time. In fact Tsubaki chains and accessories have a track record of many years' standing

The carts are each driven by a small gear

All Tsubaki drive chain, including roller

in automotive production that embraces

motor, such as the Hypoid motor made

chain, heavy duty 'Super Chain' and leaf

most of the major manufacturers.

by Tsubaki. These are available with either

chain, is made from quality materials using

a solid or a hollow output shaft and in a

advanced manufacturing techniques

In the paint shop for example, the first

wide range of reduction ratios. The robots

which minimise chain wear and

stage of the coating section involves

have multi-axis movements so are highly

elongation. Thus they have a long working

vehicle bodies being hung from a chain

dexterous and therefore need support

life, a key requirement for the automotive

conveyor and passed through a tank of

and guidance for their power cables. This

sector, where plant stoppages (planned

primer coating. Tsubaki supplies a range of

duty can be entrusted to Tsubaki plastic

or unplanned) for maintenance are to be

conveyor chains suitable for this, including

Cableveyors, which come in an extensive

avoided at all costs.

90

PECM Issue 20

Machining & Machinery New Load Cell Test Machines for Straightpoint in UK and US Straightpoint has installed two new load cell test machines—a 100t unit at Hampshire, UK headquarters and a 55t system at the North American nerve centre in Camarillo, California.

The MTS universal test machine, which arrived in UK Installation the UK from the US manufacturer at the turn of the year, can test in compression and tension, giving Straightpoint the ability to test its entire range of load cells up to 100t.

The smaller 55t (or 120,000-lb.) tensile calibration machine completed a six-figure investment across both facilities in state-of-the-art equipment that can calibrate and re-calibrate load cells made by Straightpoint and other manufacturers.

Tel: 02392 484891

Manufacturer of High Quality

www.straightpoint.com

WARDJet Announces DSG Waterjet as Authorized Representative in United Kingdom WARDJet is pleased to announce DSG Waterjet as WARDJet’s authorized representative in the UK. It was the diversity of the machine and the ability to cut so many different materials accurately and at such high quality that initially drew Dodd and Sandell to waterjet technology. They both began in the industry as waterjet machine operators, then quickly moved to servicing machines and eventually machine sales. They began their own fabrication shop which they called Northwest Waterjet. 12 months later, they formed Northwest’s sister company, DSG Waterjet.

This partnership could not have come at a better time for WARDJet, as they were seeking to expand their presence in the UK. With their central location just north of Manchester, in Lancashire, and team of skilled technicians, DSG Waterjet will be able to handle service for WARDJet’s UK customer base better than ever before. As the only authorized representatives for WARDJet in the UK, DSG is also offering the full line of WARDJet waterjets and accessories, from budgetfriendly machines to complex custom waterjet systems. For more information, visit WARDJet UK’s website at www.wardjet.co.uk or DSG Waterjet’s website at www.dsgwaterjet.co.uk.

For instant gas analysis in the field - Agilent 490 Micro GC Designed to provide maximum flexibility and ease-of use, the Agilent 490 Micro gas chromatograph offers fast and precise analysis of on-line and off-line gas samples anywhere and is available as both portable and laboratory systems.

The portable configuration can be used for measurements at natural gas pipelines and metering stations, field perimeter monitoring and multiple drilling locations. No flammable gases are used so the analyser can be used in environments where operational safety is critical.

Anti Vibration Products

Email: sales@fibet.co.uk Visit: www.fibet.co.uk | Tel: 01282 878200

New Ultra-Thin Nickel Foil from Corrotherm Corrotherm International, specialist in the supply of nickel and nickel alloy materials, is adding a new product to its already extensive line-up of heat- and corrosionresistant alloys: nickel foil.

The new ultra-thin nickel foil offers excellent corrosion, welding and forming properties, making it an alternative to the more traditional cold-rolled nickel 200 and 201. The key advantage of the new nickel foil over other alternative alloy products is that it can be manufactured in extremely thin sheets, as thin as 6μm - that’s thinner than a human hair.

Small, lightweight and equipped with rechargeable batteries and built-in gas cylinders, you can expect eight hours of productive field time. Sampling is through an integral pump with analysis completed in seconds.

Conventional rolling techniques don’t allow for such a thin result to be economically achieved. Instead the high-purity nickel foil (>99.97% nickel) is electro-deposited, which allows the material to be produced both thinly and in greater widths than with traditional techniques.

See www.analytix.co.uk for more information. Enquiries to Analytix on 0844 800 4220 or sales@analytix.co.uk

Email: sales@Corrotherm.co.uk

Configurable power supply for highest system availability

AirBench releases Highly Efficient VertEx Booth

Now, with Quint Power, Phoenix Contact offers the first customisable power supply in the world that can be delivered preset on request. Reporting thresholds and characteristic curves are individually adapted via the NFC interface.

AirBench Ltd are pleased to announce the release of our new modular booth designed for attachment to the VertEx cross-draught system.

The integrated Selective Fuse Breaking (SFB) technology delivers six times the rated current for up to 15 milliseconds to selectively trigger standard circuit breakers.

Consumers connected in parallel continue to work. The static boost with up to 125 percent of the rated current is available at all times, allowing the system to be conveniently expanded. For starting heavy loads, the dynamic boost with up to 200 percent of the rated current for up to five seconds is also available.

The advanced preventive function monitoring system provides an early warning of system-specific critical operating states, even before an error occurs. With their integrated gas-filled surge arresters, the single and three-phase 24 V power supply units offer high interference immunity and a mains failure bridging time of over 20 milliseconds.

Email: info@phoenixcontact.co.uk

www.phoenixcontact.co.uk

www.Corrotherm.co.uk

Using the new modular booth construction, a full environmental containment booth can be built rapidly from standard parts.

The use of very high efficiency fans allows the complete booth installation to operate from low power supplies while achieving very high airflows.

The booth shown in the above image is approximately 2.5m wide, 2.4m high, and 2.2m deep, and draws more than 20,000m3/h. This impressive air movement, and the associated booth lighting, all runs from a single 13a socket.

More information, including videos and datasheets, is available at www. airbench.com/vertex.

Issue 20 PECM

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Trotec Laser Reports Record Sales in 2015 I

n 2015 the Upper Austrian laser manufacturer reported record earnings of more than 100 million euros. The positive annual results showed growth of 42% over the previous year. The exceptional growth was attributed to three areas: a solid increase in core markets, significant advances in new product development, and an acquisition for laminate production in the US. Two thirds of the sales increase resulted purely from organic growth.

President Andreas Penz

The sales in Germany and the US were particularly strong in 2015; and the future expectations in these markets continue to look very positive. While, midterm growth is mainly expected in the Asian market. Trotec has more than 450 employees and production sites in Austria, Germany and the USA.

sales organisation, that is rigorously trained through the company’s globally consistent in-house Academy.

Headquartered in Wels, Trotec is a manufacturer of laser equipment for cutting, engraving, and marking as well as laser and rotary consumable

This past year, we broke through the barrier of 100 million euros; a goal we set for ourselves in 2008.

“This past year, we broke through the barrier of 100 million euros; a goal we set for ourselves in 2008.

Trotec’s key factors for success are the ongoing expansion of our technological leadership and our consistent focus on customers and their needs. I am proud that we reached the target through the consistent implementation of our strategy,” explains President Andreas Penz.

Speedy family

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PECM Issue 20

HQ Marchtrenk-front

To better support the growing Asian market, a plant in China is currently under construction. The technology leader is characterised by a direct

materials. With 16 sales subsidiaries strategically located around the globe, 70% of the Trotec team members are employed in locations outside Austria.

Trotec’s export share is 97%, and the growth trend continues steadily with an average growth rate of 24% over the past 15 years. The entry into new product areas such as the in-house production of engraved materials through the acquisition of Innovative Laminations Company in 2015 and the development of the large format business ensure the company’s continued growth. Trotec has already set new goals now that the company has reached the 100 million euro revenue goal set in 2008. As the first and most valuable point of contact for all laser users worldwide, the company will continue to pursue a path of growth.

For further information on Trotec’s laser machines or engravable materials visit www.troteclaser.co.uk, www. engraving-supplies.co.uk or call 0191 580 1184.

www.troteclaser.co.uk

Measurement & Monitoring 80 GHz : A New generation of radar liquid level sensor VEGA introduce VEGAPULS 64, a revolutionary 80 GHz frequency contactless radar level sensor for liquids. The smallest antenna diameter is less than a one pound coin, so it can be installed in the smallest of vessels. Its narrow, focused radar beam enables mounting closer to vessel walls, in long nozzles - even through isolation valves. It can handle foaming, turbulent surfaces, condensation or antenna build up, and also a great solution for level measurement of low dielectric products like LPG, without requiring stilling tubes. It has an accuracy of +/-2 mm, range up to 30m and ATEX approvals.

Mydax Celebrates 30th Anniversary 1986-2016 Mydax is proud to announce that we are celebrating our 30th year in business.

Starting in February 1986 with our patented refrigeration circuit utilizing embedded computer control, our slogan of “Advanced Temperature Control Technology” still holds true today.

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 3kW up to 30kW or more at -40°C available.

New 80GHz radar level sensor VEGAPULS 64 for liquids: The smallest antenna is no bigger than a 1 pound coin, an ideal solution for measurement in small containers.

More information available at: www.vega.com/radar

Please call or visit Mydax online for more information.

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

What do Major Water Utilities, The Houses of Parliament, numerous Original Equipment Manufacturers, The Environment Agency, a leading US climate control business, all have in common?

They rely on Caption Data Ltd for Remote Monitoring and Control of their assets.

We have been doing “Internet of Things” since long before it was called that!

What you get when you work with CDL: ✓ Talented engineers who understand their business to help you run yours ✓ End – to End solutions, from hardware to cloud portal ✓ Specialists in remote, robust, tough applications. Hardware to suit. ✓ Digital, analogue, serial, Modbus, CANbus, etc. ✓ GSM, Ethernet, Bluetooth, Whitespace ✓ Beautiful SmartHub ✓ Simple and easy to deploy, safe to scale

Caption Data Ltd 01905 754078 www.captiondata.com

Non-Invasive, Latest Generation BDR Clamp-On Liquid Level Sensor INTROTEK INTERNATIONAL, Edgewood, NY, a global leader in ultrasonic technology introduces their latest integrated design for the BDR series of Non-Invasive Liquid Level and Air Bubble Sensors. The latest generation integrated BDR delivers the answer for challenging non-invasive liquid level and air bubble detection for a wide variety of rigid tubing size and materials including plastic, metal, and stainless steel. The BDR series sensor is designed for easy install, is dry coupled for metal and steel tubes and withstands the rigorous and demanding usage often found in the Pharmaceutical, Laboratory, Chemical, Waste Management, Aerospace and Food & Beverage industries. Complete specifications, dimensions and wiring information for the BDR and other Introtek products are available at www.Introtek.com.

Email: info@introtek.com

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PECM Issue 20

www.introtek.com

The ultimate for small tanks!

The future is 80 GHz: a new generation of radar level sensors

When it comes to contactless level measurement of liquids in small containers, smaller is better. With the smallest antenna of its kind, VEGAPULS 64 is simply the greatest! With its excellent focusing and insensitivity to condensation or buildup, this new radar sensor is truly exceptional. Simply world-class! www.vega.com/radar

Mahr U.K. PLC Measuring Solutions for Accurate Automotive Manufacturing Industry

R

ecent developments in the way that we approach climate change has ramifications across all manufacturing sectors, but the automotive industry has its own unique challenges in improving efficiencies and lowering emissions in the manufacturing processes as well as in the performance of the end products.

In order to stay listed as preferred suppliers you have to produce and verify products of the very highest quality, as well as providing reductions in friction and maximisation of fuel economy that will drive the improvements in carbon emissions.

Mahr • • • • •

metrology is used to test: Engine Components Injection Systems Steering Components Transmission Components Brake Systems

Combustion Engine Components

Recognitions to the use of new materials and improvements in production processes combustion engines are now 20% lighter than those produced in the 1980s. Accurate metrology has had, and continues to play, an important role in that development. When innovation drives change measurement and quality control is paramount to success.

Mahr metrology allows accurate measurement of: • Pistons inspection • Turbochargers • Valves • Crankshafts • Camshafts • Connecting rods

Injection Systems

When working with fuel pressures of up to 2,000 bars in order to atomise fuel, injection systems need to be manufactured to the highest standard.

With narrow tolerance bands you need a constant measure of quality, precision and process reliability. Able to work within tolerances of a few µm (in the case of the guide clearance between the needle and nozzle), our metrology tools offer state of the art measurement of geometry, surface profile and form through a range of hand and precision tools.

Gearbox

Our comprehensive range of gear metrology tools give accurate and reliable measurement of: • Gear shafts and loose gears.

• Contour measurement on dog teeth.

• Form and location measurements on shafts, parts and bearings.

• Surface measurement on tooth flanks, bearings and sealing surfaces.

• Dimensional testing on the housing and nearly all mounted parts.

Brake Systems

Safety is of paramount importance when it comes to brake systems. They have to work perfectly every time and being able to provide evidence of correct measurement for quality control is an essential part of the manufacturing process.

Mahr upon • • •

In order to stay listed as preferred suppliers you have to produce and verify products of the very highest quality, as well as providing reductions in friction and maximisation of fuel economy that will drive the improvements in carbon emissions.

metrology can be depended to provide: Component geometry Shape and position tolerances Roughness and depth measurement

For more details you can visit our website www.mahruk.com and for product information to can email at info@mahruk.com or call directly on 01908 563700

Mahr Celebrating

YEARS

DYNAMIC

20 UK

PRECISION

METROLOGY

YOUR PARTNER IN MODERN METROLOGY

Recent developments in the way that we approach climate change has ramifications across all manufacturing sectors, but the automotive industry has its own unique challenges in improving efficiencies and lowering emissions in the manufacturing processes as well as in the performance of the end products.

MarSurf LD Range Combined contour and roughness measurements in just one step come courtesy of proven cutting-edge technology from Mahr metrology. ◼ Roughness and contour in just one step ◼ High measuring and positioning speed cuts measuring times dramatically

MarShaft Scope Robot

AUTO O

MAHRU.K. PLC

MarForm MFK Range

Mahr presents at this year's Control Show metrology systems that are automatically loaded by robot, automatically measure all relevant characteristics of a workpiece and combine the results into one report.

MFK form tester ideal for testing engine blocks, cylinder heads, gear cases, hydraulic elements, crankshafts and camshafts.

Generously sized, optimized design for high measuring accuracy throughout the machine.

◼ Mahr introduces 100 percent control of a shaft close to the production site on four interlinked measuring stations without operator influence and with combined data evaluation.

◼ MFK Form Testers with 3 measuring and 4 set-up axes for measuring form elements ◼ Universal form measuring station with a large measuring volume for heavy workpieces

19 Drakes Mews, Crownhill, Milton Keynes, MK8 0ER, United Kingdom

Email: info@mahruk.com Website: www.mahruk.com Tel: 01908 563700

Highly Accurate, Easy to Use & Reliable

Electrode materials from Heinrichs are traditionally available in various media

Introducing the EP/UMF2 Electromagnetic Flowmeter from Heinrichs Our electromagnetic flowmeter is simple to use, delivering accuracy and long term stability to meet the demands of our customer’s flow applications.

HIGHLY ACCURATE • Standard accuracy 0,3% of actual ± ZP • Coil current up to 250 mA • Extremely stable magnet field EASY TO USE • Simple operation via 6 push-buttons • Clear text indication for intuitive operation • Validity check • Transmitter infinitely adjustable RELIABLE • Empty pipe detection • Coil current monitoring • Clear text failure indication

EPX/UMF3 version now available With pulse, status, current output as well as HART® communication it is possible to have full overview of the sensor performance and measurement accuracy.

All outputs are galvanically separated.

Lining material such as hard rubber, soft rubber and PTFE are available alongside Rilsan® and Wagunit®, which are specially suitable for hygenic applications and for drinking water applications.

Electrode materials from Heinrichs are traditionally available in various media e.g. Hastelloy, Platinum, Tantalum or Titanium.

To simplify the installation grounding electrodes are available as an option.

Tel: 01623 427701 Email: info.uk@kobold.com www.kobold-direct.co.uk

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PECM Issue 20

With pulse, status, current output as well as HART® communication it is possible to have full overview of the sensor performance and measurement accuracy. All outputs are galvanically separated.

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A new BEKA ATEX & IECEx certified intrinsically safe rugged panel mounting Set Point Station [set point generator], enables the current flowing in a 4/20mA loop to be manually adjusted from within a hazardous area. Housed in a 316 stainless steel enclosure, this new instrument may be safely installed in an Ex e, Ex p, Ex n or Ex t panel enclosure without invalidating the enclosure’s certification allowing easy integration with plant control equipment.

The instrument is loop powered and displays the process variable represented by the 4/20mA signal in engineering units on an 11mm high display. Frequently used values may be entered as presets. A display backlight, which may be loop or separately powered is available as a factory fitted option.

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For general purpose applications, the complementary BA647E-SS is a non-certified version, the stainless steel enclosure and impactresistant armoured glass window make it ideal for installation in severe environments.

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For further information including datasheets and certificates please visit http://www.beka.co.uk/rugged_setpoint_stations.html or phone the BEKA sales office on 01462 438301.

Compact field mounting indicator has large digits By adding compact field mounting instruments to their range of 4/20mA loop powered indicators, BEKA have solved the problem of displaying a process variable in a congested area where space is limited. The new compact ‘G’ models have a robust, IP66 impact resistant GRP enclosure with an 8mm thick armoured glass window, but retain the easy to read displays from the larger models.

These new ‘G’ indicators offer a choice of four 34mm high digits, or five 29mm high digits plus a 31 segment bargraph. All have a wide operating temperature of –40ºC to +70ºC and include a square root extractor, sixteen segment lineariser and internal calibrator. For no additional charge, instruments are supplied calibrated to customer requirements with a novel slide-in scale card showing the units of measurement and tagging information.

For further information including datasheets, certificates and application guides please visit http://www.beka.co.uk/compact or phone the BEKA sales office on 01462 438301

Latest Current Probes from PEM Measure High Frequency Motor Drive Common-Mode Currents Motor installers and design engineers can deal more effectively with high frequency (hf) common-mode currents caused by variable-frequency drives, using the latest non-contact current probes from Power Electronic Measurements (PEM) Ltd. The new CMC series of current probes, using Rogowski technology, empower engineers to assess the magnitude of the threat posed by hf common-mode currents, that can damage motor bearings and interfere with nearby electrical equipment. The current measurements can help determine suitable corrective action, such as fitting brushes, insulated bearings, or choke coils, and with further measurements assess the effectiveness of the chosen remedy.

The screened coils have excellent immunity to voltage disturbances and a low frequency (-3dB) bandwidth that attenuates unwanted 50/60Hz magnetic fields while maximising the SNR of the measurement of the high frequency common mode currents.

Further information can be found at www.pemuk.com/products/cmc-probe.aspx

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Rugged Set Point Station can be installed in an Ex e, Ex n, Ex p or Ex t panel enclosure

PECM Issue 20

Fluke 1738 Three-Phase Power Logger delivers comprehensive data to optimise system reliability and savings Fluke has introduced the 1738 Three-Phase Power Logger which offers extensive power quality and energy measurements, making it an ideal tool for conducting energy studies, power quality logging and wireless logging of associated analogue data. The Fluke 1738 is enabled with the Fluke Connect® app and the new, optional Fluke Connect Assets software, making it an ideal test tool for storing, archiving and tracking power quality measurement data. Other Fluke Connect 3000 Series modules can be connected to the Fluke 1738 to simultaneously log up to two other measurement parameters.

The Fluke 1738 Three-Phase Power Logger features an optimised user interface and an intelligent measurement verification function designed to reduce measurement errors by digitally verifying and correcting common connection errors. Setup can be further simplified by powering the logger directly from the measured circuit. The standard flexible current probes cover most applications, and optional current measuring accessories offer the ability to measure very low currents or up to 6,000A on larger conductors.

www.fluke.co.uk

Mabey Hire EnviroGuard System offers improved safety, efficiency and cost savings.

Mabey Hire Ltd, has announced the launch of its new EnviroGuard complete environmental monitoring system, featuring a modular range of instruments, detectors, power supplies and network communications that work together to provide unprecedented monitoring capabilities covering the full spectrum of industrial and construction monitoring needs.

Mabey Hire LIVE Instrumentation, Mabey Hire’s dedicated instrumentation division, will tailor every EnviroGuard installation to each customer’s exact requirements, selecting from a range of more than 15 sensor packages that detect and monitor everything from airborne particulates and wind speed to vibration, water pressure and volatile organic compounds.

The whole EnviroGuard system is managed from Mabey’s LIVEsite, a sophisticated web based suite of tools and reporting functions that allows users to monitor instrument readings in real time, export historical data and overlay readings to compare recent with historical data or correlate readings across different sensors.

www.mabeyhire.co.uk

Monitor

MORE

Processes.

Devices.

Locations.

IIoT Advantage: Visual Management for Process Visibility Red Lionâ&#x20AC;&#x2122;s ProducTVity Station is a ready-to-deploy system that gathers data to drive plant-floor performance and improve process visibility in days, not months. t Display real-time KPI data and Andon messages on any television t Enable communication between 300+ industrial protocols t Support a variety of physical interface media, from serial to Ethernet and USB

Learn more today at www.redlion.net/VisualManagement

Connect. Monitor. Control. I www.redlion.net Š 2016 Red Lion Controls, Inc. All Rights Reserved.

Measurement & Monitoring

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PECM Issue 20

Don’t over do it!

Where ever you are working we won’t over stress the installation.

By limiting test over-voltages to 2%, rather than the usual 10-20%, the NEW MIT400/2 series sets a new standard for insulation testing!

Insulation testing up to 1000 V and 200 GΩ range Single range, faster continuity testing from 0.01 Ω to 1 MΩ User variable insulation test voltage from 100V to 1000V Test result storage and Bluetooth® downloading Rechargeable options for mains and car charging

For more information call 01304 502 101 or visit our website at uk.megger.com Megger Ltd, Archcliffe Road, Dover, CT17 9EN

Lean In

A

s the world accelerates,

the customer receives what they want,

culture isn’t easy, and it isn’t something

more companies are

consistently, first time, every time. By

you can do sitting behind a desk. It is

looking to lean principles to

continually examining, experimenting

essential that everyone involved can

transform the productivity,

and improving those standard processes,

see, feel and experience the benefits of

quality and responsiveness of their

lean companies eliminate waste, reduce

the lean approach at first hand,” he says.

operations. To achieve its full potential,

errors and increase their ability to respond

“We had to take a ‘go and see’ approach,

however, the approach requires changes

to customer demand. Organisations don’t

spending time talking to our operators,

to every aspect of an organization

develop those capabilities overnight,

asking them about the problems and

and its culture, from sales processes to

however. Lean is a journey, involving deep

challenges they faced every day. Then

maintenance.

and far reaching culture change

we looked at how lean principles could

At Huco a leading manufacturer of precision

address those issues.”

In the decades since Toyota emerged as one of the world’s leading manufacturing organisations, there has been growing interest in the approach it pioneered.

Lean principles, the basis of the Toyota production system, are sometimes – incorrectly – seen as a way of organising manufacturing operations. In fact, lean is much more fundamental, applicable to any process within a business, from the back office to the factory floor.

At its heart, lean is about applying standards to business processes, to ensure

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PECM Issue 20

couplings, the journey to lean began in earnest a decade ago, when it became part of Altra Industrial Motion, a leading global supplier of power transmission components.

Over many years, Altra has developed and refined its own approach – the Altra Business System – adapting proven lean principles to the specific needs of the two dozen companies in its portfolio.

Some of the most important activities in lean are deceptively simple. Take the 5S approach for example: sort, set, shine, standardise, sustain. 5S is much more than workplace housekeeping. A properly organised workplace enables operators to do their jobs effectively, without wasting time searching for tools or materials, or working around obstructions. Even more

The first steps of that journey were taken

importantly, organisation brings clarity,

in Huco’s manufacturing operations,

allowing everyone to see problems and

explains Operations Director Liam Noone.

improvement opportunities.

“Changing long-established processes and

At Huco, acceptance of the potential of

Lead times have fallen from more than

minutes, then to ten. Now a changeover

lean came early, says Noone “We set up

four weeks to less than two days. Quality

takes 58 seconds, which means we can

a model of good practice in one area of

levels have risen dramatically and on-time,

manufacture in any batch size we want.”

our Hertford plant, establishing a cellular

in full delivery performance is now higher

approach to manufacturing, removing

than 97 percent. In some product lines

excess inventory and streamlining

customers can now order in any quantity

operations. The advantages of the new

they want, with guaranteed delivery within

approach were so obvious to everyone

three days.

in the plant that there was immediate appetite to adopt it elsewhere.”

This kind of performance matters. If customers have the confidence that they

Today, the company’s manufacturing

can get the products they need, when

operations have been transformed. It has

they need them and at the right quality,

established dedicated production cells

they can hold smaller inventories without

for each product group. The majority of

fear of downtime due to missing parts.

products flow through manufacturing

That means less cost, less risk and greater

processes one by one, rather than in

responsiveness in their operations.

batches. Production teams run those operations using standardised processes, with team leaders trained in problem solving and improvement techniques.

Management boards at each cell record problems and improvement opportunities, and the company uses Pareto analysis to focus its on-going improvement efforts on the most important issues first.

The new flexibility and responsiveness has called for changes right across the organisation, as sales and order management processes have had to adapt to cope with "a far higher number of transactions."

The company has changed its relationships with suppliers too, in order to streamline upstream processes as well as internal ones. Take heat treatment for example. In the past, parts might have spent a week or more at an external supplier receiving heat treatment, now, says Noone, the supplier

Customers have seized that opportunity,

will collect a batch of parts at 8.30am and

says Noone, changing their purchasing

return them 24 hours later.

habits to order smaller quantities more regularly. But that change in purchasing behaviour makes operational flexibility even more important. “We have done a lot of work to reduce changeover times between product lines,” he explains. “On our bellows coupling line, for example, it

For Huco’s customers, the impact of the

used to take 30 minutes to switch between

change has been highly significant too.

product types. We reduced that to 15

Despite the huge strides Huco has already made, there is still more to do, "An outsider looking at our operations might assume we are 99 percent of the way there," says Noone. "But we think we're only 30 or 40 percent into the journey."

Issue 20 PECM

105

Part of the company's TPM approach is aimed at relieving operators of the need to disrupt their work to attend to machine breakdowns or maintenance activities. "The responsibility for routine maintenance should fall to the team leader," Noone explains.

"We want a situation where the operator can concentrate on standard work and, if something goes wrong, they use an andon cord to alert the team leader to the problem." Elsewhere, the company continues to adopt practices developed and refined by its parent group. The latest of these is a certification system created as part of the Altra Business System.

"There are two levels of certification – silver and gold – and they can be applied to individual manufacturing cells or entire value streams," explains Noone.

To achieve certification, the cell or line must demonstrate that it has achieved 12 specific objectives, including proven problem solving skills, a suitably qualified and experienced team leader and a support network of maintenance and other personnel. Huco's first cell-level certifications are now taking place, and the company is moving towards certification of full value streams for key products in the near future.

"Certification is another important step," concludes Noone, "but in the lean culture of never ending continuous improvement,

headed, we are travelling day and night,

“We ran a TPM event on a single machine,

but the journey is never done."

and the amount we were able to take

there is always much that can be done.

Among the company’s on-going efforts

Everyone in the Altra group knows the

to further improve its performance is

'True North', the direction the company is

increased attention to maintenance activities. “A large number of our activities involve highly automated ‘lights out’ machining, which means the performance and reliability of our machines is of paramount importance,” says Noone.

“As machines age, their performance changes and so does their ability to hold

“These changes have produced significant productivity improvements,” says Noone,

the required tolerances. We realised that we need to know our machines better than their own manufacturers do.”

away from that session was mind blowing.

Changes to the machine included removal of redundant parts, the installation of new inspection panels and a number of measures to reduce the ingress of swarf and improve coolant and lubricant integrity.

“Combined with new operating and maintenance practices, the overall effectiveness of the machine as risen from 62 percent to more than 95 percent. By changing our maintenance approach, we’ve also been able to add years to the life of a machine that might otherwise

“Allowing operators from some lines

To gain that knowledge, the company

have been scrapped and replaced. Huco

to be reallocated to other activities

is introducing a total productive

is now rolling out the same techniques

and easing the challenge of finding

maintenance (TPM) approach across its

across its full range of production

new, skilled production personnel

operations. From the start this has been a

equipment.”

as older members of staff retire.”

highly informative process.

Call for a free on-site survey!

Old, Tired, Troublesome Valves?

Leaking shaft seals? Worn out valve? Product discharge problems?

We offer a free of charge assessment of any rotary valve or diverter valve to help diagnose the fault.

With DMN’s unrivalled knowledge and experience of rotary and diverter valves we are sure to have the solution to keep your process in operation.

O LI LIDS I DS HANDLING H AN ANDL D I COMPONENTS FOR BULK SOLIDS

Process Technologies

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

www.dmnwestinghouse.uk

H+E Industrial Water Treatment H+E designs, supplies, installs and commissions water and wastewater treatment plants for a huge range of industrial applications worldwide. Since 1932, H+E has built literally thousands plants, including many for the same client.

Treatment plants are built to meet the necessary discharge limits to enable the wastewater to be discharged. However, nowadays, as discharge limits become ever tighter and all costs increase, recirculation of the treated water is more commercially attractive.

Whatever your need is, for secure plant design, long service life and cradle-tograve service and technical support, do contact us and we will be pleased to discuss your needs.

Tel: +44 1403 272772 www.he-water.co.uk

Email: sales@he-water.co.uk

Cutting Precoat to 1/20th the Thickness of a Human Hair Filtration Services Ltd, a supplier of industrial vacuum filtration equipment for the bulk separation of solids from liquids has developed a unique precoat automatic knife advance system [AKAS™]. Precoated rotary drum vacuum filters (RDVFs) are used in many industries for a wide variety of applications.

They are used to ensure that the filtered liquid is clear, bright and, above all, solids-free.

Tel: 0208 339 7370 Fax: 0208 339 7371

Unit 5 Russell House, Molesey Road Walton-on-Thames, Surrey KT12 3PE

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PECM Issue 20

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

The AKAS™ uses synchronous digital technology to control the operation of a precoat discharge assembly in increments of 5 micrometres; about 1/20th the thickness of an average human hair. This level of control allows the knife advance rate to be finely adjusted and optimised for each application. Set up and operation of the AKAS™ is quick and easy via the touchscreen interface, with four built-in ‘recipe’ selections for switching between pre-set values. The control unit has the capability for local or remote recipe selection depending upon the site specific requirements.

Tel: 01625 616109

www.filtrationservices.co.uk

FLEXIBLE SOLUTIONS FOR ANY ATMOSPHERE A

meriflex, Inc.速 provides flexible solutions from conceptual design, prototypes to mainstream production and operates on a simple philosophy based on Integrity, Service, and Quality. Our commitment to this philosophy is put into practice on a daily basis in the manufacture of our precision bellows, flanges, and other quality products. With the latest in technologies we supply a wide range of industries ranging from Semi Conductor, Medical, Oil/Gas, Food and Beverage and Automotive. ur bellows and e pansion joints are designed to absorb and reduce

vibration and relieve structural stress from working under pressure, extreme temperatures, and other variables. We specialize in thinwall bellows. We also offer the highest quality metal braided flex hose in the industry. Our braided hose is designed for high pressure applications. It provides the protection needed for the inner convoluted hose to withstand high pressure and for vacuum or partial pressure applications requiring protection from hazards.

Our stainless steel braided hose can be found on ASA s uriosity Mars Rover, on still-in-development commercial spacecraft, and in countless other applications.

Also produced is a full line of bellows assemblies to complement our metal bellows. We manufacture bolt-style and clamp-style bellows assemblies, flanges, valve assemblies, and e pansion joints. very bellows assembly we make is ultrasonically cleaned prior to welding, and helium leak tested after to ensure weld integrity and defect-free construction.

2390 Railroad Street, Corona, CA 92880 Tel: (951)737-5557 www.a eri e .net

Issue 20 PECM

109

Product engineering and quality of materials

Our staff and our branches are close to you with 41 company premises worldwide

V-Belts and conveyors for more than 45 industrial applications

www.megadynegroup.com

V - BELTS

CONVEYORS

TIMING BELTS

Process Technologies Save energy & save money!

Air Dryer Technology is an independent specialist company providing service and after sales support on all types and makes of compressed air/gas dryer, filtration and condensate management systems.

The main activity is providing technical support and comprehensive packages for on-site servicing of compressed air/gas treatment equipment and desiccant air drying plant.

Air Dryer Technology also provides consultancy and equipment upgrades to increase efficiency and reduce energy costs. Retrofitting a dryer control system provides significant benefits by operating to actual site conditions, rather than original design specification. It will also restore customer confidence in equipment operation and performance.

Installing a dewpoint control system to a compressed air desiccant dryer will save energy, considerably reduce operating costs, and provide efficient dewpoint control. Features and benefits include; • • • • • • • •

Controls Compressed Air Monitor Dewpoint Extends Service Time Extend Cycle Time Constant Dryer Knowledge Retrofit Design Record Performance Data Installation Service/Technical Support

Tel: 0161 788 7900

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

www.airdryertechnology.com

Off-the-shelf colour anodised extruded aluminium enclosures KGA Enclosures provides a range of off-the-shelf colour anodised extruded aluminium enclosures, in various lengths and profiles. Our cases are used in electronic applications both for prototyping and production. We can customise the cases and end plates with holes, slots and graphics.

KGA is UK based and we hold a large stock of enclosures, end plates and accessories including dovetail mounting flanges and TPE end caps.

Telephone 01535 636856 Email sales@kgaenclosures.com www.kgaenclosures.com

Exact Tools Oy Offers PipeCut 360E the Portable Cast Iron Pipe Cutting Solution Exact Tools offers the PipeCut 360E for cutting a range of large-diameter cast iron, multi-layer, steel, stainless steel, copper, and plastic pipes. This model is the largest universal Pipe System that Exact Tools offers, featuring two-stage motor speed control, constant torque, soft start and automatic overload protection. PipeCut 360E easily cuts cast iron, multi-layer material, steel, stainless steel, acid-resistant steel, copper as well as all plastic pipes. This largediameter Portable Pipe System can cut 75 to 360 mm diameter pipes with maximum wall thicknesses up to 10mm.

One of numerous different models available, the PipeCut 360E is used in a variety of applications including water and waste water systems, power generation, refinery and chemical plants, hospitals and facilities, home building and renovation, shipbuilding, pulp and paper, heating and cooling systems, gas installations and maintenance and repair.

Further information can be found by visiting: www.exacttools.com

Issue 20 PECM

111

Barnshaws Enables Visitors to Ride New Arcelormittal Orbit Helter-Skelter

O

ne of the defining structures

to the design peculiarities of the sculpture,

highest quality. Barnshaws Hamilton

of the London 2012

the staircase required numerous sections

Branch enabled this via consistent quality

Olympics, the ArcelorMittal

of varying lengths and curves to achieve

checks to appropriate execution class and

Orbit reaches 115 metres

the desired effect. Luckily Barnshaws'

meticulous in-house research.

into the London skyline around Queen

expertise was available to complete the

Elizabeth Olympic Park. Designed by Sir

project to the highest specification. Due

Anish Kapoor and Cecil Balmond, the

to the great variance of sections required

famous landmark is now incorporating

to fabricate the staircase, months of

a 584 ft long helter-skelter to provide

testing time was needed to guarantee the

visitors with a unique view of the capital's

correct specification of section and that

landmarks. Set to be the world's largest

the spiralling applied to the sections was

tunnel slide, riders will be able to reach

accurate.

the heights of the structure thanks to the metal bending expertise of Barnshaws Section Benders Scottish Division.

The structure was initially opened as a centre piece attraction for the London 2012 Olympic Games, before being closed for its redevelopment into a public space, reopening to the public on 5th April 2014.

A structure that combines structural rigidity with sculptural instability, the spiral stair case ensures visitors can enjoy

Each section was required to be mandrel

all facets of the sculpture and its views

spiralled, a new process developed by

of the London cityscape. Despite the

Barnshaws, with each particular section

ArcelorMittal Orbit's somewhat unstable

When the structure was erected in

displaying varying length and spiral

appearance, those afraid of heights can

2012, Barnshaws' Hamilton Branch was

attributes. Due to the complicated nature

rely on Barnshaws metal expertise to

contracted to help produce the complex

of the process and variety of sections,

provide the confidence to make it to the

staircase to provide visitors access to the

it was vital to ensure that every piece

top.

top of the freeform skeletal structure. Due

of each particular module was of the

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PECM Issue 20

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

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

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

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

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

Duty Standby with CVE Package Plant

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

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

Pumps More than just pumps

Certified since 1995

FLUX – World leader in drum & container pumps.

FLUX - originator of the first electric drum pump - offers solutions for all industries with unsurpassed quality and numerous advantages over the competition such as: ` Materials (PP, PVDF, SS, AL, Hastelloy C) provide solutions for challenging fluid applications ` Offering pumps in lengths from 300 mm to 3000 mm accommodates pails, carboys, drums, totes, tanks ` Quality construction makes pumps easy to clean & maintain, providing extended service life ` Various design solutions for high viscosities, sanitary, mix & pump, 99.98 % emptying, etc. ` Vast product range including liquid meters, verticals, accessories, etc. - all from one source

Phone: 01202 823304 · sales@flux-pumps.co.uk www.flux-pumps.co.uk

Switches, Sensors & Systems

Issue 20 PECM

115

Switches, Sensors & Systems

Rotech Systems Number One For Screen Monitoring Solutions Rotech Vibration Sensor – VS4000 Series

M

ost modern screens are designed with the benefit of modern CAD & computer simulation techniques and can cope with a wide range of operational conditions under very different applications.

However, variations in feed rates and composition of the material being processed can, in some circumstances, result in an excessive amount of material being on the screen at any one time. If, as a result, the rate and speed of vibration of the screen slows down, even temporarily, problems can quickly occur, causing blockages, stoppages, downtime etc, inevitably leading to a major situation & proving to be very costly to rectify.

Material continues to be fed on to the screen at the normal rate but the slowdown causes the discharge rate to be reduced, a marginal overload can quickly enter a runaway

situation with material arriving at the screen causing an ever increasing overload and further slowdown.

Mechanical failure, V-belt ‘burn off’ or the intervention of the drive motors electrical overload is often the first time the operator will know that all is not well.

Rotech’s Vibration sensor VS4000 fitted to a screen is designed to monitor its rate of vibration and will operate an alarm or switch the in-feed conveyor off if the screen slows down. Even a drop in speed of 5% for a few milliseconds can be detached and action taken almost instantaneously. On V-belt-driven screens the drive motor can be switched off the moment any slippage occurs, preventing extensive & expensive damage to the belts.

The VS4000 signal output can be connected to the Plant Control PLC/Computer

Rotech’s Vibration sensor VS4000 fitted to a screen is designed to monitor its rate of vibration and will operate an alarm or switch the in-feed conveyor off if the screen slows down.

On V-belt-driven screens the drive motor can be switched off the moment any slippage occurs, preventing extensive & expensive damage to the belts.

The VS4000 signal output can be connected to the Plant Control PLC/Computer or independently used with the Rotech Vibration Relay – SR4000 series. or independently used with the Rotech Vibration Relay – SR4000 series.

Typically on a screen vibrating at 750 throws per minute, the SR4000 Vibration Relay is set at 725 TPM, if the screen speed drops below this level, the relay operates in less than 10 milliseconds, resulting in immediate protection of the plant BEFORE things start to go drastically wrong!

For details, Contact:+44(0)151 3562322 sales@rotechsystems.co.uk www.rotechsystems.co.uk

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Switches, Sensors & Systems

Make your checkweighers fit for speed and precision

Processes under control...

Plant safety, product quality and reproducibility are important factors to consider for every tank and batching scale. HBM components meet the most stringent demands - anywhere in the world.

At home in many sectors of industry - worldwide • Chemical Industry: HBM components provide winning solutions especially in potentially explosive atmospheres • Pharmaceutical Industry: HBM components provide for a constant quality of the medicines produced

Fit for speed Top speed in measurement signal conditioning with up to 180 weighings per minute, FIT7A is guaranteeing speed and efficiency in your machines.

Fit for precision Top values when it comes to precision, with standard deviations of only 0.1 g for 10 kg and the new accuracy class C4.

So your machines can guarantee safety and precision with minimum reject rates.

Fit for competition

• Cosmetic Industry: Batching with HBM products for lifestyle, health and beauty • Building Materials Industry: HBM load cells weigh tons of stocks in silos and batch e.g. additives for different types of concrete • Food Industry: Our hermetically encapsulated load cells in stainless steel construction provide for a long service life with absolute weighing precision, even in wet corrosion-hazard areas • Synthetic Material Processing: HBM technology supports weighing and batching processes in the synthetic materials processing industry • Animal Feed Industry: We ensure that your animals receive as much as they need • Steel Industry: HBM load cells provide reliable results even at high temperatures

With up to 60% cost advantage over other load cells based on electromagnetic force compensation, the FIT7A is competitively priced.

Process Weighing with HBM...

Your machines can stay competitive and help you open up new, previously unobtained market segments.

HBM provides complete process weighing solutions offering load cells and electronics as well as ready-touse weighing modules for mounting under silo feet. The products comply with current standards and, thanks to their high accuracy, ensure maximum efficiency in your processes.

More information: www.hbm.com/automation-fit7a

Silos, containers or stores: HBM offers the right solution whenever correct dosing and level measurement in process weighing is required.

We provide load cells, weighing modules, electronics and software for ...

• level monitoring • tank and batching weighers

HBM United Kingdom Ltd info@uk.hbm.com www.hbm.com

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PECM Issue 20

• weighing of additives and silos For further information, contact HBM on +44 (0) 20 8515 6000 or via email: info@uk.hbm.co.uk or visit the HBM website at www.hbm.com

Switches, Sensors & Systems Hummingbird Launches Innovative New TCD measurements for OEM Applications

WE BELIEVE IN ACCURACY WE BELIEVE IN ACCURACY Introducing our new G5 Series process weighing instrumentation with Introducing our new G5 Series extensive communication options process weighing instrumentation with extensive communication options

Hummingbird has announced the launch of its revolutionary TruRef Thermo-Conductivity Detector (TCD). The TruRef series of measurements covers applications requiring the accurate and stable measurements of a range of binary mixtures including helium, hydrogen and Argon.

Hummingbird’s TruRef is the world’s first true TCD gas measurement, which, for the first time, makes a true thermal conductivity measurement of a gas. TruRef technology co-locates the reference and measure elements under isothermal conditions in the sample gas, effectively eliminating the errors due to changing sample conditions such as pressure and flow. This patented measurement principle delivers unrivalled performance standards, particularly in terms of measurement accuracy, repeatability and stability - making it ideal for use in purity and process control applications.

Fully enabled by Hummingbird’s advanced Nekta communications protocol, the new transducer offers measurements that are available in ranges between 0-100% with high purity accuracy also offered. Other gases and ranges are also available. For more information on the full capability of the TruRef series, visit: www.hummingbirdsensing.com

Contact: blhnobel.uk@vpgsensors.com blhnobel.com Contact: blhnobel.uk@vpgsensors.com

blhnobel.com

©2016 Vishay Precision Group, Inc.

©2016 Vishay Precision Group, Inc.

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PECM Issue 20

Software & Systems

Issue 20 PECM

121

Ensuring Visibility and EďŹ&#x192;ciency Across The Manufacturing Environment

Storage, Handling & Distribution Blue Diamond Expands Storage and Distribution Capability Blue Diamond Technologies of Southampton, designers and manufacturers of custom-made mechanical components, has expanded its storage and distribution capability with the purchase of a new 1250 sq metre warehousing facility just along the road from the company’s existing headquarters.

Whilst previously all Blue Diamond operations had been housed under one roof, the additional space will allow even greater efficiency in the storage and distribution of the Company’s specialist products and will be particularly helpful as regards time-critical delivery arrangements such as Just-in-time (JIT) and KANBAN. To see a video of the preparation of the new facilities, go to YouTube and enter Blue Diamond Technologies Enhanced Storage.

Email:bdsales@rolwey.com

www.blue-diamond.co.uk

GA Pet Food Partners When Roger Bracewell purchased his tractor driven extruder in 1992 to turn the wheat grown on his family’s farm into a simple dog food, little could he have imagined that, 25 years later it would employ 350 people over two sites, and export their goods throughout Europe and beyond.

As the business grew over the years, technology has improved, and procedures have changed. There was the need to install high speed doors on some of the exterior openings to the production facility to help prevent ingress of pests as well as controlling the ambient temperature of the facility. The company selected a door that, at the time they believed would be perfect for them, from a company that they could rely on. Unfortunately, previously this was not the case as they were being let down by the response times they were receiving, as well as the ongoing maintenance costs of the doors. The decision was made to trial a door from Klimate, which is a trading division of BID Group.

This new door proved to be a much better solution than the previously purchased doors and as such in the following seven months a further eight doors were specified, ordered and installed taking the total number of Klimate doors on site to nine with an additional one outstanding.

Tel: 0870 607 5050

www.klimate.co.uk

Tools Putting Information in the Frame Info Cube is a unique new concept from The Tube & Bracket Company that allows businesses to create highly personalised structures to display important information in almost any environment.

The reusable modular components used to create an Info Cube are available in a variety of durable materials and colours so that users can devise robust and visually appealing designs that match corporate styles. Info Cube is ideal for visual management applications as well as retail displays, signage, promotions, temporary exhibitions and other settings where an impact is needed.

The simplest Info Cube is built using interchangeable and reusable lengths of steel or aluminium tube and composite brackets. Whiteboards, noticeboards, leaflet dispensers, screens and similar flat items can be mounted into the frame to complete the Info Cube. Wheels or castors can be added to make mobile structures.

Tel: 01295 277791

www.tubeandbracket.com

UNISIG: The deep hole drilling experts UNISIG deep hole drilling systems consist of machines, durable tooling, and automation, and are designed to meet the highest performance standards possible. Products are engineered and manufactured in the USA using metric hardware, and include the integration of premium components such as FAG, INA, Parker, Rexroth, Rohm, Schunk, SKF, Wittenstein alpha and ZF. Products are designed following all applicable ISO, DIN and IEC standards, and are exported worldwide.

At the EMO 2015 show in Milan UNISIG presented the updated series of BTA deep hole drilling machines with ball screw feed for machining high-strength alloys.

The model B380 was shown under power configured with 1,500mm depth, rotating workpiece and counter rotating tool with full guarding representing the recently updated line.

Further information on all machines included in the B series and the complete UNISIG machine program available at: www.unisig.de or at MACH 2016 from 11-15 October 2016 at Birmingham’s NEC, UK, Hall 5/5684.

Issue 20 PECM

123

LiHD. REVOLUTIONARY BATTERY PACK TECHNOLOGY FOR NEW EXTREME PERFORMANCE.

Li HD R

100 % MORE SERVICE LIFE

T E C H N O L O GY

W RL WO RLD' D'S S

FIRST

MORE POWER R

MORE RU N TIM ME

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

Training & Recruitment Dr Justin Steele-Davies, Academic Lead in Engineering at UDOL

The recent news of the Palmyra Arch replica highlighted additive manufacturing, or 3D printing, as a tool to replicate just about anything including historic artefacts. However, these reports were a bit of a misnomer and you may, like me, have been surprised to see a subtractive CNC milling machine at work in this case!

It is clear the term ‘3D printing’ has captured the popular imagination encompassing the notion of a digital model quickly being manufactured to order. The twist being that it feels like photocopying a real world object, another reason why printing is latched on to due to the link with photocopying.

What’s really interesting is that like many other fields before it, the manufacturing industry’s move to digital opens up access to the majority rather than the minority. A prime example is the music industry, where music recording and sequencing can be done with a laptop rather than expensive instruments, or publishing which can now remain entirely in the digital domain with an exceptionally low cost of entry.

Now a whole range of services allow individuals and companies alike to order items that would have required significant planning and cost in the past. Those with the knowledge and skills in digital manufacture will be able to design and build with limited intervention from anyone else (just like in music and publication now), significantly reducing the cost of some custom solutions. These skills will become increasingly important in the future for the manufacturing industry in all shapes and sizes. It’s an exciting time to get involved and anyone can gain the specialist skills in this area with access to computing resource and time.

The University of Derby Online Learning (UDOL) is proud to introduce our new MSc in Advanced Materials and Additive Manufacturing, teaching innovative skills essential for success in this advanced industry. This cutting-edge Masters degree can be studied part-time and entirely online allowing you to implement your learning in your own real-world work environment.

READY TO BECOME A CHARTERED ENGINEER? Study our online MSc Professional Engineering course alongside your career and work towards achieving Chartered Engineer (CEng) status, recognised by a wide range of engineering institutes including ICE, IMECHE and IET. Choosing to study online allows you to achieve a qualification alongside your career and personal commitments, from anywhere in the world.

Whether you’re starting out, moving up or starting again WE’RE READY WHEN YOU ARE

Start May or September Call 01332 594000 www.derby.ac.uk/engineering

To find out more visit the UDOL website at www.derby.ac.uk/online

Training for the Future Tipped to become the UK’s premier training provider, The Resources Group brings a refreshing, and holistic approach to the management and delivery of training.

Boasting decades of expertise, gained across a variety of specialist fields, including; MHE, Health and Safety, Driver Training and Learning and Development, The Resources Group offers a truly one stop shop for all of your training needs.

As well as delivering courses, accredited to a plethora of prestigious awarding bodies, The Resources Group is also well versed in developing bespoke training programmes, including eLearning; which provides a cost effective solution to learning, tuition and compliance.

For further information about The Resources Group Call: 01865 304911 or Email: info@the-resources-group.com or Visit: www.trg-world.com PLUS! Mention PECM Magazine for an Exclusive 15% Discount!

Safety in Numbers Excel is a fabulously versatile tool, but it is not easy to make it clear to users how your spreadsheet reaches its results.

Do you know how the results you use have been derived?

One of the benefits of developing strong spreadsheet skills is that you can lift the lid on the methods employed. Learn a bit of Visual Basic, and even macros need not stand in your way.

Nicholson Solutions is a Learning and Performance Institute accredited learning provider, with a track record of developing spreadsheet solutions and analysing existing ones.

www.nicholsonsolutions.co.uk Issue 20 PECM

125

World Class Independent Valve & Actuator Training One-day training courses from leading industry professionals. Independent courses.

No sales pitch, just quality, technical training.

Introduction to Valves - Monday 4th July Members: £260.00 | Non Members: £390.00

PED / ATEX Directives - Monday 11th July Members: £260.00 | Non Members: £390.00

Introduction to Actuators - Tuesday 5th July Members: £260.00 | Non Members: £390.00

Safety Integrity Levels (SILs) - Tuesday 12th July Members: £260.00 | Non Members: £390.00

Control Valves - Wednesday 6th July Members: £260.00 | Non Members: £390.00

Valves – Advanced Level (2 day course) Monday 18th July and Tuesday 19th July Members: £260.00 | Non Members: £390.00

Safety Valves - Thursday 7th July Members: £260.00 | Non Members: £390.00

All prices exclude VAT

BOOK NOW! Online: www.bvaa.org.uk/training_courses.asp Email: enquiry@bvaa.org.uk Tel: 01295 221270 For full details on each course, visit: www.bvaa.org.uk/training_courses.asp Tel: Fax: Email: Web:

+44 (0)1295 221 270 +44 (0)1295 258 893 enquiry@bvaa.org.uk www.bvaa.org.uk

British Valve and Actuator Association Limited 1A Banbury Office Village Noral Way Banbury OX16 2SB

Valves & Flow Control

Made in Britain

TELEPHONE

Rotor Protection System R

ota Val’s Rotor Protection System is designed to instantly detect any contact between the rotor and valve housing while at the same time it sends a signal to the panel to isolate power to the drive motor. It will primarily be of interest

to manufacturers where product contamination due to metal to metal contact is a significant issue.

There can be many reasons for contact between the rotor and valve housing including excessive loads on the rotor, product build-up causing rotor shift, ingress of ‘tramp’ material in the working clearances, bearing failure or lack of maintenance.

By installing a Rotor Protection System it will prevent valve material shedding into and therefore

contaminating the product being handled, it protects the valve components from serious damage and prevents valve start-up if assembled incorrectly.

The system can prevent damage to ATEX Autonomous Protection Equipment which can lead to invalidation of ATEX certification.

The RotaSafe can be retrofitted to existing rotary valves but does require complete reworking of the valve.

The trip amplifier mounted in the control panel is programmed to eliminate ‘nuisance tripping’ and is available as a stand-alone device for multiple valve installations.

Validated as ‘Simple Apparatus’ by our notified body (Baseefa) by complying with clause 5.7 of EN60079-11.2012 the system is an excellent addition for manufacturers that use rotary valves in their production processes.

Email: sales@rotaval.co.uk Website: www.rotaval.co.uk Telephone: 00 44 (0) 1249 651138

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PECM Issue 20

GLOBAL SUPPLIERS OF QUALITY PRODUCTS AND SERVICES

Flottweg centrifuge technology

Filter press technology and spares

Mobile/contract dewatering

Belt filter technology

Advanced SAF Technology & Anoxic SAF â&#x20AC;&#x201C; for removal of Nitrate

Sales Rental Maintenance Refurbishment Spare parts

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

Euroby Limited is a leading UK environmental waste equipment provider and well-regarded processing expert .

Equipment and service providers for solids - liquid separation and treatment E uroby Limited is a leading UK environmental waste equipment provider and well-regarded processing expert based in Worthing, Sussex with a factory/workshops in the Midlands. Although originally formed in 1996 to provide consultancy services to the power industry, the level of the group’s technical expertise led them to swiftly diversify into the water sector.

“Our ethic is to fulfil the needs and exceed the expectations of our customers,” commented Barry Ley, Euroby Limited’s Founder and Managing Director. “This is achieved with our State of the art products and practices and a high standard of service delivered by skilled employees and suppliers. We see ourselves as a forward-thinking company constantly striving to improve the environment whilst seeking opportunities for further growth”.

“From our point of view we want to grow long term partnerships with our customers. It isn’t our objective to secure sales on a one-off basis; we much prefer to create lasting, loyal business relationships because we want our customers to contact us again should they need further support or additional machinery.”

Reducing operational costs and increasing the sustainability of procedures is made possible courtesy of Euroby’s wide range of

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PECM Issue 20

systems and services. Its all-encompassing product portfolio comprises equipment such as decanter & special purpose centrifuges & separators, Submerged Aerated Filters (SAF), belt conveyors, lime stabilisation systems, filter presses, filter plates and belt filter presses, whilst its capabilities extend to system design, supply (sale or rental), installation, commissioning, operation, maintenance, refurbishment and client training.

Reducing operational costs and increasing the sustainability of procedures is made possible courtesy of Euroby’s wide range of systems and services.

The Euroby team is just an email or phone call away, so get in touch today if you would like to enquire about any of the aforementioned services or products.

Alternatively, you can visit the company website for further information on these quality systems by exploring the online brochures and dedicated tabs.

T 01903 69 44 00 sales@euroby.com www.euroby.com

Level probes - extended Several new variants of ifm's popular LMT point level sensors have been added to the range.

Longer probes, up to 250 mm, are particularly useful in overfill applications.

Internal timer functions can be set using standard IO-Link accessories.

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

THE NEW FILTER FAN PLUS

EXPELS MORE AIR FROM AN ENCLOSURE.

STEGO ‘the protector of electronics’ have developed a new filter fan series. This series has a more effective airflow and significantly increases air volume, thanks to its unique air-flap outlet technology, and only one filter mat. But there is more …

TAKE A LOOK AT ALL PRODUCT HIGHLIGHTS:

WWW.FILTERFAN-PLUS.COM

STEGO UK Ltd. | Unit 12, First Quarter Bus. Park | Blenheim Road, Epsom | Surrey KT19 9QN | www.stego.co.uk