PECM - Issue 57 2022

Engineering Process

Control &

MANUFACTURING

OIT - 14

MGP - 24

Optimal to showcase the importance of data-driven strategies at IFPAC-2022

MGP delivers business support plea after passing 10,000 jobs milestone

PECM

Global Success Through Innovation Issue 57 2022 £4.95 www.pecm.co.uk

EU AUTOMATION- 36 Automation cells and the standardisation of manufacturing components

Out of the Box Such is our confidence in this technology we offer an unparalleled 5 year full warranty on all models

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Engineering Process

Sections

Control &

MANUFACTURING

Inside...

Inside Issue 57

Editors Choice

4

Automotive

34

Boilers & Maintenance

35

Control & Automation

36

Electrical & Electronics

48

Facilities Management

54

Fluid Handling

55

Gears, Drives & Motors

55

Health & Safety

56

Machining & Machinery

60

Measurement & Monitoring

64

Process Technologies

68

Pumps

69

Software & Systems

71

Tools, Plant & Equipment

77

Training & Recruitment

79

Valves & Flow Control

80

INTERTRONICS

MASON

OIT

ABB

Adhesive considerations at the design stage Optimal to showcase the importance of data-driven strategies at IFPAC-2022

CRESSAL RESISTORS

Vibration isolation specialist keeps high precision manufacturing on track Are Robotics Set to Play a Starring Role in the Next Ten Years of British Manufacturing?

Resistor manufacturer launches new load bank division

CP AUTOMATION

WATLOW

SULZER

Solving thermal system complexity

MGP

MGP delivers business support plea after passing 10,000 jobs milestone

VOLKSWAGEN

Volkswagen Commercial Vehicles (VWCV) is ringing in a new era of vehicle production

Tips for mitigating harmful harmonics Innovative solutions to reduce carbon emissions

ECS

New job opportunities highlight growth at ECS Engineering Services

TEEPEE ELECTRICAL

Teepee harnesses electrification dreams for fire and rescue appliance specialist

Cover photo: Volkswagen

“The centre of excellence for strainer and filtraaon technology”

www.bartonfirtop.co.uk Issue 57 PECM

3

Level sensors from ifm:

Non-contact level measurement for hygienic applications

LW sensors from ifm provide: • 80 GHz frequency enabling level measurement with millimeter precision up to 10 meters • Non-contact measuring principle: no failures due to deposits or wear • Certified for use in hygienic areas • Simple installation and maintenance-free operation • Remote sensor parameter setting and level monitoring via IO-Link

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Engineering Process

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Issue 57 PECM

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EDITOR’S CHOICE

THE PATH TO PRODUCTION INTERTRONICS

Adhesive considerations at the design stage Adhesives are often treated as the final piece of the jigsaw puzzle. But by the end of the design stage, it may be difficult to find an adhesive that meets all the criteria, meaning the design must be amended, or even started again. Here Simon Gibbs, Technical Sales Executive at adhesives specialist Intertronics, explains the benefits of considering adhesives early in a project.

Though it may seem initially like a simple task, adhesive bonding is a vital and challenging part of product design. Every application is different and establishing what works best for your application involves detailed discussions and testing.

For design engineers without specialist adhesives experience, consulting with an adhesives supplier early on will avoid complications later down the line, saving time and money.

In many cases, manufacturers contact adhesives providers once most of the design work is done — once they have finalised and assessed bondline design, substrate selection, environmental resistance, and more. The difficulty with this approach is, with much of the design finalised, there will be a particular set of requirements the adhesive needs to meet — a very specific gap in the jigsaw for the adhesive to fill. There may not be an adhesive that meets the criteria without major compromise, or a suitable adhesive may not be available in the specified packaging or quantities. If this is the case, the design may need to be changed, delaying the project and increasing the costs.

It is much easier to make changes to the design earlier, while the process is fluid.

We therefore recommend contacting an adhesives specialist at a stage where the substrates and bondline geometry could still be changed. Your supplier can lean on previous experience to tell you what a suitable candidate is to test — and explain why.

PROTOTYPE TO PRODUCTION Adhesive applications are complex and can easily become unstuck. A small change to a design can have a big impact on the performance of the adhesive;

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PECM Issue 57

then developed another version of the same product, which involved bonding the plastic LEDs to anodised aluminium instead. The new product did not pass the required testing, and the design had to be changed to incorporate a different adhesive.

Simon Gibbs, Product Specialist at Intertronics

Adhesive applications are complex and can easily become unstuck. A small change to a design can have a big impact on the performance of the adhesive. tweaking one thing can mean an adhesive that previously passed the testing for that application now has the potential to fail.

For example, something as simple as how the substrate is pre-treated or cleaned can lead to part failure.

One common reason the bond fails testing at the later stages of a project is that the prototype has been made differently, or using different materials, to the production parts. For example, if the prototype was done using one white plastic and then later changed to another.

Though it might be natural to expect the same result, the adhesive may no longer bond.

We recently supported a customer bonding plastic LEDs to plastic housing using a UV curing adhesive. The company

Another factor to consider when changing the substate is that many modern materials are formulated with specific properties where the benefits to the application, such as chemical resistance or UV blocking, are the same reason that makes the application challenging.

For example, properties that make design engineers select polypropylene as substrate (e.g. low surface energy, solvent resistance, opaque), are the same properties that may make it more difficult to bond.

As well as changing the substrate from prototype to production, we sometimes see manufacturers change the adhesive.

In some cases, design engineers will prototype their product using an adhesive they have available in the lab or which is already used in the factory for another application. They will then select a different adhesive for the production parts using data sheets, subsequently meeting a challenge when production has started and the specified material doesn’t pass functional tests. It is important to note that the data sheet may not always give the same insights as practical observations, experience, and tests; in many cases, the data needs to be interpreted and extrapolated to fit with the individual scenario.

FROM DESIGN TO PRODUCTION Another possible hurdle is that the specified adhesive does not line up with the production team’s schedule. For example, many manufacturers request UV curing adhesives due to their ability to cure on-demand and in seconds, but the adhesive might not meet the functional requirements for the application in question. However, it is a challenge to simply swap one adhesive for another to meet a production-related challenge.

For example, one automotive customer was using a two-part epoxy cured in an oven to bond parts. Months later, as the production cell was being finalised, the company swapped to a UV material, because the epoxy’s cure time was too long. However, the same design bonded with a different adhesive didn’t pass any tests, and it was back to the drawing board on adhesive selection, adding time and cost to the project.

A good adhesives supplier can speak to the design engineer about the full complexity of the project, to establish the speed and long-term throughput requirements and make a recommendation for materials and dispensing technology to match. This advice means a design engineer can greatly impress his or her production engineering colleagues, when the product is easily moved into the production stages, without a need for last minute changes due to line speed and yield requirements.

Similarly, if the supplier talks the design engineer through the return on investment (ROI) considerations upfront, they can save their production colleagues time by ensuring what they have specified is commercially and technically viable. For example, a supplier could explain how

switching from a manual to an automated process could offer a good ROI, by resolving issues around validating the process, removing operator variance, and reducing the risk of operator RSI. A bonding process consists of the cost of a material purchase and the cost of processing it — often the latter is a bigger proportion of the overall cost.

THE EARLY BIRD GETS THE WORM These issues can be easily avoided by contacting an experienced adhesives supplier early in the project, so they can advise on material selection, bondline design, and more. It is important that your supplier provides you with all the information you need on the adhesive, including its chemistry, how it cures, and how it can be dispensed. For example, if you are dispensing a cyanoacrylate with a secondary UV curing mechanism, which dispensing technology should you use to avoid clogging?

The adhesives supplier can explain why a material might work, using evidence from previous experience to advise on why it is a good selection, how it might be dispensed and cured, and to highlight any downsides or compromises. There is no ideal adhesive — if your supplier says a material “will definitely work”, this should trigger alarm bells. Good suppliers

It is important that your supplier provides you with all the information you need on the adhesive, including its chemistry, how it cures, and how it can be dispensed. will be honest and up front about any problems they expect might arise, and which potential failure mechanisms should be checked. At Intertronics, we recognise the importance of asking our customers the right questions, understanding the detail of each application, and giving honest answers.

Getting to the final piece of the puzzle only to discover the final piece doesn’t fit is downright frustrating. Don’t let the same be true of your adhesive selection.

To speak to an adhesives specialist, call us on 01865 842842 or visit https://www. intertronics.co.uk/ and get in touch.

For further information, please visit www.intertronics.co.uk Issue 57 PECM

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EDITOR’S CHOICE

Shrink energy costs by using Linear Motors instead of Pneumatics Powering actuators directly with Linear electric motors rather than air cylinders can result in huge cost and emission savings across the board.

The recent dramatic increase in energy cost is a big concern for industry, which makes switching to electrical actuators even more attractive. Compressed air is very wasteful of energy and can be eliminated in machines by using linear motors in place of air cylinders.

Quin Systems, exclusive UK suppliers of LinMot Linear Motors for over 25 years, can help you calculate the predicted carbon and energy savings achieved by switching from a pneumatic solution to a linear motion solution.

LinMot, one of the world’s leading manufacturers of industrial linear motors has released a new component of its LinMot Designer software that can quantify just how energy efficient its solution is, and the sizeable return on investment their motors can provide over pneumatics.

EXAMPLE

cover its higher initial outlay within a very short timeframe, typically less than a year.

Take an example within the handling and assembling sector. Linear actuation is required on the horizontal plane to move items through to the next stage of the production process.

A single LinMot Linear motor with guide can replace a traditional 63mm diameter rodless air cylinder for this task, ultimately reducing annual energy cost by over 10,000 EUR and CO2 emissions by over 26,000 kg.

Combined with the extraordinarily long operation life of LinMot Linear Motors and the next to zero servicing requirements mean LinMot’s solution will continue working for years.

This improves the cost benefits and environmental efficiency of your production line by a significant margin.

For more information, please contact Quin Systems, the LinMot distributor for UK & Ireland on 0118 977 1077 or sales@quin.co.uk.

The return on investment is significant.

Energy saved by using a single electrically driven actuator over a basic traditional pneumatic cylinder has the potential to

Website: www.quin.co.uk/linmot

The innovative Linmot Linear motor combined with a high stiffness linear guide provide high-speed and energy-efficient performance in a clean design.

Direct mounting of the load with absorption of

2

sales@quin.co.uk

8

PECM Issue 57

EDITOR’S CHOICE

Your technical experts for plastic injection moulding

DESIGN DEVELOPMENT MOULDING TOOLING BEYOND THE MOULD Make Pentagon your UK supplier of choice for Mould Tool manufacture and Plastic Injection Moulding.

Whether you need a supplier for a new injection moulding project or sourcing a new manufacturing partner for existing production, Pentagon will support you at every stage.

www.pentagonplastics.co.uk | websales@pentagonplastics.co.uk Tel: +44 (0) 1403 264 397 |

Issue 57 PECM

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EDITOR’S CHOICE

FUME FAN MAINTENANCE AXAIR FANS

As the Summer sees a busy time for school facilities and maintenance teams upgrading or replacing old laboratory parts, Axair discuss how their complete fume fan pack can simplify school fume cupboard maintenance Installing, maintaining and testing fume cupboards can be problematic for schools and universities because of a lack of experience. Senior management of schools rarely understand the problems which may arise when ducting and the fume cupboard itself are installed and commissioned. These problems then differ for maintenance or health and safety inspections.

A fume cupboard is intended to minimise exposure to hazardous gases, vapours or dusts. A secondary function can be to act as a safety screen to protect students and staff from minor explosions or splashes. Protection is achieved by a flow of air created by an exhaust fan which is designed to ensure the contaminant remains inside the fume cupboard.

If the airflow rate is too low, hazardous fumes may escape, especially if the air is disturbed by cross-draughts or people moving about nearby. On the other hand, if it is too high it may destabilise Bunsen burner flames, waste energy and be noisy.

Airflow rate is very much dependent on the fan, the ducting, the sash height, the presence of a baffle, bypass, damper, and inverter.

A centrifugal fan that is part of a fume cupboard system is mounted on the outside of the building or on the roof space. This ensures that the ducting inside the building is under negative pressure, compared to atmospheric pressure, and that any leakages are into the duct and not into the rooms. Older fume cupboards used to have axial fans mounted just above the fume cupboard. These noisy fans put the whole of the ductwork under positive pressure and caused leakage of fumes to surrounding spaces. The exterior stack height must be sufficiently high above the building to prevent the air re-entering, which can be a problem for schools that

Airflow rate is very much dependent on the fan, the ducting, the sash height, the presence of a baffle, bypass, damper, and inverter. are situated in residential areas due to unsightly stacks.

The fan and ducting must be correctly sized to give the required face velocity, without requiring major adjustment by a damper or inverter. While a damper should be fitted, it should not be required to do more than make small adjustments to the air flow. Fitting an over-powerful fan and using the damper to reduce the air flow to an acceptable level is a waste of money.

EC fume fans were introduced to save on average 20% of fan energy consumption

without affecting performance. As an alternative to a damper, some fume cupboards may have an inverter, which is used to adjust motor speed allowing a slow ramp up time and a reduction in start-up costs. Whichever option is used, once set, it should be locked into position and not altered during normal use. Dampers may also increase noise levels if they are used to produce a considerable reduction in velocity from an unnecessarily powerful fan.

All parts of any fan in the airstream should be resistant to the airborne contaminants which may be present. Corrosion resistant centrifugal fans made form polypropylene with either backward-curved or forwardcurved blades should be used. Antivibration fan mountings should be used, to ensure that vibrations are not transmitted from the fan to the building or to the duct.

The customisable fume fan pack from Axair Fans offers a complete fume cupboard extraction fan set along with complementary accessories such as inverter, isolator, wall mountable pedestals and AV mounts for simple school and university installations. Contact our team to discuss your fume fan maintenance and airflow requirements.

For further information, please visit www.axair-fans.co.uk

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PECM Issue 57

REDUCE FAN ENERGY

CONSUMPTION Now offering an impressive range of energy efficient corrosion resistant fans with EC motors to reduce fan energy consumption in fume extraction systems.

FANS WITH ENERGY EFFICIENT

IE5 EC MOTORS Axair Fans UK Limited www.axair-fans.co.uk 01782 349 430

EDITOR’S CHOICE

ACHIEVING MORE WITH LESS NORTH RIDGE PUMPS

7 Ways to Reduce Pump Maintenance

If you are facing a reduced maintenance budget, looking to achieve more with less or simply looking to optimize your current process, reviewing recent pump maintenance could help indicate where process improvements can be made.

If you are frequently having to replace the same spare parts consistently, experiencing low or slow flow between processes, or experiencing frequent process stoppages and downtime, it could indicate another problem.

Here are 7 Steps you can take to reduce the time spent on pump maintenance, improve plant efficiency and process uptime:

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PECM Issue 57

CHECK ACTUAL PUMP DUTY VS DESIGN DUTY Over time a pump’s performance may deteriorate or the conditions it faces change.

A pump’s performance should always be checked to ensure it is achieving the designed flow and not experiencing another issue such as cavitation.

Cavitation – a phenomenon which leads to accelerated failure of pumps occurs due to a lack of suction pressure.

As pumps wear the inlet suction pressure required for optimal performance can increase due to internal wear experienced within the pump. If this new demanded suction pressure is not met and symptoms

A pump’s performance should always be checked to ensure it is achieving the designed flow and not experiencing another issue such as cavitation.

are not addressed quickly - such as heavy vibration or loud noise, damage can occur with casings experiencing rapid wear or impellers crack under the forces experienced.

HAVE A LUBRICATION & INSPECTION SCHEDULE Insufficient lubrication & too much lubrication is often a cause of bearing failure, but more often that not seal failure is a primary cause of pump seizure and bearing failure.

equivalent reduction in spares costs, but also in the speed of maintenance.

Maintenance can often take longer than is required on inferior designs not always considered at the time of pump purchase.

If a mechanical seal leak remains undetected for some time, fluid will leak from the pump casing into bearings which if left unresolved, can lead to catastrophic bearing failure and prompt pump seizure.

of pumping equipment this could be one cause.

Using a maintenance schedule provides indicative time frames for scheduling maintenance ensuring machinery remains well lubricated in line with manufacturer specifications.

Some designs of pump, like in the below comparison have far more spare parts than other models. Maintenance can become puzzling trying to refit all parts, with time pressure constraints making mistakes likely.

DROP IN REPLACEMENTS

Maintenance can often take longer than is required on inferior designs not always considered at the time of pump purchase.

The time is taken to service some pumps can be reduced by up 50% when using our design.

Pump Inserts or bareshaft pumps ensure replacement pumps can be placed into process with minimal disruption or downtime maximising process uptime.

Having drop in replacements ensures engineers no longer need to rush to overhaul or service pumps, allowing time for all parts to be inspected and replaced as required, ensuring when the pump is returned to service, prompt failure does not occur.

If you find a diminishing mean time to failure

CHANGE PUMP DESIGN

CHANGE PUMP TYPE Not all pumps are created equally.

Some designs are better suited for abrasive slurries, can accommodate dry running and a better fit for 24/7 operation. Changes in pump types can not only mean energy savings of between 20-30% with an

By re-evaluating your current application against the pump type in use, could mean another solution is better suited to your process.

INCREASE PUMP SIZE Quite often a pump is installed in an application based on initial cost rather than factoring in full application details and total cost of ownership.

Units may be operating too fast meaning spares are being replaced frequently.

Increasing the pump size and running it slower is often a way of ensuring longevity by reducing wear due to abrasion.

PUMP MONITORING Remotely monitoring your pump can mean early detection of a reduction in flow or pressure, vibration, excess temperature or increases in power consumption far more in advance than is detectable by maintenance personnel.

This enables condition-based maintenance to be undertaken before failure and requirements become urgent.It also means pumps are dismantled when required rather than unnecessarily at set operation intervals.

If you are interested in reducing pump maintenance, are experiencing frequent process issues, want to reduce plant stoppages and prevent excessive pump maintenance visit www.northridgepumps. com to see how we can help.

For further information, please visit www.northridgepumps.com Issue 57 PECM

13

EDITOR’S CHOICE

PHARMA 4.0 OIT

Optimal to showcase the importance of data-driven strategies at IFPAC-2022

Optimal Industrial Technologies will show how (bio)pharmaceutical manufacturers can remain competitive in an evolving marketplace at IFPAC-2022, taking place from 12th-15th June. Contributing with multiple presentations and experts on hand at a dedicated exhibition stand, the company will highlight the benefits of embarking on a digital transformation journey and how to make it a success with its platform, synTQ.

transformation of (bio)pharmaceutical manufacturing by supporting Industry 4.0 applications. He will also provide an overview of the various departments, besides manufacturing, where PAT can be applied to futureproof operations. For instance, R&D laboratories and pilot plants, together with analytical laboratories, can also greatly benefit from data-driven automated operations.

An established premier event focused on industrial process analysis, process knowledge and quality assurance, IFPAC will return as a live event in June. Optimal, a leading industry player in Process Analytical Technology (PAT), will offer a unique insight into how companies can advance their businesses by adopting future-oriented, PAT-driven solutions. These include process automation, the Industrial Internet of Things (IIoT), Cloud computing and digital twins.

In addition to presenting during the event, Optimal will demonstrate how its PAT knowledge management platform, synTQ, can be deployed as an enabling technology to support the digitalisation of businesses. synTQ provides robust storage and visualisation of process data, instrumentation settings and control parameters, allowing operators to have a comprehensive and holistic overview of all manufacturing processes. In addition, synTQ hosts and executes multivariate quality prediction models, delivering live feedback to key equipment for real-time process monitoring and control.

Martin Gadsby, VP at Optimal Industrial Technologies, will deliver two presentations focusing on how PAT can enable the digital

Martin Gadsby adds: “We look forward to returning to the IFPAC Annual Meeting in Washington. Since the last time we exhibited in person at the event, we have developed a number of advanced functions within synTQ to support smart manufacturing operations.

“The software is a proven and wellaccepted knowledge management framework used by leading global pharmaceutical companies. In fact, it is an award-winning technology that is recognised for its unique ability to support even the most ambitious Industry 4.0 applications. Our experts will be available throughout the event to discuss specific requirements and implementation questions around PAT and synTQ.” Visit Optimal Industrial Technologies on Booth 306 at 2022 IFPAC Annual Meeting, taking place from 12th – 15th June at Bethesda North Marriott, North Bethesda, Maryland (Washington, D.C.) U.S.A.: http://www.ifpacglobal.org/

For further information, please visit www.optimal-tech.co.uk

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PECM Issue 57

EDITOR’S CHOICE

You could be entitled to R&D Tax Credits The R&D Tax Relief scheme is basically a form of tax relief that may reduce your company or organisation’s Corporation Tax bill. Tax relief can be claimed on a wide range of R&D projects – even those that ultimately proved unsuccessful.

It’s quick and easy to determine if you might be able to make a claim for R&D Tax Relief. But 97% of eligible businesses don’t check or claim – don’t let your business miss out in this way!

www.mcs-corporate.com | charlotte@mcs-corporate.com | +44 (0)1926 512475

Issue 57 PECM

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EDITOR’S CHOICE

POWER PROVE CRESSALL RESISTORS

Resistor manufacturer launches new load bank division High power resistor manufacturer Cressall Resistors has launched a new division specifically for its load bank range — Power Prove. With over 100 years’ experience in the manufacturing resistors and load banks, and in response to growing customer demand, Cressall launches Power Prove as a dedicated brand to satisfy growing customer demand for load banks.

Power Prove offers its customers an extensive range of load bank designs, competitive lead times and pricing, and enhanced features such as power measurement, data logging, remote control and multi-load bank networking. Its extensive range is suitable for a range of applications where generator testing, battery discharge testing or ballast load is required.

The Power Prove range includes several products to suit a growing demand for portable AC load bank solutions. The AC6 load bank, for instance, provides six kilowatts (kW) of load capacity with a manual control interface at a weight of just twelve kilograms (kg). Its compact design enables the AC6 to fit into site vans for easy travel to test locations.

Additionally, the AC100-CPT is another lightweight ultra-portable load bank that offers superior power density, with 100 kW of load capacity at 31kg of weight. Offering easy connection to power supply using Powersafe connectors and real-time measurement display and data logging, the AC100-CPT is supplied with a travel case with casters and a pull handle to complete the package as one of the most convenient load banks on the market for site testing work.

Power Prove’s division director, Andrew Keith, has previously spent 14 years at Cressall specialising in product development.

With Power Prove, Keith is dedicated to developing a standardised range of load banks to meet the needs of customers in the generator manufacturing and maintenance markets.

electricity generation, data centres and transportation infrastructure — has resulted in an ever increasing and changing customer demand for portable AC load banks available to purchase immediately,” explained Keith. “By launching Power Prove, we hope to provide our load bank customers with a wide range of solutions from our extensive standard product range and enhanced feature set, catering for all load banking requirements.”

“The growth of industries that require load bank testing — including distributed

“Cressall has over 100 years’ experience in the manufacturing and global distribution

of custom-made resistors and load banks,” added Simone Bruckner, managing director of Cressall Resistors. “Power Prove consists of an experienced team of engineers and manufacturing experts that take time to advise and deliver the latest load bank technology that it suitable for the application.”

Power Prove is now live, offering a comprehensive range of AC and DC load banks available for global distribution. To find out more, please get in touch with a member of the team via the website.

For further information, please visit www.powerprove.com

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PECM Issue 57

EDITOR’S CHOICE

Standard Flow Measurement Solutions INTRODUCING THE UK’S FLOW METER DISTRIBUTOR – MARSTON FLOW

Marston Flow aims to deliver standard flow meter solutions with quick delivery times and lower costs.

Following the successful website launch in April, Marston Flow (forming part of Litre Meter) brings a range of standard flow meter solutions direct to businesses within the UK.

With a range of flow meters from Litre Meter, KEM, Sierra, TRICOR Coriolis and AW Lake, you can be sure to find your standard flow solution with Marston Flow.

www.marstonflow.co.uk

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Cutting We can cut and shape perforated sheet to meet the needs of your final application.

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Rolling and forming We can roll, bend and form perforated sheets to match your design.

Aesthetic finishes and protective coating We can offer powder coating and hot dip galvanizing solutions to meet your specifications.

For more information please contact us tel: 01925 839610 | email: info.uk@rmig.com | www.rmig.com

Issue 57 PECM

17

EDITOR’S CHOICE

THERMAL SOLUTIONS WATLOW

Solving thermal system complexity Thermal solutions are a part of almost every industry, from chip manufacturing and medical devices to oil and gas operations.

What these diverse industries have in common is a need to design simple, yet responsive systems that can monitor and maintain the precise application of heat.

However, this need means that engineers must contend with various complexities.

Here, Brandy Phillips, engineering manager at industrial electric heating element manufacturer Watlow, explains how adaptive thermal solutions (ATS) can provide an answer to common heat processing challenges.

Any device or process with a heater needs some degree of thermal control, with some devices or processes needing more precise control than others. That precision is traditionally achieved by adding sensors and controllers to heaters. The more precision needed, the more complex the control apparatus and the wiring becomes.

ATS, which combines sensing, heating and control technologies, represent a different and more innovative approach to controlling thermal performance for complex systems.

However, adding the complexity is not always an option, which is where challenges present themselves.

COMPLEX SYSTEMS IN SMALL SPACES A surface that needs to be heated to within a certain temperature range requires not only several heating elements, but also sensors that can detect the temperature of the

surface at various points. Those sensors then deliver that feedback to a controller that then responds by adjusting the power sent to the heaters. If the temperature of the surface fluctuates, the sensors and controller should be able to respond in tandem to maintain the desirable temperature range.

Traditionally, the approach to getting such fine control of the heating surface has been to increase the zone count, which requires the addition of independent sensors, wires and controllers. As the system scales, the complexity grows, but the overall space in which this needs to happen does not.

In many manufacturing scenarios, precise control is needed in a confined space, and additional wiring and equipment is not feasible.

UNLOCKING THESE CHALLENGES Precision and tunability of a thermal system is traditionally achieved by adding sensors and controllers to the system. But there are plenty of applications where this is not a viable option, including semiconductor manufacturing, analytical devices and home medical devices. ATS makes possible a greater degree of control in systems where piling on more components is simply not an option.

Manufacturers may experience disconnection between their control systems.

Different banks of sensors at different points in a process are often connected to separate controllers, which might not be networked in such a way that their activity can be coordinated easily, which results in unresponsive systems.

Every application is unique, and some can take advantage of many ATS technologies at once while others might use just one. In semiconductor manufacturing, deposition pedestal heaters must reach certain temperatures during the chipmaking process, and temperature uniformity is critical to quality control. The pedestal itself allows little room for extra wires. With high TCR materials and multi-loop control and sensing, individual heaters can be made into sensors, and the number of heating zones can be more than doubled.

These zones can be independently controlled, in real time, adjusting heater output to achieve a more uniform surface temperature.

The above challenge often results in adding an element of unpredictability to the system.

The added complexity of additional sensors and controllers will, for some applications, either compromise adaptability or prevent the system from achieving desired thermal uniformity. These, in turn, lead to excess waste and variable material quality.

Furthermore, existing medical and analytical equipment often have to meet new agency requirements, like safety specifications for allowed temperatures. Having heaters that can sense their own temperature, when then adjusts power levels via power conversion, helps to keep temperatures within safe limits.

CONTROL SYSTEM CHALLENGES

Watlow, which manufactures industrial heating technology, has decades of experience with thermal systems to help engineers and designers to incorporate ATS technology into a variety of industrial processes and products.

The beauty of ATS is that it is not one solution, but a suite of solutions that can be tailored to specific engineering challenges.

Unlocking the benefits of this technology requires a deep understanding of the product or process in question, including the thermal and power requirements of the system.

For more information about ATS, visit watlow.com

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PECM Issue 57

Designed for ISO 14644 ygienic standards Designed with creativity and obsessive attention to detail, for tomorrow’s ultra-sterile spaces, today.

From a team renowned for outstanding service and support.

Visit: teknomek.co.uk/hygienox Call: +44(0)1603 788833

EDITOR’S CHOICE

Even in deep tanks, ifm senses levels precisely With the new LW2720 radar level sensor from ifm electronic, accurately measuring the level of liquid media in large tanks and vessels is no longer a problem; this innovative sensor has a measuring accuracy of ± 2 mm at ranges up to 10 m. In addition, it is fully certified for use in hygienic areas, making it an ideal choice for food and pharmaceutical applications, including those that involve CIP and SIP operations.

The ground-breaking LW2720 measures levels using an FMCW radar-based system operating at a frequency of 80 GHz. This provides stable and accurate non-contact measurements that are unaffected by changing pressure, temperature and the presence of steam or condensates. In addition, the 80GHz operating frequency of the sensors provides a very narrow beam angle that gives a reliable level measurement even in applications where agitators, stirrers and scrapers are present.

www.ifm.com

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PECM Issue 57

EDITOR’S CHOICE

A HISTORICAL PERSPECTIVE 3DPRINTUK

Optimising Outcomes with 3D Printing – Design for Additive Manufacturing (Part 1)

Nick Allen, MD, 3DPRINTUK In this 3-part series of articles, we will be considering the important issue of Design for Additive Manufacturing (DfAM). The series will start here in part 1 by addressing the evolution of product design to provide some context in terms of the state of the design industry when 3D printing first emerged and how both technology sets (digital design and 3D printers) have evolved alongside each other. This will provide a broad historical perspective illustrating how design processes today inform successful uptake of industrial 3D printing for a wide range of applications.

Then, parts 2 and 3 of this series will go on to explore the intricacies of designing specifically for 3D printing, the advantages it offers over more traditional manufacturing processes and the pitfalls to avoid to achieve the most successful outcomes.

The history of 3D printing / additive

3D printed prototypes remain a universally accepted and dominant application of the technology set today. manufacturing (AM) dates back almost 35 years and as a technology set it proved to be disruptive across many industrial sectors, and continues to evolve and disrupt to this day.

Back at the beginning, what is now referred to as AM or industrial 3D printing began its journey as a technology universally referred to as “rapid prototyping” or RP. This was

Complex 3D printed part designed

by Komodo Simulations

because it was viewed as a technology that singularly allowed design engineers and manufacturers to easily, quickly and cheaply produce physical prototypes of their new products / components.

It is also pertinent to remember that back in the 1980’s digital design was also still relatively new. Indeed, it was progress with 3D CAD that went some way to facilitating 3D printing itself. Product development — including design — is an iterative process, and getting a product from idea to manufacture involves a great many steps, often in a linear / circular way. This includes going through numerous iterations of a product to optimise it — factoring in market research feedback and manufacturability.

Designing for the manufacturing process of choice has always been a thing.

When 3D printing really broke through as a means of rapid prototyping in the 1990’s, it offered companies a viable and

Brushtec 3D Printed jigs in situ

economically attractive way of producing multiple design iterations to optimize the final product without extending lead times and often shortening them. It is also vital to note that “rapid prototyping” and “3D printing” — then and now — are used as umbrella terms for a number of different additive processes. There are seven additive manufacturing process types in total.

The very first process was Stereolithography (SLA), a VAT polymerization process, that used resin materials, which resulted in the first commercial 3D printing system — the SLA-1 — from 3D Systems Inc. This was closely followed by two more: the Selective Laser Sintering (SLS) process, originally developed at the University of Texas and commercially licensed by DTM Corp; and the Fused Deposition Modelling (FDM) process developed and commercialized

by Stratasys Inc. SLS now falls under the generic process name of Powder Bed Fusion (PBF), while FDM comes under the Material Extrusion process name.

The other four additive manufacturing processes that are now firmly established are Material Jetting, Binder Jetting, Directed Energy Deposition, and Sheet Lamination.

The major advantage that 3D printing offered for rapid prototyping, and the reason it took hold is that it enabled a concurrent or simultaneous engineering approach that eliminated the existing linear / circular “over-the-wall” silo culture of product development and drastically reduced design to market times and costs.

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PECM Issue 57

3DPRINTUK has mastered the process of 3D printing with polymer powders, with no need for support material, virtually no layer lines and short turnaround times.

First-3D-Printer-Invented-in-1983

3D printed prototypes remain a universally accepted and dominant application of the technology set today.

The thing to note here, though, is that 3D printing offered a way of improving the product development process — it did not affect the nature or methodology of the design itself. It essentially embedded itself originally as a useful tool for improving the development process (including improving the design through iterative feedback) for existing, traditional manufacturing processes.

Throughout the 90’s early adopters highlighted progression by including tooling managers in the product development process much earlier — sometimes just days into the product life-cycle rather than the traditional weeks or months it would usually take.

As a result, they could provide valuable input that helped avoid costly mistakes and speed up time-to-market. Further evolution saw tools themselves become a key application of 3D printing — cue the moniker “Rapid Tooling.” This application area provided a highly cost-efficient way of producing tools for low and medium volumes of products. Again, this is still a viable application of AM technologies today.

As time moved on — and really getting traction in the last 10 years or so — 3D printing began to evolve from being a prototyping or tooling technology to a true “production” technology, highlighted in the terminology used to describe it today: Additive Manufacturing or industrial 3D printing.

With this shift, the ability for AM to continue its “disruptive” role was redoubled, as now the focus was on “if” and “how” the various AM processes, together with new and improved materials for AM, could truly replace or complement traditional manufacturing processes. The development of more robust, accurate, speedy, repeatable and cost-efficient machines, especially with the PBF process has reinforced the importance of industrial 3D printing as a true production technology, and today opportunities exist for the intelligent and judicious use of it as a viable and competitive serial production solution.

However, it was this shift that has also meant that design engineers that are developing products that will be produced with AM — or considering it — have had to alter their approach to design. As I mentioned before, designing for the manufacturing process has always been a thing, whether for injection moulding, casting, or CNC machining. The point here is that for Additive Manufacturing, the design rules are a bit different, in fact, they kind of break the mould!

In part 2 of this series, we will look at just how different DfAM is from traditional design for manufacturing approaches, the opportunities this brings in terms of product innovation and functionality, and the ability to optimise products in a way that reduces weight and material usage.

3DPRINTUK is a specialist in low volume production using state-of-the-art powder bed fusion (PBF) 3D printing systems with polymer materials. The company bridges the void that exists between prototyping and injection moulding, such that if tooling costs are prohibitively expensive for an application that does not require the volume demanded by injection moulding, 3DPRINTUK can provide a high quality, cost-effective and fast solution.

3DPRINTUK has mastered the process of 3D printing with polymer powders, with no need for support material, virtually no layer lines and short turnaround times. The company is an ideal partner for producing one-off prototypes through to production runs of tens of thousands of parts — on demand.

3D Printed jigs by Brushtec with complexity designed in.-3dprintuk 1 For further information, please visit www.3dprint-uk.co.uk Issue 57 PECM

23

EDITOR’S CHOICE

LATEST NEWS FROM MGP MGP

MGP delivers business support plea after passing 10,000 jobs milestone from ERDF and into a new landscape where each place (it could be as small as a District Council) will be given control of what they want to invest in and how they want to shape their local investment plan,” explained Dean.

A business support programme that has created and safeguarded over 10,000 manufacturing jobs is urging local authorities to ensure assistance is still in place under the new funding landscape.

Bosses at the Manufacturing Growth Programme (MGP), which provides grants and dedicated consultancy to SME manufacturers in 18 LEP regions, are warning that the potential gap between European Regional Development Funding and the UK Shared Prosperity Fund (UKSPF) could see businesses left without the assistance they need.

Regional Director Dean Barnes believes the fragmented nature of UKSPF – where each local district will receive its own pot of money – means it will be difficult to deliver good quality support to management teams that have guided their firms through Brexit and, more recently, Covid-19.

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PECM Issue 57

The rallying call comes as MGP reveals its latest performance data, with more than £13.5million in grants delivered to 4300 companies over the last three years.

This has leveraged £21m of private sector investment and helped manufacturers enter new markets, diversify their products/services, improve efficiencies and secure vital quality accreditations.

“We’re about to enter one of the most exciting, but challenging times in business support where the focus will fall away

“It is key that neighbouring councils work together to pool funding to deliver support at a regional level to ensure they get the most out of their budgets and reduce the amount of ‘business support’ noise in the marketplace.”

He went on to add: “The UK Shared Prosperity Fund is intended to help the Government’s desire to ‘level up’, but businesses must have a voice on what they want.

“They don’t just need grant funding, they also want advice, best practice implementation and help with long-term improvements.”

Funded by the European Regional Development Fund (ERDF) and delivered

by Oxford Innovation Advice, MGP was launched in 2016 to create a targeted service to support manufacturing SMEs. This focused on creating a team of Manufacturing Growth Managers who work with management teams on initially completing strategic business reviews.

From there, they provide grant funding and signposting services to specialists that deliver improvement projects in strategic planning, productivity and process improvement, competitiveness, innovation and leadership and management.

Nearly a third of firms so far have chosen to tap into marketing and market knowledge support, followed by a quarter choosing help to improve productivity and 14% wanting assistance with continuous improvement.

Jane Galsworthy, Managing Director of Oxford Innovation Advice, commented: “We are already helping with the ‘levelling up agenda’ by supporting small businesses in less developed areas to grow and have adapted our support model to meet evolving business needs.

There has been some massive strides forward in business support and we’ve seen first-hand how the right expertise can unlock the potential of some of our brightest SMEs.

“These include continuing to boost productivity, helping firms work towards Net Zero, job creation, internationalisation and, increasingly, embracing digitalisation and Industry 4.0.”

She concluded: “There has been some massive strides forward in business support and we’ve seen first-hand how the right expertise can unlock the potential of some of our brightest SMEs. It would be foolish to throw that all away with the launch of UKSPF funding!”

For further information, please visit www.manufacturinggrowthprogramme.co.uk or www.oxfordinnovationadvice.co.uk.

You can also follow @mfggrowthp or @oi_advice on twitter Dean Barnes & Jane Galsworthy

For further information, please visit www.manufacturinggrowthprogramme.co.uk | www.oxfordinnovationadvice.co.uk.

Issue 57 PECM

25

EDITOR’S CHOICE

More for Engineering from EEMUA…

People in engineering work to make businesses, the environment, and everyone’s future prosperous and safe – EEMUA’s publications and other resources help people in engineering to get that work done.

EEMUA shares engineering task know how contributed ‘by industry, for industry’ as practical aids for engineers in their work – wherever they are, whatever time they have.

Available to all in industry…

All publications and many other resources are downloadable from EEMUA’s Shop – where you can also register to take part in EEMUA events and training.

Members help yourselves…

Many EEMUA resources are free or discounted for members, so please log in and help yourself to guidance notes, training, e-learning, checklists, live webinars, seminars, recordings, and much more.

Join in…

New Corporate Members are always welcome to share EEMUA’s knowledge and influence.

Call on EEMUA…

www.eemua.org membership@eemua.org +44 (0)20 7488 0801

SmartZone G5 Security Handle Offers Secure Dual Authentication

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PECM Issue 57

Panduit has launched the SmartZone™ G5 Security Handle for ITE cabinets, which is designed to meet the most rigorous security challenges, both physical and digital, in today’s data centre environments. The multifunctional smart handle offers multiple configurations with and without a keypad to compliment users’ operational requirements.

The integrated keypad version enables dual authentication by allowing for a card swipe and pin-code combination to access the cabinet.

the capability to read both low frequency (125kHz) and high frequency (13.5MHz) cards. The handle has been designed to be current and future compliant with regulations required within this environment and is also GDPR ready, HIPAA ready and PCI-DSS ready to ensure that this design meets data centres and users’ cabinet security needs.

It can support 200 authorised users and features an integral humidity sensor allowing humidity sensing to be optimally placed near the centre of the cabinet.

The G5 Security handle seamlessly mates with most data centre cabinets and has

To learn more, visit www.panduit.com.

EDITOR’S CHOICE

SHAKE, RATTLE AND ROLL STAR FASTENERS

Vibration has met its match with Huck® Fasteners The Huck brand means one thing - reliably strong joints, even in the most extreme environments. They provide consistent, extremely-high shear and tensile strength and are proven to hold their clamp, even with constant vibration.

COLLAR

NUT

BOLT

HUCKBOLT

HUCK FASTENERS DO NOT SHAKE LOOSE

GAP

Huck fasteners are reliable performers in mobile and permanent structures and are used widely in the quarrying, mining, construction / demolition and recycling industries, as well as the concrete and asphalt production industries.

COLLAR

NUT

Two-Piece Two-Piece Two-Piece HuckBolts HuckBolts HuckBolts

They are regularly installed in crushing, screening, aggregate washing, scrubbing / rinsing (fine material Screw Washers and wet processing equipment) conveyors (belt, roller, chute, wheel, vibrating), hoppers, feeders, mobile aggregate processing plants and heavy equipment – in fact anywhere where vibration is an issue and structural integrity and reliability are paramount.

Swaged HuckBolt direct metal to metal contact compared with standard nuts and bolts

®

®

STANDARD NUT & BOLT Two-Piece HuckBolts

Two-Piece HuckBolts

BobTail

®

BobTail BobTail BobTail BobTail

Huck’s swaged-on fastener with ® no

® pintail. Corrosion ® ® and break-off resistant

C50L

®

®

HUCK BOBTAIL

®

C6L /C120L/C150L

®

®

C50L C50L C50L C50L

Superior vibration resistance and

durability for heavy-duty applications.

®

The ® classic 6-groove locking fastener

® of applications. ideal® for a wide range

® ® ® C6L C6L/C120L/C150L C6L /C120L/C150L C6L /C120L/C150L /C120L/C150L ®

Huck technology delivers one-time fastening Huck’s swaged-on fastener with no Superior vibration resistance and The classic 6-groove locking fastener Huck’sHuck’s swaged-on fastener swaged-on fastener with no fastener with nowith and no Superior Superior vibration Superior resistance vibration resistance andresistance and and The for classic classic The classic locking 6-groove locking fastener locking fastener fastener break-off pintail.

Corrosion resistant durability forvibration heavy-duty applications. ideal aThe wide6-groove range of6-groove applications. that is completely maintenance-free, Huck’s swaged-on break-off break-off pintail. break-off Corrosion pintail. pintail.

Corrosion resistant Corrosion resistant and resistant and and durability durability for heavy-duty durability for heavy-duty for applications. heavy-duty applications. applications. ideal forideal wide for ideal range a of arange wide applications. range of applications. of applications. installs with lightweight ergonomic Meets or exceeds all ASTM A-325 Available inagrades 2, wide 5,for and 8. unrelenting in their performance, Huck tooling. standards shear, tensile and fatigue installs with installs lightweight installs with lightweight with ergonomic lightweight ergonomic ergonomic Meets or Meets exceeds Meets orfor exceeds all or ASTM exceeds allA-325 ASTM all ASTM A-325 A-325 Available Available in grades Available in 2, grades 5,inand grades 2,8.

5, and 2, 5, 8.and 8.

3/16” - 3/8” fasteners are the future for manufacturers of life. tooling. tooling.tooling. standards standards for standards shear, fortensile shear, for shear, and tensile fatigue tensile and fatigue and fatigue 1/4” - 3/8”, 1/2” - 1” and 12mm - 20mm 3/16” 3/8” 3/16” 3/16” 3/8” 3/8” Steel, Aluminum, Stainless, all types of equipment used in demanding life. life.– 1-3/8” life.

1/2” Steel Pin with Stainless Head Steel, Aluminum, 1/4” - 3/8”, 1/4”1/2” - 3/8”, 1/4” - 1”-1/2” and 3/8”, -12mm 1” 1/2” and -Stainless 1” -12mm 20mm and 12mm - 20mm - 20mm high-stress, high-vibration environments.

Steel, Aluminum, Steel, Steel, Aluminum, Stainless, Aluminum, Stainless, Stainless, installs with lightweight ergonomic

Meets or exceeds all ASTM A-325

tooling.

standards for shear, tensile and fatigue

1/4” - 3/8”, 1/2” - 1” and 12mm - 20mm Steel, Aluminum, Stainless Grade 2, Grade 5 (Class 8.8), Grade 8 (Class 10.9)

Grade 2, Grade 5 (Class Steel, Aluminum, Steel, Steel, Aluminum, Stainless Aluminum, Stainless Stainless 8.8), Grade 8 (Class 10.9)

Available in grades 2, 5, and 8.

life.

3/16” - 3/8”

Steel, Aluminum, Stainless, Steel Pin with Stainless Head

1/2” – 1-3/8”

Steel, Aluminum, Stainless

Grade 5 (Class 8.8), Grade 8 (Class 10.9)

Grade 2, Grade 5 (Class 8.8), Grade 8 (Class 10.9)

Steel, Stainless 1/2” – 1-3/8” 1/2” –Aluminum, 1/2” 1-3/8” – 1-3/8”

Grade 5 (Class 8.8), Grade 8 (Class 10.9)

Grade Grade 5Steel (Class Steel 2, Pin Steel withPin Stainless with PinStainless with Head Stainless Head Head 8.8), Grade 8 (Class 10.9)

No re-checking. No re-torquing. No Grade 2,Grade Grade 2, Grade Grade Grade 2,5Grade (Class 2, Grade 5 (Class 5 (Class Grade Grade 2,5Grade (Class 2, Grade 5 (Class 5 (Class 8.8), Grade 8.8),8Grade 8.8), (Class Grade 810.9) (Class 8 (Class 10.9) 10.9) re-tightening, saving time, money and 8.8), Grade 8.8),8Grade 8.8), (Class Grade 810.9) (Class 8 (Class 10.9) 10.9) Grade 5Grade (Class Grade 58.8), (Class 5Grade (Class 8.8),8Grade 8.8), (Class Grade 810.9) (Class 8 (Class 10.9) 10.9) labour - reliable fasteners with outstanding performance. highest level of vibration resistance of any force over the joint. The pin and swaged collar combine to form the installed fastener fastener. HuckBolts use direct-tension to HOW DIRECT-TENSION HUCKBOLTS providing a permanent and completely deliver consistent clamp; spreading the vibration resistant joint.

WORK tensile load evenly between the LockBolts provides stronger, fatigue-resistant joining HuckBolts are precision engineered twoCONSISTENT CLAMP IS THE ULTIMATE power every time. piece fasteners that, once installed with GOAL direct-tension swaging, maintain clamp LockBolts consist of a headed pin and a force.

To maintain structural integrity consistent collar that is swaged over locking grooves clamp is the ultimate goal, without it, you risk in the pin. The pin is made with a series of bolt failure. The consistent clamp of direct There’s no fastener, more vibration-resistant pulling grooves at its tail end. The installation tension HuckBolts ensures a more secure fastener than a Huck LockBolt. Even in the tool (driven by pneumatic, hydraulic or joint than conventional nuts and bolts. most vibration-intensive environments, Huck battery power) grips these grooves, pulls the fasteners maintain their structural integrity work together, the conical shaped cavity of for the life of the joint.

When the same torque is applied to standard the nose assembly is forced down the collar. nuts and bolts, a wide range clamp-force can be recorded among each fastener. The This progressively cold forms (swages) HuckBolts are not subjected to the twisting tightest bolt can end up carrying the load it into the grooves of the harder pin. The force of torsion that a torque wrench applies of 4 or 5 bolts, causing it to fail from fatigue squeezing action reduces the diameter to a conventional bolt, they can safely be strength, this puts even more tensile force of the collar, increasing its length. This in taken to higher preload values, resulting on fewer bolts. turn stretches the pin, generating a clamp in higher clamp, higher strength and the

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PECM Issue 57

Steel, Aluminum, Steel, Steel, Aluminum, Stainless Aluminum, Stainless Stainless

Even in the most vibration-intensive environments, Huck fasteners maintain their structural integrity for the life of the joint. the DIBt. The world-renowned institute grants European technical approval for construction products and systems.

HuckBolts are applied with direct tension to provide consistent clamp, time after time.

SPOTLIGHT THE HUCK C6L® LOCKBOLT® The Huck C6L is amongst the most popular and enduring fastening systems today. It’s direct-tension design is stronger, easierto-install, and more durable than welding, adhesives, or conventional nut and bolt threaded fasteners.

The C6L’s exclusive locking 6-groove design and consistent, high clamp force ensure a secure, permanent fit and a strong, vibration-resistant seal.

• Available in grade 5.8 as C6L • Available in grade 8.8 as C120L

Installed C50L Huck Fasteners in Screening Equipment

Installed C50L Huck Fasteners in Screening Equipment

SPOTLIGHT THE HUCK C50L® LOCKBOLT® The C50L has defined LockBolt for more than 50 years. It offers superior vibration resistance and overall durability for heavyduty fastening jobs and is ideal for use within applications where consistent, uniform high clamp force is required. Testing has proven that C50L fasteners meet, or exceed the performance of torqued bolts in both shear and tensile strength, as well as fatigue life.

For applications ranging from railcar to mining equipment manufacturing, the C50L is the strong, reliable choice.

• Superior vibration resistance and overall durability for heavy-duty applications.

• Meets or exceeds torqued bolts in shear and tensile strength, and fatigue life.

• Offers consistently high, uniform clamp force.

• Exceeds ASTM 325 specifications.

• Available in grade 10.9 as C150L Its exclusive locking 6-groove design and high-uniform clamp ensure secure, permanent fit.

Ideal for general manufacturing, HVAC, truck, trailer, and container assembly, rail applications.

SPOTLIGHT THE HUCK BOBTAIL® LOCKBOLT® HuckBolts such as C6L® and C50L® have been on the market for many decades and are well known and used. The Huck BobTail® is the next generation Lockbolt; offering up to 10 times the fatigue strength of conventional nuts and bolts, BobTail delivers ultimate strength, installation speed, and vibration resistance. It has been designed to provide superior joining strength in even the most extreme environments.

After lengthy and vigorous testing, the Huck BobTail® HuckBolt® (12mm, 14mm, 16mm, 20mm and 1” diameter) has been certified to be maintenance-free by

Engineered for high performance and reliability with a unique, pintail-less design, unmatched installation speed – often under 2 seconds. Benefits of installing BobTail include: • Unique, low-swage technology allows lightweight, ergonomic tooling.

• No-break pintail means highest corrosion resistance in its class.

• High speed, easy to install systems reduce production time.

• Wide grip ranges minimise fastener inventory.

• Improves health and safety - replaces welded joints.

• Tamperproof – once installed cannot be removed without specialist tooling.

• Quick visual inspection assures quality joint.

• Fit up ability – helical lock-groves allows for pre-assembly / project alignment before the final swaging process.

• Installation indicator on collar for visual inspection to ensure correct installation – a red collar is also available that gives a clear visual installation that the collar has been fully swaged.

In addition, if necessary, the fastener can also be removed which is ideal for a project where maintenance is required. Users can simply change the nose assembly to a collar cutting nose assembly and quickly splice the collar in two.

We are Star Fasteners; fastener experts and the largest UK Huck fastener distributor. We work globally with a diverse range of end users and distributors from across a number of industries, offering technical application knowledge and customer support. Huck fasteners guarantee performance and help maximise your return on investment; get the right fastener for your project and achieve your business goals.

For further information, please visit www.starfasteners.co.uk Issue 57 PECM

29

EDITOR’S CHOICE

EMERGENCY UPS POWER HIRE POWER CONTINUITY

UPS HIRE installation for Power Continuity Power Continuity engineers, can deliver to site NO BREAK power protection solutions from 30kVA up to 10 megawatt temporary UPS installations In fact, we not only deliver UPS systems to site but our own ‘in house’ team of site experienced engineers will install the temporary soltions too.. We keep your business running.

SHORT NOTICE EMERGENCIES NEVER take for granted that your National Grid supply will always be there come rain or shine. The Ukraine war is causing pressures on the national infrastructures of all countries including the UK. Power Cuts are coming.

The government has already issued warnings for this winter for the UK. Power Continuity, provides temporary critical installations across the UK on an annual basis. Whether your site needs whole site protection or just departments we’ll ensute you’re operational status doesn’t suffer from brown outs or spikes.

TEMPORARY UPS INSTALLATIONS Containerised UPS solutions allow the best weather protection for exposed sites. “Walk Inside’ UPS containers together with AMF switchgear allow our systems to even be backed up by temporary generators.

Choice any of the following UPS Hire UPS with Batteries UPS solutions in containers Multiple UPS’s across a site Rotary Fly Wheel containerised solutions up to 3 megawatts For over 25 years, Power Continuity has provided temporary critical emergency power for production plants, hospitals, banks, data centres, coast guard and blue light emergency services.

We’ll install temporary 100% NO BREAK power protection with remote monitoring all ‘in house’ by Power Continuity.

We’ll install temporary 100% NO BREAK power protection with remote monitoring all ‘in house’

by Power Continuity.

• Whole event power protection

SEAMLESS UPS POWER PROTECTION

• Absolute Critically

UPS installation for temporary power continuity, that incorporates, Uninterruptible Power Supplies ( UPS) to cover the first seconds whilst the temporary emergency power generators start up.

At POWER CONTINUITY we place our reputation on the quality of our temporary installations.We’re here to keep you protected 24/7

This is termed ‘NO BREAK Power Protection’.Your site will NEVER lose Power Continuity, even for a millisecond. Absolute seamless electricity when your facility or event MUST remain in operational 24/7.

THE SHOW MUST GO ON Power Continuity Solutions are already protect the critical operations for over 19% of the UK population. Silently providing peace of mind to ensure that what’s important to you is available every hour of the day. Here is a range of UPS solutions to ensure your event goes on:-

UPS HIRE • Inside your building • Outside in containers

Emergency Power Systems is what we do.

Power Continuity is what we install. WE ARE POWER CONTINUITY ltd.

With our 25 years of experience protecting Banks to Hospitals, from Pharmaceuticals to Manufacturing, our Power Continuity systems operate 24/7/365, year in and year out, protecting our clients even when the vulnerable GRID supply fails.They keep functioning without letup.

For UPS Hire call Power Continuity - Don’t panic…..Just call us…..

Call us on 0845 055 8455 We’re here to help you 24/7/365 We are POWER CONTINUITY

For further information, please visit www.powercontinuity.co.uk

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PECM Issue 57

EDITOR’S CHOICE

SeaShield 2000FD™ System selected for jetty pile protection at RNLI Lifeboat Station Winn & Coales (Denso) Ltd.’s SeaShield 2000FD™ System was recently specified for the protection of 31 jetty piles at the Royal National Lifeboat Institution’s (RNLI) station in Padstow, Cornwall.

The existing epoxy coating on the piles had begun to fail due to its length of time in service and abrasion caused by exposure to the local marine environment. The complete coverage of each pile required the installation team from PSJ Marine Services to work at height, from the beach, and subsea to fully protect the 16 piles of 762 mm diameter and 15 piles of 813 mm diameter.

The SeaShield 2000FD System, consisting of Denso Paste S105™, Denso™ Marine Piling Tape and a tough outer HDPE jacket, offers heavy-duty protection from corrosion and is suitable for application both above and below the water line, making it the ideal choice for this project and making Padstow the latest RNLI site to be protected with a SeaShield system.

www.denso.net

Good Practice Guidance for Electrical, Control and Cyber Security in Industrial Engineering • Practical guidance for everyday and irregular situations and tasks

• Readily accessible for all in the industry – wherever they are, whatever time they have

• Verified and developed from contributions by the industry, for the industry

• FREE task and procedure checklists • E-learning for professional development

Management of ageing electrical assets Publication 227 Edition 1

®

To purchase or for more information, please visit www.eemua.org

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PECM Issue 57

EDITOR’S CHOICE

HRS offers stand-alone Cleaning-in-Place (CIP) system Maintaining hygienic, and in some cases sterile, production equipment is a key aspect of modern food processing, as well as the production of pharmaceuticals and other products. Cleaning-in-Place (CIP) is the standard technique to effectively and efficiently clean equipment which contains pipework, enclosed spaces and small apertures in situ.

HRS Heat Exchangers offers cleaning-in-place (CIP) and sterilisation-in-place (SIP) systems for cleaning and disinfection for all hygienic industries, including food and pharmacy industry systems. Our single- and multi-tank HRS CIP / SIP Systems are supplied complete with a control system to enable automated cleaning cycles.

The systems are fully skid mounted and have modular designs for quick and easy site installation. The single-tank (ST) system is designed for simple cleaning applications where recovery of the cleaning fluid is not required, while multi-tank (MT) systems are suitable for more complex situations.

For small, portable applications the tank can be heated to 85°C using electric heating elements, but steam heating using an HRS K Series multitube heat exchanger is also available. Units start at 500 litre capacity, and single tank systems are available up to 2,500 litres. Larger systems can be provided using multiple tanks and centrifugal sanitary pumps are fitted as standard.

Above, All HRS CIP and SIP systems are fitted with PLC and HMI controls for automatic operation, or can be integrated into existing factory systems.

Right, An HRS multi tank (MT) CIP system

Systems are fully automated using Programmable Logic Controller (PLC) systems and Human-Machine Interfaces (HMI), which can be stand-alone or integrated into the factory’s main control system.

www.hrs-heatexchangers.com

HRS Heat Exchangers operates at the forefront of thermal technology, offering innovative and effective heat transfer products worldwide, focusing on managing energy efficiently.

Pasteurisation Sterilisation Heating/Cooling Evaporation CIP/SIP Systems Process Skids

HRS Heat Exchangers +44 (0)1923 232 335 | info@uk.hrs-he.com www.hrs-heatexchangers.com

Issue 57 PECM

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AUTOMOTIVE

ID. BUZZ PRODUCTION VOLKSWAGEN

Up to 130,000 units per year from Hanover Volkswagen Commercial Vehicles (VWCV) is ringing in a new era of vehicle production at its Hanover plant. Production of the new allelectric ID. Buzz and ID. Buzz Cargo recently started there and the first vehicles will be delivered to customers in the autumn. The brand is therefore systematically pressing ahead with the electrification of the site and securing the future of VWCV in line with the GRIP 2030 strategy. In the course of the year the company plans to increase the plant’s daily production to a total of 900 vehicles. In future, there are plans to build up to 130,000 units per year at VWCV’s main plant.

With the production start of the ID. Buzz , the VWCV plant in Hanover is now the third German production site for vehicles of the ID. family.

“The ID. Buzz is a milestone in the electrification of the brand and the plant in Hanover”, says Josef Baumert, Member of the VWCV Brand Management Board for Production and Logistics. “In just eight years’ time more than 55 per cent of our vehicles in Europe will have battery-electric drive. The ID. Buzz has a leading strategic role in this”, says Baumert.

This year VWCV is planning to produce a total of around 15,000 ID. Buzz . Baumert adds: “As we develop our portfolio, after 2023 we will produce up to 130,000 units of the ID. Buzz and ID. Buzz Cargo at our Hanover plant.”

THREE VEHICLE CONCEPTS, ONE PLANT, FLEXIBLE PRODUCTION. Since May of this year VWCV has produced three models at the Hanover plant. They are based on three different platforms and can have three different drives: the ID. Buzz as a battery-electric vehicle, the new Multivan as a plug-in hybrid and with conventional drive and the variants of the T6.1 with a combustion engine. In the factory the vehicles are partly produced on one line. “Our production method is highly complex, but it enables us to respond flexibly to customer demand”, says Baumert. Despite the many factory modifications over the past two years, production of the popular T6.1 continued uninterrupted.

4,000 EMPLOYEES TRAINED TO PRODUCE THE ID. BUZZ The first all-electric vehicle from Hanover and new, digital systems also resulted in far-reaching new demands on the employees. During the start-up of the ID. Buzz 4,000 employees in the factory were trained for the production of the new vehicles. “We trained our employees in high-voltage technology and also adapted our apprenticeships to the new tasks”, Baumert adds. Apprenticeships offered by VWCV in Hanover include mechatronics technician for system and high-voltage technology.

Commenting on the production startup of the ID. Buzz , Baumert says: “The workforce did a great job during this time: they accomplished training for the ID. Buzz parallel to the series production of the T6.1 and the new Multivan – and all this during the Covid-19 pandemic. I would like to thank all VWCV employees for their commitment and their determination to get the ID. Buzz off to a good start.”

INCREASED PRODUCTION OUTPUT Modern digital systems and new processes enable the production to be increased at the site. By 2023 VWCV plans to produce up to 900 ID. Buzz , New Multivan and T6.1 per day in Hanover. Until now the maximum production was 810 vehicles.

BRAND FORGES AHEAD WITH AUTOMATION AND DIGITALISATION STRATEGY New plants and processes in the factory: for the body construction of the ID. Buzz , the degree of automation has increased by 15 percentage points to 92 per cent compared to the T6.1. Skilled workers manage large parts of the plants using computers and mobile devices such as smartwatches.

Operators and machines are in constant contact. The robot systems report possible problems in good time, which can be solved during operation. Baumert sums up the development in Production in a nutshell: “Hanover is on the way to becoming a ‘smart factory’.”

COMPONENTS TO PRODUCE THE MEB BATTERY SYSTEM IN HANOVER IN FUTURE Volkswagen Group Components is responsible for assembling the whole front and rear axle of the ID. Buzz and ID. Buzz Cargo , the newest and largest vehicles to date to be based on the MEB, in nearby Barsinghausen. From there they are delivered to VWCV in Hanover. At the same site Group Components already produces hardware in the form of the flexible fast-charging station for establishing a fast-charging infrastructure for electric vehicles, and motor housings for the MEB. From 2024 the MEB battery system for the ID. Buzz , which is currently supplied from the Components site in Braunschweig, will also be assembled.

For further information, please visit www.volkswagen.de/de.html

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PECM Issue 57

BOILERS & MAINTENANCE

Agreement with South Korean distributor enhances Lanemark Combustion Engineering capability Process gas burner specialist, Lanemark Combustion Engineering Ltd., is announcing a major agreement with a new distributor in South Korea. The link with Shinsung Ener-Tech Co., Ltd., based in Seoul, South Korea will create opportunities for both organisations in one of the most active markets in the region.

“Shinsung is very well established in the field of HVAC and process burners which are used within a variety of applications,” says Jeff Foster, Sales Director at Nuneatonbased Lanemark. “We share a commitment to quality, efficiency and environmental optimisation so are confident that, jointly, we can bring proven performance and key benefits to the regional customer base.”

The agreement with Shinsung is set to strengthen Lanemark’s own burner sales in the new distributor’s markets. The company’s (TX) tank heating burners, (FD) forced-draught oven burners, (FDB) forced-draught duct burners and its (DB) duct burners – each used extensively in processing and manufacturing operations from aluminium anodising to food processing – will, in turn, all enhance Shinsung’s own market strength.

“We are committed to building on the close relationships that we have with distributors around the world, and we are, therefore, delighted to be able to add Shinsung to this list,” concludes Jeff Foster, Sales Director

at Lanemark. “The area within which both companies have developed leading reputations is highly specialist so we are confident that the link between us will offer major gains to our respective customers.”

www.lanemark.com

Gas Process Burners Lanemark gas burner systems offer users reliable, high efficiency, process heating solutions.

FD Series Packaged Oven/Dryer Burners Specifically designed for process air heating applications in convection ovens and dryers High turndown/short flame lengths providing accurate process temperature control High efficiency gas + air modulation, gas only modulation and simple high/low control options Heat Input Range: 9 kW – 1550 kW

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Midco HMA Series Air Replacement or “Make-Up” Air Heating Burners Direct fired, high efficiency burner systems, for high volume air heating applications such as paint spray booths, ovens and dryers.

Supplied either as Midco burner heads for OEM system integration or as Lanemark DB or FDB complete packaged systems including modulating gas valve trains and controls Wide range of firing rates to suit alternative temperature rise and air velocity system requirements DbCalc system design software

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

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

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•

COMBUSTION ENGINEERING

31/08/2016 09:04

Issue 57 PECM

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CONTROL & AUTOMATION

A MORE AGILE BUSINESS MODEL EU AUTOMATION

Automation cells and the standardisation of manufacturing components production process — some models even come on wheels.

The COVID-19 pandemic, a tense socio-political global climate, and an increasingly demanding customer base have all contributed to a growing need for flexibility in manufacturing. As a result, manufacturers need equipment that can be quickly and easily reconfigured, rather than fixed production lines where every change may require weeks of downtime.

Here Neil Ballinger, head of EMEA at EU Automation, a global supplier of quality automation components, explains the role of automation cells in transitioning to a more agile business model.

Another great advantage of automation cells is that they can be placed in any building where there is enough floor space.

This means facilities like empty warehouses can be easily repurposed to set up a new production plant in record times.

This approach is perfect for manufacturers that need to establish a new production line very quickly, for example to respond to a sudden surge in demand. However, it will also facilitate those who are planning to bring production closer to the final customer to save on logistics costs, reduce lead time and minimise the company’s overall carbon footprint.

Customisation and high-mix low-volume (HMLV) production are not new concepts in manufacturing. Both have risen to prominence in the last decade, with the demand for increasingly personalised products and services. These trends require manufacturers to rapidly adapt to changing market conditions, and to reconfigure their production and assembly lines accordingly.

The need for adaptability intensified during the pandemic, when many production plants experienced a boom in demand and needed to set up extra lines to produce critical supplies such as respirator components and personal protection equipment (PPE). On the other hand, some companies needed the flexibility to switch their production to entirely new items — from alcoholic drinks to hand sanitiser, from luxury fashion to medical gowns.

Another great advantage of automation cells is that they can be placed in any building where there is enough floor space.

THE SOLUTION IN A NUTSHELL In this context, closed-loop automation cells have become increasingly popular.

Automation cells, or robot cells as they are often called, are closed systems containing equipment that can automate several stages of the production process.

For example, they may include robotic arms that load and unload the parts to be machined, in-feed and out-feed conveyors, and machine vision systems that determine what part is being fed-in, and that measure and inspect post-processed items.

Compared to traditional production lines, automation cells offer unprecedented

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PECM Issue 57

flexibility. Since the days of factory pioneer Henry Ford, manufacturing plants have worked in a similar way — with long, linear production lines where items pass from station to station, being processed and finally inspected and shipped. In these lines, every change requires the intervention of multiple experts and can lead to several weeks of expensive downtime.

On the other hand, automation cells allow for a modular and easily scalable factory structure. These cells can be quickly rearranged on the factory floor whenever manufacturers need to restructure the

For example, British electric vehicles (EVs) start-up Arrival uses flexible automation cells in its microfactories, which are smallscale production plants that the company is planning to set up on the outskirts of cities worldwide. The use of automation cells allows the company to set up new production lines very quickly, so instead of relying on production sites overseas, Arrival has chosen this innovative approach to reduce costs by bringing production closer to where its vehicles are needed.

A further advantage of automation cells is that a factory structured this way can be very easily scaled up and down according to market demand, by simply adding or subtracting cells. This is a great approach for start-ups and smaller manufacturing companies who might not be in the position to invest in a huge and cost-prohibitive facility but want to give themselves space to grow.

A LOOK WITHIN — STANDARD COMPONENTS The beauty of automation cells is that they contain everything the plant needs to automate the production process — or at least some of its core aspects — in an extremely compact architecture. Like Lego building blocks, the components in the cells are structured so that they all fit together to occupy the least possible space.

out the necessary tasks within the cell and establish the optimal workflow. There are even useful digital tools to help users in the process. For example, FANUC’s Build Your Cell configurator guides users at every step to create the ideal cell for their application.

The benefits of automation cells are clear — production can start shortly after the manufacturer perceives the need for new workstations, either because of unprecedented demand, or because of the necessity to adapt production to new specifications. As well as this, costs are minimised and the overall agility of the plant is increased.

This is leading to an interesting phenomenon in equipment manufacturing — the standardisation of automation machinery. Traditionally, production and assembly lines were bespoke projects that required the expertise of several high-skilled professionals, such as design engineers and systems integrators.

Designing, building and testing the line took several months, was extremely expensive, and required long periods of downtime.

On the other hand, automation cells can be realised in less than one week, although up to three weeks may be needed to map

It seems clear that manufacturing is evolving from an industry based on cumbersome, bespoke projects to one that requires extreme flexibility through the use of modular architectures and standardised components. Automation cells offer a great chance to innovate manufacturers’ business models and keep up with the ever-evolving needs of an increasingly demanding global market.

For weekly updates on the new trends in smart manufacturing, and to order a wide variety of quality automation components from all major brands, visit https://www.euautomation.com.

For further information, please visit www.euautomation.com Issue 57 PECM

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CONTROL & AUTOMATION

NOW WITH NEW ACCESSORIES SCHMERSAL

slimline AZM150 solenoid interlock The DHS-150 door handle system is especially suited to heavy swing doors

With the new practical DHS-150 door handle system, the slimline AZM150 solenoid interlock from Schmersal is now even easier to use. The ergonomic DHS-150 avoids the need for a separate door handle and is suitable for machine enclosures or fencing and for all standard aluminium profiles with a width of 40 mm. T he robust door bolt is particularly useful on heavy swing doors and in for use in harsh environments. One benefit of the new accessory is that the actuator is prepositioned by the bolt in the DHS system, thus ensuring its optimal insertion into the device. This gives the system stability against lateral forces. In the event of lateral forces on interlocks that cannot be overcome, the safety door will not be opened – thus causing delays in the production process.

In this regard, the DHS-150 door handle

system, in conjunction with the AZM150 solenoid interlock, contributes to improved system availability. In addition, the DHS-150 door handle system is also equipped with an integrated locking device (LOTO). This locking tag function protects operating staff from mistakenly being locked inside larger, walk-in systems and machines while they are performing servicing and repair work.

The locking device ensures that the door of the protective device cannot be closed and unintentional machine start-up is prevented.

The AZM150 solenoid interlock has an interlocking force of 1500 Newtons and is characterised by a slimline, space-saving design. In addition, it can be combined with three different actuators for different attachment situations. A positive of the interlock is the rotating actuator head which can be locked with ease by simple

placement on the cover, rather than being bolted into place. The rotating actuator head with its two insertion slots enables various installation positions and actuating options and makes the interlock particularly versatile in use.

The AZM150 solenoid interlock is electromechanical in design and can be combined with a high safety standard: the interlock is supplied with a low coding level as standard, or optionally with a high coding level in accordance with ISO 14119. The DHS-150 door handle system can be used with the B1 straight actuator for the standard version as well as for the individually coded version. The B1 actuator is supplied with the high coding level version of the device, but must be ordered separately for use with the standard version.

For further information, please visit www.schmersal.co.uk

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PECM Issue 57

CONTROL & AUTOMATION

VIBRATION CONTROL MASON UK

Vibration isolation specialist keeps high precision manufacturing on track As microprocessors continually get smaller, manufacturing becomes more accurate, working on the nanometer scale which is highly intolerant to disruption. To create the environment needed to facilitate precision manufacturing, it is essential to control vibration, temperature, humidity and particulates. Here’s how vibration control specialist, Mason UK, designed a sophisticated vibration isolation system to ensure conditions at an advanced manufacturing site in Ireland were ideal for high-precision manufacturing.

Mason UK was commissioned to provide vibration isolation support at a vast site upgrade project in Ireland. In fact, the site is one of the most technologically advanced manufacturing locations in Europe and the facility has undergone an upgrade that has enabled production of 14nm process technology.

However, these cutting-edge chips could not be realised without very precise manufacturing conditions. This requires a vast array of heating, cooling and filtration systems, all of which must be correctly isolated, since even exceptionally low levels of vibration can cause errors in fabrication. To achieve the stable environment required in the fabrication clean rooms, mechanical processes such as cooling, heating, ventilation and filtering systems are necessary — all of which generate unwanted vibration at every pump, fan, valve, duct and pipe support.

Systems are vast, some ducts being over four metres in diameter, so the project is challenging.

MEETING THE SPECIFICATION Mason UK was brought on board by the contractor early to support the design. What makes this project unique is the scale of the facility and volume of vibration control required. As a result, not only the vibration but factors such as wind loading, thermal expansion and the clash of services in a crowded area had to be considered.

As one of the biggest construction projects that Ireland has ever seen, the shear amount of product that Mason UK supplied

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PECM Issue 57

What makes this project unique is the scale of the facility and volume of vibration control required. was staggering. In total the vibration specialist has so far supplied 3800 spring mounts, 1600 hangers and 400 flexible pipe connectors for the site. With such an unprecedented undertaking ahead, it is little wonder that there was a very onerous specification.

“The first requirement is ensuring quality of the engineering design, for example, specifying a particular spring geometry or housings made in a certain way,” explained Adam Fox, director at Mason UK. “The second requirement is ensuring the product has the correct vibration isolation properties. This is determined initially by the location in the building and the experienced product selection of the Mason UK engineering team.

“The closer you get to the fabrication, the more urgent the need for vibration isolation. Similarly, the higher up you go in the building, the more lightweight the structure gets, and more vibration isolation is necessary. Down in the foundations, vibration is minimal, but if you’re on the roof, that roof structure can be quite sympathetic to vibration. The vibration isolation properties can also be equipment driven. By and large, the bigger the diameter of your pipe, the bigger your pump or your ducting gets and the more energy it is able to carry.

Consequently, larger pipes require a higher level of vibration isolation.”

DESIGN SUPPORT LIKE NO OTHER Not only was Mason UK brought on board to supply the vibration control products, but the team was also invited to conduct associated design work. Mason UK has unrivalled design capabilities in this area, so this was a welcome invitation for its experienced engineers.

The team took 3D models of the ducts and supporting steels and generated their own drawings using building information modelling software, Revit. Mason UK also produced detailed 2D drawings using AutoCAD. These were used to calculate

how much each component weighs, how much it expands and how much it contracts.

This process was repeated for hundreds of pieces of plant equipment and kilometres of building services, for all locations and configurations, to show which products were required where. Crucially, this removed some responsibility from the contractor.

However, the project was not without its engineering challenges. Instead of simply supplying a standard catalogue product, Mason UK made bespoke spring mounts with different housing to meet the needs of this project. This allowed for clearance on vertical ducts when they grow and shrink thermally.

As with any project of this magnitude, smooth installation is key. The physical size of the products, some of which were half a metre in height and a vast range of sizes, could have proved tricky. Mason UK went above and beyond to help simplify the process. The company anticipated that it would be difficult to detail all duct supports and created bespoke spring mounts, with consistent dimensions and attachments.

This ultimately made the installation cheaper and easier.

QUALITY OF PRODUCT Mason UK also supplied flexible connectors for the project to isolate the pumps from the ground. The flexible pipe connectors

selected were the Safeflex variety, using a uniquely robust flange design and reinforced with Kevlar, which has immense strength and fantastic resistance to becoming brittle over time. Cheaper variations use nylon and can become brittle if heated water passes through it.

This can lead to failure which is absolutely unacceptable for a continually running fabrication process.

“No one else builds connectors in this way,” continued Fox. “With the vast majority of connectors, you snap them on to their flange — but if you can snap them on, you can also snap them off. We use a solid steel ring which is bolted in place so that there’s no way it can snap out and fail.

“Our connectors can accept steam or

chemicals passing through at high pressure and temperatures. If it were to burst, severe injury or flooding can result. From damage to equipment, to whole buildings being written off — the repercussions would be huge.

Our Safeflex flexible pipe connectors are such a reliable design that we’ve never had a failure.”

While this project was clearly a massive engineering exercise, the quality and reliability of Mason UK’s products, coupled with the company’s unrivalled design expertise, proved invaluable to ensure the upgrade will be a success.

For more information about Mason UK’s design services or its comprehensive range of vibration control products visit www.mason-uk.co.uk.

For further information, please visit www.mason-uk.co.uk.

Issue 57 PECM

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CONTROL & AUTOMATION

ROBOTICS AS A SOLUTION ABB ROBOTICS

Are Robotics Set to Play a Starring Role in the Next Ten Years of British Manufacturing?

Technology is constantly changing our day-to-day lives and has had a particular impact on the working world. Automation is fast becoming a key conversation within multiple industries in Great Britain, including manufacturing with robotics emerging as the solution.

Over the past few years, a need to move towards more automation in the manufacturing industry has been seen.

In fact, a survey done by ABB Robotics found that of 250 SME and manufacturing companies, 81.2% were considering incorporating robotics into their processes to combat issues with workforce shortages and supply chain disruptions.

In this article, we’ll look at how, in order to keep up with the demand British manufacturing faces, more businesses are adopting robotics as a solution. We’ll also dive into what they can do for your business.

WHAT CAN ROBOTS DO FOR YOU? A big question from businesses still on the fence about bringing in robots is what can they do to improve processes. By automating sections of your manufacturing processes with robots, you’re given an opportunity to stay competitive within a constantly evolving industry.

Substituting traditional labour with robots within your processes can help to provide added efficiency. Robots don’t require breaks, and they’re programmed to carry out specific practices with much smaller margins for error than humans. This results in a more cost-effective output from your business, which could see greater revenue for less paid labour.

Robotics can also be useful when it comes to tasks that require a steadiness that can’t always reliably come from humans.

Whether it’s handling or removing materials that can be harmful or dangerous, welding, or separating materials from one another, robotics makes those tasks much easier to carry out.

THEY WORK AMONG US… The UK’s manufacturing industry has leant into a ‘quality over quantity’ mentality, focusing on top value from each product made, and robotics are now being incorporated into processes.

Between 2020 and 2021, the UK became one of the top 15 for sales of industrial robots globally. The International Federation of Robotics (IFR) found that 2,205 industrial robots were installed throughout 2020, which brought the total in the country to around 23,000.

These robots are primarily found in the automotive manufacturing industry in the UK with around 875, making up 16% of those that were installed in 2020. Several sectors are seeing a benefit in robot application due to a lack of workers, including the food and beverage sector, which already uses industrial machinery and hydraulic cylinders, has seen an increase to 304 robots in 2020.

This is a 96% increase in volume since the previous year.

LOOKING TO THE FUTURE Though these numbers continue to rise, the IFR still ranked the UK outside of the top 20 countries with robot density within manufacturing. We can take from this that there is still room for robotics presence in manufacturing to grow on our shores.

The government itself outlined how much growth was possible in a Business, Energy

Between 2020 and 2021, the UK became one of the top 15 for sales of industrial robots globally. and Industrial Strategy (BEIS), estimating that there was a potential 40% annual growth for robotics and autonomous systems in the UK between 2020 and 2030. This could in turn mean an extra £6.4 billion in value for the UK economy by 2035. And if our creation and sale of autonomous robots is set to increase, our use of them across a number of industries may be set to increase alongside it.

Automating your business process with robotics is not something to be scared of. The myth that robotics steals jobs has long since been debunked, and there is plenty of room for improvements within the manufacturing industry that they can help solve. Implementing robotics can help keep your business competitive in the global market, as well as provide an efficiency that is impossible to achieve with manual labour.

There are currently a record number of robots installed; however, there is still room for growth, and the amount of revenue that could stimulate the UK economy if more is installed is staggering.

For further information, please visit https://new.abb.com/products/robotics

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PECM Issue 57

Your Full Palletizer Solution Palletizing is a labor intensive, repetitive and unergonomic task, which makes it ideally suited to automation.The benefits of automating palletizing tasks include increased productivity and throughput, higher quality, and improved ergonomics. However, the cost and complexity of traditional palletizing robotic systems has prevented small to medium sized businesses from introducing automation to their facilities.

Now you can get exactly the palletizing solution you need with OnRobot’s new modular, fully configurable Palletizer.

Complete, configurable, and modular palletizing solution supports leading robot brands and fits in existing floorplan Intuitive, step-by-step software quickly programs and reconfigures palletizing tasks Automatic optimization of robot motion reduces cycle time and extends equipment life Electric solution offers fast out-of-the-box deployment without the complexity and cost of external air supply

The OnRobot Palletizer is available as a complete solution that is more versatile and affordable than competing The OnRobot Palletizing, intuitive software designed to ensure fast set up, regardless of the end user’s prior robotics deployment experience The OnRobot Lift100 is a long-stroke, high-payload elevator with minimal deflection that ensures precise positioning of boxes, even at high speeds. Its integrated safety features, with TÜV-certified stop functionality, facilitate collaborative deployment.

Out-of-the-box integration with the OnRobot palletizing solution shortens deployment time, and offers future-proof flexibility.

The OnRobot 2FGP20 palletizing gripper offers a wide stroke and customizable arms to handle heavy or open boxes, shelf-ready products, and other containers that can’t be handled with traditional vacuum grippers. An integrated vacuum gripper places slip sheets without changing the gripper or requiring another handling method.

The OnRobot Pallet Station is a durable, floor-mounted pallet fixture that ensures consistent positioning and includes a built-in sensor for detecting pallet presence.

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Contact OnRobot to find out more about our palletizing solutions. north-europe@onrobot.com Or visit our Learningsite on Collaborative applications know-how to all learn.onrobot.com/en

CONTROL & AUTOMATION The World’s Leading One Stop Shop for Collaborative Applications

HOW TO BUILD A PICK & PLACE APPLICATION Regardless of which process you want to improve, and which robot you prefer, the One System Solution helps you automate swiftly and seamlessly.

OnRobot’s cutting-edge solutions and tools provide thousands of businesses worldwide with perfect versatility and ease of use. The possibilities are utterly limitless, but if you’re curious for examples, find the most common collaborative applications for pick and place projects below. There are more to be found when visiting OnRobots website.

GECKO

MG10

RG2

2FG7

2FGP20

EYES

3FG15

SOFT GRIPPER

VG10

For more information visit our site at www.onrobot.com Or contact us at: north-europe@onrobot.com

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PECM Issue 57

4/26/2022 12:29:14 PM

CONTROL & AUTOMATION

HARMONIC CURRENTS CP AUTOMATION

Tips for mitigating harmful harmonics The rise of non-linear loads in industrial environments over the last two decades has resulted in the growing problem of harmonic currents and utility-level voltage distortion. Facing a lack of awareness, the industry has struggled to implement effective mitigation techniques. Here, global sales & marketing director of CP Automation, John Mitchell, discusses useful tips for mitigating harmonics.

and detuned contactor based units, thyristor capacitor banks and fine tuned passive filters. These methods were principally developed to resolve reactive power and not specifically for harmonic mitigation.

Today, I would hope no one is installing capacitor banks by themselves and, at the very least, using de-tuned ones – with an inductor for example.

Voltage distortion, caused by current harmonics can wreak havoc in a plant, damaging its equipment and the mains power supply. Damage can be serious and varied with the most common symptoms including voltage notching, motor vibration, arcing on bearings, nuisance tripping, electromagnetic interference (EMI/RFI) and overheating.

Series-active takes the form of an ActiveFront-End (AFE) VSD. It replaces the rectifier diodes in a regular VSD with an IGBT controlled rectifier to eliminate switching based signal noise.

The very first place to start is to ensure you comply with regulations. International harmonic control requirement, IEEE-519, limits “the maximum frequency voltage harmonic to 3 per cent of the fundamental and the voltage total harmonic distortion (THD) to 5 per cent for systems with a major parallel resonance at one of the injected frequencies.” Some form of filtering is subsequently recommended.

SERIES-ACTIVE

Voltage distortion, caused by current harmonics can wreak havoc in a plant, damaging its equipment and the mains power supply. what options are available to you, can help the overall efficiency of the harmonic mitigation process.

We’re lucky in the UK to have a stiff power grid, but this is not true everywhere.

Developing countries often aren’t as lucky.

Weak grids with an unreliable supply and inadequate infrastructure are common in other parts of the world. The power ratings on products are often based on calculations performed in ideal conditions. Buyers would be wise to note that these products may perform adversely in weak grids and may not perform to IEEE-519 standards in these conditions.

Passive and active harmonic solutions can be installed in both series and parallel (shunt) configurations within a system. Series solutions operate in line with the load, meaning that units must be sized for the full current load. Shunt units can be sized only for the harmonic disturbance. There is a clear decision to be made between seriespassive, shunt-passive, series-active and shunt-active solutions.

Remember to always stay on your toes. The last few decades have seen a rise in the use of non-linear loads such as transistor based variable speed drives (VSDs) and line commutated DC drive systems. The processes of high frequency switching and pulse width modulation (PWM), introduce unwanted multiples of the fundamental 50hz frequency in the form of harmonics. Knowing

The most straight forward series-passive solution can be achieved using a line reactor. This is a low cost way to reduce current harmonics, while adding a level of protection to the rectifier.

SERIES-PASSIVE

SHUNT-PASSIVE Shunt passive is power factor correction, often using fixed capacitor banks, tuned

AFEs are great at significantly lowering THD and maintaining good power factor.

However, AFEs have some serious drawbacks. In order to maintain a small form factor, lower switching frequencies are used, which result in high switch ripples on the voltage waveform. This can cause other sensitive equipment like PLCs and telemetry and communications networks to nuisance trip and malfunction.

In addition, although this unit may at first seem to eliminate harmonics, it must be noted that with the AFE in addition to the VSD, there are now two drives in the circuit producing twice the heat. This means twice the heat and with a 200kW AFE it soon adds up. For the panel builder or system integrator, bigger cooling systems are needed to cope with the excessive heat.

SHUNT-ACTIVE Active filters provide the most efficient harmonic compensation in a compact unit that has little loss, is insensitive to grid conditions, cannot be overloaded and is easy to retrofit. All of this comes at a slightly higher cost, which is offset by the better return on investment over the longer term.

Understanding the often subtle differences between various harmonic filtering technologies can yield better cost savings, reduce complexity and prolong equipment life. Getting your head around what options are available really is worth it in the long run.

For further information, please visit www.cpa-ltd.net Issue 57 PECM

45

CONTROL & AUTOMATION

FLEXIBLE APPLICATION MK PROFILES

Automation Line for Motor Assembly TASK mk recently helped an automotive supplier that manufactures and assembles motor blocks and cylinder heads. The customer had various motor components that needed to be flexibly supplied for feeding the main assembly line so that they can be subsequently assembled. There is no interim storage on the assembly line, meaning that production occurs just in time, which requires a certain degree of flexibility. Zones for walking and driving must remain clear with a relatively low flow rate.

MK SOLUTION Based on the requirements, a solution with automated guided vehicles (AGVs) together with the appropriate mobile racks and load handling equipment was suitable in this case. mk supplied mobile racks that are coupled and carried by the AGVs as towing devices, thus allowing them to be brought to the respective stations in a flexible manner.

Driven roller conveyors act as load handling equipment on the racks and transport the motor components onto the AGVs and onto the subsequent lines at the stations. In one case, a roller conveyor with split rollers and centre guide was designed for the product. The roller conveyors are driven by friction wheels, each attached to the roller conveyor and corresponding station. The roller conveyors therefore do not need their own motor and thus power was not supplied by the battery of the AGV. Furthermore, any motor can be used at the stations to drive the roller conveyors. However, solutions with small, light motors for the load handling equipment on the AGVs, for example with 24 V or 48 V DC, are also possible.

Applications with chain conveyors or accumulating roller chain conveyors can also be used as load handling equipment if the products must be transported on pallets. Stoppers used as transport safety devices on the conveyor prevent products from falling while the AGV is in motion. The stoppers are mechanically unlocked at the stations, and thus do not require a separate power supply. The controller for both the load handling equipment and the AGV are integrated in the master controller for the

production process. In addition, the mk safety guards provide work piece protection and protective guarding at the respective transfer stations. Protective tunnels on the mobile racks are also available to protect the products from manipulation during transit.

mk were able to provide their customer with excellent integration into their existing systems and controllers and provide a flexible application thanks to the modular profile design.

To find out more about the complete mk range please visit www.mkprofiles.co.uk, call (01949) 823751 or email info@mkprofiles.co.uk.

For further information, please visit www.mkprofiles.co.uk

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PECM Issue 57

Machine Housings for Increased Occupational Safety

Modular guarding based on our profile system Attractive design that is also stable and functional Screw connections provide the flexibility

www.mkprofiles.co.uk

mk Profile Systems Limited a company of the mk Technology Group

ELECTRICAL & ELECTRONICS

Leaders in temperature measurement

Thermocouple Cables

In Stock For Immediate Worldwide Despatch Heading 3

IEC or ANSI Colour Codes PVC, PFA, PTFE, Glasfibre & Silicon Rubber types available Flat pair or twin twisted pair in various calibration types

XE-2440-025

XE-2800-050

10m, 25, 50, 100m & 200m lengths from stock XE-2801-010

www.labfacility.com Bognor Regis tel: +44 (0)1243 871280

XE-2275-050

XE-2363-100

PRT

XE-2757-025

sales@labfacility.com Sheffield tel: +44 (0)1909 569446

Exponential growth at Electro-Wind Established in 1979 ElectroWind have been designing and manufacturing single and three phase transformer products for customers in the UK, Europe, and Global Markets over the past 40 years. As a secondgeneration family owned and operated company, over the past couple of years ElectroWind has seen exponential growth, both standard and custom-built products have proved to be in demand.

With a very low staff turnover, many of the long-established team members have worked for the company for over 20 years, however the business has expanded dramatically over the past few years with the addition of many new recruits.

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PECM Issue 57

Jeff Roberts background in the electrical distribution and wholesale markets Justyna Rokita electrical assembly work and winding small to medium sized coils.

Jack Colclough mechanical work placement before joining Electro-Wind Alister Holmes experience came from working in Bespoke Lighting Matt Gould electrical background as a qualified Electrician Chris Ball worked in construction whilst working on an engineering qualification.

https://electro-wind.co.uk

W02h/0

ELECTRICAL & ELECTRONICS

Hospital Air Disinfection System uses Lascar’s PanelPilotACE Display Compromised air quality in hospitals can increase the severity of infections in patients and negatively impact staff. According to significant research articles, over 35% of infections can be transmitted through the air.

These types of infections can leave particles suspended in the air for extended periods of time.

The S400 is a mobile air disinfection unit designed to remove airborne contaminants, pathogens, and odours of all types

Scientific Air Management, created the S400 to reduce these transmissions in critical areas.

The S400 is a mobile air disinfection unit designed to remove airborne contaminants, pathogens, and odours of all types. The device utilizes Lascar Electronics’ SGD 43-A programmable TFT panel meter, chosen primarily for its programmable interface and ease of use. The free configuration software supplied with the panel meter enabled Scientific Air Management to design and create a multi-page user interface. The design utilized two PWM outputs to control fan speed and illumination of the UV bulbs. The SGD 43-A also displays the HEPA filter runtime to ease maintenance and ensure efficient operation.

completed assembly. Lascar proudly helped Scientific Air Management meet the high demand for S400 devices, supplying them to hospitals during the Covid-19 crisis.

Lascar recently designed and manufactured a PCB that eases the assembly process and greatly speeds up the production time of the

Lascar Electronics | lascarelectronics.com | sales@lascar.co.uk | 01794884567

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Issue 57 PECM

49

ELECTRICAL & ELECTRONICS

Audible & Visual Alarms

Pre Assembled and Modular Light Towers Multifunction Light and Acoustic Options 36mm, 50mm & 70mm Ø, Round & Elliptical Super bright LED Technology LED Beacons - Rotating, Flashing & Steady Light Output Multi Tone Sounders IP65/66 Ingress Rating UL, UKCA & CE Approved

Celebrating 40 years in the supply & distribution of high quality Control & Automation Products.

t: 01785 818600 f: 01785 811900 e: sales@switchtec.com

www.switchtec.com

Lightning & Surge Protection Solutions SPD Ltd and our partners have been solving problems in Lightning & Surge Protection for over 50 years. Our devices are European designed and manufactured, state of the art products, which exceed the requirements of the latest standards. With over 3000 products in our range, we are the markets Surge Protection specialists, with a device to suit every installation.

We carry out many seminars with consultants and specialist training organisations as well as attending exhibitions and conferences both in the UK and overseas, where our knowledge is renowned. We also hold regular contractor training sessions online, some of which are live webinar sessions, where you can ask our Technical Director any questions, and some are ondemand, so can be accessed at a time to suit yourself.

If you have any questions at all please give us a call on 01484 851 747 or email info@surgedevices.co.uk.

www.surgedevices.co.uk

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PECM Issue 57

Follow us on:

Importer and specialist distributor of E-MECH products

4M ST ELECTRONICS AUTOMATION E-Stop Switches XW Series

XW Illuminated

HW Series

Smart Cable Management Split Cable Entry System

Brush Plates

Strain Relief Plates

IMAS Connect

Digital Design Tools

From Concept to CAD in minutes! Our 3D configurators feature an intui�ve graphical user interface, dynamic CAD genera�on and full integra�on into website without addi�onal so�ware installa�on.

Varistar Cabinet Configurator

T: +44 (0)1371 811 171 E: sales@4most.co.uk

www.4most.co.uk

Novastar Cabinet Configurator

Pla�num Distributor

ELECTRICAL & ELECTRONICS

A TRUE WARRANTY WILKINSON STAR

JASIC 5 Year Warranty Charter on all models There is no compromise on the quality of JASIC equipment..such is our confidence in this technology we can offer an unparalleled 5 year ‘true’ warranty on all models. Jasic’s manufacturing site is over 80,000m2 and is arguably the largest and most modern inverter manufacturing base in China.

team of technicians in our JASIC Technology Centre.

• We have the facility to test products extensively on load banks and can validate machines to certification requirements.

How do Wilkinson Star provide such an industry leading product guarantee?

EQUIPMENT QUALITY WE ARE SERIOUS ABOUT PRODUCT QUALITY. SOUND PERFORMANCE AND RELIABILITY IS WHAT YOU CAN EXPECT FROM JASIC PRODUCTS • The manufacturer has invested millions of dollars into cutting edge integrated test laboratories on site – JASIC undergoes 42 individual tests to meet high quality standard.

• If required, Wilkinson Star will arrange at its expense to collect and return your JASIC product to carry out service or repair in our workshops

• Jasic’s 4 centre strong R & D facilities has been ranked as the most progressive facility along with being the first welding laboratory awarded UA certification by China from TUV Rhineland.

BE VIGILANT WHEN PURCHASING EQUIPMENT WITH EXTENDED WARRANTY

UNPARALLELED AFTER SALES SUPPORT

JASIC’s warranty is a true 5 years; this means a problem at 6 months, 3 years or 4 years 11 months is treated with the same level of care.

NO OTHER DISTRIBUTOR CAN MATCH US ON THE LEVEL OF SERVICE FACILITY INVESTMENT MADE IN THE UK • Wilkinson have 50 years’ experience in servicing welding equipment. Our state of the art service workshop facility and our 16 strong after sales service team offer the most recognised technical support in the welding industry.

All equipment is fully supported by Wilkinson Star trained technicians.

• No other UK wholesaler can repair inverter boards to component level. At Wilkinson Star we have a dedicated

WITH JASIC 5 MEANS 5

CUSTOMER CONFIDENCE CARE IS OUR BYWORD AND YOUR PRODUCTIVITY IS OUR PRIORITY • We provide a dedicated technical support line which you can call for any technical support queries

No extensions. No additional costs…… just 60 rolling months of product peace of mind ALL YOU NEED TO DO IS REGISTER YOUR PURCHASE AT JASIC.CO.UK FOR 5 YEARS PEACE OF MIND – IT’S REALLY THAT SIMPLE

• If on site support is needed we provide this through our highly trained technicians who cover the country • We can also interchange power sources to keep you up and running

For further information, please visit www.jasic.co.uk

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PECM Issue 57

ELECTRICAL & ELECTRONICS Kraus & Naimer

E-stop stations twist or key release

D ANLERS

New Smart ISI range

38mm mushroom head IP40-IP66/67/69K enclosure range

View the Range

new website

with or without protective shroud

flush mounted option available

most products

Next-day delivery

For Kraus & Naimer full product range

visit: krausnaimer.com

T: 01635 26 26 26 E: sales-uk@krausnaimer.com Kraus & Naimer Ltd 115 London Rd Newbury Berkshire

♦ Ideal for energy-saving automatic lighting control ♦ PIR occupancy switches with built-in photocells ♦ Free-to-download DANLERS iOS and Android app ♦ Easy-to-use; quick set-up ♦ Versions for switching & for DALI & 0-10V dimming ♦ Programmable setback light levels and fade rates ♦ Upgradeable via over-the-air updates for extra features such as group control and asset tracking

DANLERS Lighting Controls T: +44 (0)1249 443377 E: sales@danlers.co.uk www.danlers.co.uk

your reliable solution partner...

+44 (0)1925 811 290 / sales@tempapano.co.uk / www.tempapano.com

Issue 57 PECM

53

FLUID HANDLING / GEARS, DRIVES & MOTORS

Rotaflow continue to find solutions for bespoke swivel joint needs on bulk carrier vessels Following the successful design, manufacture, and installation of previous tailored solutions Rotaflow were once more tasked with finding a workable solution for specific requirements…

With ongoing development of the fire suppression pipe system for sea going bulk carriers and in conjunction with Canada Steamship Lines Rotaflow has developed the next generation of arm.

The arm provides fire and dust suppression water to the conveyer belt boom. The boom which raises and rotates over the dock for unloading of aggregates, requires an articulated pipework to provide a water supply. The dust produced during unloading can create an explosive combustible atmosphere for which fire and dust suppression systems are required to mitigate risks.

Rotaflow is a global leader in swivel joint design and manufacture. We engage with clients all over the globe to produce swivel joints for a wide range of industrial uses, from drilling and mining, food and drink production, pharmaceutical, process and plant, to subsea oil and gas extraction.

If you have an engineering problem and would like to speak to the team at Rotaflow, you can reach us via the following options.

Tel: +44(0) 1663 735003 Email: sales@rotaflow.com

www.rotaflow.com

Cross+Morse Power Transmission Manufacturing Specialists ◊ ◊ ◊ ◊ ◊ ◊ ◊ ◊ ◊ ◊ ◊

Since 1984

Manufacturing up to 1450mm diameter Turning - CNC lathes, Vertical Machining Centre Gear Cutting - Hobbing, Planing, Shaping Gears Bevel Gears, Helical, External & Internal cut Gears Rack Shaping, Broaching, Keywaying Vertical Boring, Centreless & Rotary Grinding Bore Honing ◊ Induction Hardening ◊ Blacking Drilling & Tapping ◊ Marking Large stocks of Transmission Drive components CAD - CAM Design & Development ISO 9001 : 2015

Yes we can make it.

Cross + Morse. Shady Lane, Great Barr. Birmingham. B44 9EU sales@crossmorse.com Tel: +44 (0)121 360 0155 www.CrossMorse.com Issue 57 PECM

55

HEALTH & SAFETY

TANK PROTECTION REMBE

Breather valve for overpressure and vacuum safety In all industries in which sensitive process media are used, the highest demands are placed on maintaining the quality, shelf life and product purity of the processed liquid or solid substances. This is often the case in the food industry and in the chemical and pharmaceutical sectors.

The ELEVENT breather valve from REMBE protects vessels with low design pressures against overpressure and vacuum in a pressure range of 2–200 mbarg. This makes it the optimum solution for lowpressure vessels inside storage tanks, dryers and other vessels in the chemical, pharmaceutical and food industries.

For example, ELEVENT is ideal for use in dryers in which free-flowing process media, such as cocoa, raw tablet materials or teas, are processed under vacuum. If the vacuum pressure inside the vessel begins to drop, the valve opens and thus ensures targeted pressure equalisation, which is of immense importance both for the stability of the dryer as well as the quality of the sensitive substances inside. Controlled maintenance of the pressure level is achieved via a very low leakage rate of up to 1x10-6 mbar x l/sec. This prevents both emissions of volatile gases or other environmentally harmful substances, as well as the formation of explosive mixtures or a potentially dangerous ingress of air.

The ELEVENT’s modular design makes it possible to manufacture the individual parts of the breather valve from different materials, such as stainless steel or Hastelloy, and to use special coatings, such as Halal, to meet the challenges of the respective processes. The use of housing clips not only allows the individual components and gaskets to be selected in accordance with the relevant process conditions, such as extreme temperatures, pressures and process media – but also ensures they can be replaced without a problem. Maintenance and cleaning work can also be carried out quickly and easily.

For substances that require high product purity, oxidation is one of the greatest dangers. If oxygen or gases from the

ELEVENT breather valve

atmosphere penetrate inside the vessel, there is a risk of significant economic damage for the company concerned.

To prevent this, the -KLI version of the ELEVENT features an inerting connection that introduces the required amount of nitrogen to prevent subsequent reactions with the medium.

All in all, REMBE’s ELEVENT represents a safe solution for plants in a wide variety of fields. Indeed, numerous market-leading plant manufacturers worldwide have already chosen to rely on the high quality and efficiency of the ELEVENT breather valve.

The ELEVENT breather valve from REMBE protects vessels with low design pressures against overpressure and vacuum in a pressure range of 2–200 mbarg.

For further information, please visit www.rembe.de

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PECM Issue 57

T +49 2961 7405-0 hello@rembe.de

Made in Germany

Your Specialist for

PRESSURE RELIEF and

EXPLOSION SAFETY

© REMBE® | All rights reserved

Consulting. Engineering. Products. Service.

Gallbergweg 21 | 59929 Brilon, Germany F +49 2961 50714 | www.rembe.de

HEALTH & SAFETY

MEWA helps companies improve health, safety and compliance Leaks and spills onto floors and surfaces are a common occurrence in industrial workplaces, which can increase the risk of slips plus exposure to hazardous liquids such as solvents and degreasers.

MEWA’s reusable, rentable cleaning wipe service helps companies ensure spills are mopped up quickly and efficiently by always having exceptionally absorbent cloths to hand.

Used cloths are then stored in MEWA’s SaCon safety container until collected and replaced with clean ones, giving companies peace of mind that soiled and contaminated wipes are stored safely in a fire-resisting closed container and are compliant with hazardous waste regulations and will be cleaned safely in line with legal requirements.

Advanced technology With over 20 years’ experience in preventing workplace health and safety issues, Reactec introduce R-Link, our latest workplace wearable with expanded functionality.

With the R-Link watch, fully integrated ecosystem, and the powerful Reactec Analytics, you have an unprecedented view of your employees’ environment to deliver effective risk prevention and open new avenues to improve operational efficiency: • Keep workers safe from proximity to dangerous equipment or vehicles • Gain real insight of exposure to vibration and readily show compliance • Create exclusion zones, based on workers’ credentials, to restrict access • Send alerts and track lone workers • Track employee movements and activity levels The R-link eco-system and cloud-based analytics are easy to deploy, and simple to use.

www.mewa.co.uk

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PECM Issue 57

Info@reactec.com | www.reactec.com

50 Year old product makes dramatic comeback to help beat the virus!

The current necessity for virus protection is why the Melaphone® Speech Unit is enjoying renewed success. Its unique design eliminates the muffled sound of speech through a screen.

Completely air-sealed, certified to ISO 14644-1 Class 5. Class 5, it is specified by architects and designers for hospitals, laboratories and cleanrooms. This simple but ingenious invention requires no servicing, no electricity and is very easy to keep clean.

The Melaphone® is built into our Defender Virus Screens which the company has supplied to hundreds of UK doctors’ surgeries, medical centres, and pharmacies.

Screens are made to the highest quality, providing hygienic, sleek and permanent protection in any environment.

All ‘MADE IN THE UK’ - by us in London and used in the Astra-Zeneca factory as seen on BBC. www.melaphone.co.uk

Your One Stop Fluid Power Source NEW

2022-23

CATALOGUE

36,000 Fluid Power Products Vast Stocks - Next Day Delivery Pneumatic & Hydraulic Hose Assembly & On-site Testing 24 Hour Bespoke Pneumatic Cylinder Build An Expert Fluid Power Focused Friendly Team

CELEBRATING

Challenge our expert team to source the right

fluid power products for you; no matter what your application, design or

REQUEST YOUR COPY

email: catalogue@tom-parker.co.uk

project needs are.

&

01772 255109

sales@tom-parker.co.uk

tom-parker.co.uk

MACHINING & MACHINERY

SPECIALISTS IN TOOLS & GAUGES WISEMAN THREADING TOOLS LTD

WISEMAN THREADING TOOLS LTD Specialists in Tools & Gauges for Screw Threads We have been supplying threading tools and gauges since 1987.

Together with supplying plain plug and ring gauges this is all that we do, we therefore consider ourselves to be specialists in this field.

We supply worldwide.

We hold extensive ready stocks that include all of the standard stuff that others offer, but also includes taps, dies, die nuts, die head chasers, thread rolls and gauging for threads not normally available 'off the shelf '.

Our real time stocks can be checked and purchased online at www.threadtools. com Just enter the thread details into the search box on the home page.

You will be directed to the item, if stocked, or to our specials, (custom manufacture), sales team. who will quote to supply at competitive rates, in good time.

As an account holder you can also order online from our listed in stock items, at your normal terms. We realise that you need the right item at the right price and quality, and in a reasonable time frame.

We are geared to provide that.

We can ship stocked items same day.

Our experienced sales staff can assist and advise you on any technical issues.

We welcome enquiries from resellers and can offer terms to suit.

WISEMAN THREADING TOOLS LTD 11 Padgets Lane South Moons Moat Redditch B98 0RA UK +44(0)1527 520 580 sales@threadtools.com www.threadtools.com

For further information, please visit www.threadtools.com

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PECM Issue 57

Threading Tool Specialists

HSS DIES & DIE NUTS Large shelf stocks for all Standard and many Special Threads. Check our stocks online.

THREAD CUTTING AND ROLLING HEADS and parts and repair service

THREAD ROLLS FOR ALCO & FETTE HEADS. READY STOCKS CUSTOM MANUFACTURURE

HSS TAPS Huge Stocks for all Standard threads CUSTOM MADE taps our SPECIALITY! We stock taps for many non standard (SPECIAL) threads All types; Spiral flute and point, Fluteless, Left Hand, etc, etc.

Wiseman Threading Tools Ltd 11 Padgets Lane, South Moons Moat. Redditch B98 0RA Worcs UK +44(0)1527 520 580 sales@threadtools.com www.threadtools.com

THREAD GAUGES all types. Large stocks for standard and SPECIAL threads. Any non stocked can be quoted for custom manufacture.

CHASERS FOR COVENTRY & LANDIS TYPE DIE HEADS Ready stocks for most size heads most standard and some special threads Geometry available for most materials.

Custom manufacture our speciality!

MACHINING & MACHINERY

THE RIGHT CHAIN SOLUTION DONGHUA

To help customers select the right chain solution, Donghua Limited has developed a simple tool - the Donghua Chain Selection Chart Donghua Limited is the UK arm of one of the world’s largest chain manufacturers who produce over 40 million metres of finished chain per year which is supplied world-wide. Our UK operation is based in Wolverhampton, West Midlands where our sales office, 25,000 sq ft warehouse, technical laboratory and chain workshop are located.

Our Chain Selection Chart is a reference guide specifically created for our growing network of Approved Product Partners and Stockists. It provides a visual 1-5 star rating highlighting Donghua Chain recommendations for: • wear resistance • fatigue resistance • high speed • strength • shock load • high strength/high shock • corrosion resistance • self-lubricating • easy break • FDA approved • damp/wet environment • general purpose • high temperature

To download your copy of the Chain Selection Chart visit: www.donghua.co.uk/roller-chain or for a laminated hard copy call 01902 866 200.

The Chain Selection Chart includes our new EXL and X3 Roller Chain.

EXL CHAIN EXL Chain offers significant benefits over standard Roller Chain. It utilises different materials, material treatments and layer technologies, to offer the best possible quality/price ratio for all applications.

Aimed specifically for the after-market, EXL Chain is designed, manufactured and tested for unbeatable accuracy and performance in arduous conditions, offering enhanced wear and fatigue resistance and greater precision.

The chain is designed with a new hardened, shot-peened wide-waist plate for increased fatigue strength and a seamless cold forged solid bush and roller to give full contact between the pin, bushing and roller for higher durability.

It’s a must-have reference document in an engineer’s toolkit.

The EXL Chain has optimised cylindrical parts which improve sliding contacts to help increase service life. It also incorporates Donghua’s unique ‘Easy Break Technology’

Chain Problems?

We’ve got the solution.

which enables the Chain to be cut in the field using Donghua’s Plate Extractor tools.

Watch our video showing how to cut the EXL Chain using our Plate Extractor tools: https://youtu.be/UD6rtBEJrkM

X3 CHAIN X3 Chain, which was launched earlier this year, is manufactured on its own purposebuilt production line which encompasses new production techniques and new surface treatments.

Designed with a unique pin coating, optimised plate geometry and high precision stamping, X3 offers a new deluxe chain solution and is designed for sectors that use high demand drives such as Timber, Waste & Recycling and Mining & Quarrying.

The new X3 Chain delivers three times the performance for wear resistance, fatigue resistance and high speed performance for comparable Roller Chain. Its superior quality, durability and outstanding wear and fatigue resistance are realised by the new hardened, shot-blasted plate shape, calibrated pin and bushing holes, special heat-treated and surface coated pins, seamless rollers and bushings and high performance pre-lubrication.

Our X3 Chain is supplied pre-loaded and pre-lubricated as standard and is available in British Standard 06B to 24B in simplex and duplex, ex-stock.

Download the Chain Selection Chart here:

donghua.co.uk/roller-chain Or call us to request your printed copy:

01902 866200 To download our X3 catalogue visit: https://www.donghua.co.uk/X3-chain

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PECM Issue 57

66

11

22

A PREMIUM CHAIN SOLUTION FOR HIGH DEMAND DRIVES

33 44 55

1 1

Optimised Optimised plate plate shape shape

2 2

Calibrated Calibrated pin pin and and bushing bushing holes holes

3 3

High High press press fit fit to to guarantee guarantee maximum maximum fatigue fatigue strength strength

4 4

Special Special heat heat treatment treatment and and surface-coated surface-coated pins pins give give exceptional exceptional wear wear life life

5 5

Seamless Seamless bushings bushings & & rollers rollers throughout throughout

6 6

High High performance performance pre-lubrication pre-lubrication

A new Chain for the UK market offering a premium solution with three times the performance for wear resistance, fatigue resistance and high speed performance of comparable Roller Chain.

Designed with unique pin coating, optimised plate geometry and high precision stamping, the X³ Roller Chain delivers significantly reduced maintenance downtime and longer service life.

Available from Approved Product Partners and Stockists.

Tel: 01902 866200

DOWNLOAD THE NEW X³ CATALOGUE

donghua.co.uk/X3-chain

Donghua Donghua Limited Limited Sidings Sidings Close Close Wednesfield Wednesfield Way Way Wolverhampton Wolverhampton West West Midlands Midlands WV11 WV11 3DR 3DR

Tube Tube

MEASUREMENT & MONITORING

Visilume’s range of Sight Glasses Visilume present our tried and tested range of sight glass assemblies and spares, suitable for a wide variety of process applications.

Available in a range of materials, our sight glass and process vison solutions will be sure to cater for your needs.

Typically used to visually verify stages of a process, inspect process media, and to observe liquid levels.

sales@visilume.com | +44 (0) 1457 865700 www.visilume.com

Accurate Temperature Measurement Inside Industrial Furnaces Infrared Camera System for Continuous Reformer Tube Monitoring and Temperature Measurement Inside Furnaces Advanced Energy’s FurnaceSpection™ system provides real-time continuous temperature measurement inside hightemperature furnaces in refining, metals, and glass production processes. By utilizing this accurate system, users are equipped to identify process abnormalities before they develop into problems that can lead to unplanned outages.

FurnaceSpection measures the temperature of product, refractory, and heat transfer surfaces inside natural gas-fired furnaces. It also enables the monitoring of flame condition, helping users reduce the production of NOX, which results in less environmental impact and longer furnace lifetime.

The system consists of an accurate 640 x 480 focal-plane array thermal imaging camera with high-quality optics and builtin flame filter, which reduces the influence of furnace chamber flame, as well as CO2.

FurnaceSpection is covered by a highly efficient housing, enabling air or optional water cooling to resist high ambient temperatures.

With the FurnaceSpection system, multiple measuring points on the furnace ceiling, end wall, and side wall can be independently monitored by adding measuring regions of interest.

The system helps operators monitor and control process temperature uniformity by streaming images documented by a powerful software for analysis and historical trends. In

www.advancedenergy.com | info@aei.com

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PECM Issue 57

FurnaceSpection measures the temperature of product, refractory, and heat transfer surfaces inside natural gas-fired furnaces.

addition, outputs to automation and DCS and a real-time web server broadcast these images on the plant’s local network.

At a cost of several thousand dollars per furnace and re-tubing costs in the millions, the system is designed to save a significant amount of capital by preventing complete furnace failure, as well as maximizing the lifetime of the refractory linings.

Tel: 0191 410 5886 Units 11 & 13 First Avenue, Drum Industrial Estate, Birtley, Co Durham DH2 1AG

MACHINERY Your quality used ENGINEERING, SHEET METAL FABRICATION & WOODWORKING machine supplier; established in 1984 our experience and expertise in high quality machinery is second to none

We Know Our Machines!

Arboga Maskiner ER825 24” Radial Arm Drill. £2,950

Startrite Vertical Bandsaw 14-S-5. £2,350

J & S 540P Surface Grinder with Diaform Attachment. £6,950

XYZ 1500 Vari-Speed Turret MIll. £5,950

Needs Analysis: We Only Offer The Right Machine Colchester & Harrison Lathes Ready Now

Colchester Mascot 1600 Gap Bed Centre Lathe. POA

Colchester Triumph 50” & 30” available

Harrison M300 25” Centre Lathe. £5,750

Rigorous Multi Point Pre‐Despatch Inspection

Edwards Truecut DD Power Shear 1,250 x 2.5mm. £5,350

Edwards Pearson VE Power Shear 3m x 6.5mm. £14,750

Edwards 1270 x 1.6mm Treadle Shear. £1,795

WANTED! YOUR SURPLUS MACHINERY

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Morgan Rushworth Hand Operated Box Pan Folder 1250 x 16g. £1,875

Kingsland 55XS 55-ton 2 Operator Hydraulic Steelworker. £7,750

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CONTACT US NOW! 0191 410 5886 Web: www.rondean.co.uk Email: info@rondean.co.uk

*Prices *Prices do do not not include include VAT VAT or or delivery delivery

MACHINING & MACHINERY

AN ESTEEMED REPUTATION TOM PARKER

Leading Independent Fluid Power Distributor Celebrate 50th Anniversary The entire team at Tom Parker Ltd, including the Preston Northwest HQ, those based in the Basingstoke branch and the network of Area Sales Managers covering the UK, are immensely proud to be celebrating their 50th anniversary.

Tom Parker Ltd have worked hard over the last five decades to build a thriving business that now has 80+ employees and to earn their esteemed reputation in the industry of being one of the leading fluid power distribution companies in the UK, whilst remaining an independent family business.

Whilst there have been many changes throughout the company’s history many of their core values remain the same.

Their focus remains firmly on supplying high quality connection solutions, whilst prioritising their customers’ needs and providing high levels of technical advice and support.

CONNECTION SPECIALISTS Mr Tom Parker first established the business back in 1972, distributing Swedish connection specialist Cejn’s innovative quick connect couplings to the UK pneumatic and hydraulic market.

The company went from strength to strength, soon acquiring the UK distribution rights for products from American connection specialists CPC – Colder Products Company; both of whom the company are proud to work closely with to this day alongside a portfolio of other leading brands.

In 1999 Tom Parker Ltd started to produce product catalogues aimed at distribution, OEM and end users: building up a comprehensive resale network of companies who distribute fluid power products alongside their own ranges and specialist services throughout the UK.

A ONE STOP FLUID POWER SHOP Tom Parker Ltd consider their expert technical knowledge, high quality products,

pneumatics, hydraulics, industrial and process markets.

Our people, as well as our on-site vast stock levels and a passion for putting our customers’ needs first are the main reasons behind our ongoing success. after sales service and close working relationships with suppliers and customers to be their major ongoing strengths.

Their recently launched 2-year product catalogue contains 36,000 product lines with more than 80 brands spanning the

Services also provided from their on-site facility is a BFPA certified and approved hydraulic and pneumatic hose assembly, in-house pressure testing, and a 24-hour bespoke pneumatic cylinder build service.

UK Sales Manager and BFPDA Board Member, Seb Cole comments: “We have built up a strong team here at Tom Parker Ltd with a wealth of experience.

Our people, as well as our on-site vast stock levels and a passion for putting our customers’ needs first are the main reasons behind our ongoing success. …We pride ourselves on our ability to source complete turnkey product solutions to the most challenging of fluid power projects. We particularly relish a challenge so why not put us to the test?

For further information, please visit www.tom-parker.co.uk

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PECM Issue 57

MACHINING & MACHINERY

DRILL SERVICE (HORLEY) LTD WWW.DRILL-SERVICE.CO.UK

Hand Tools

CNC deburring and polishing

P09 XEBEC BrushTM Surface End Type

P07 XEBEC BrushTM Surface

P10 XEBEC BrushTM Wheel Type

Cutter mark removal and flat surface polishing.

Deburring after face-milling, end-milling and drilling. Cutter mark removal and surface polishing.

Deburring after end-milling, threading, and drilling. Polishing side surface and inner diameter.

P18 XEBEC StoneTM Flexible Shaft

P11 XEBEC BrushTM Crosshole

P15 XEBEC Back Burr Cutter and PathTM

Hole deburring.

Deburring after drilling. Cutter mark removal and inner diameter polishing.

Deburring after drilling.

FOR YOUR DEBURRING AND SURFACE FINISHING SOLUTION Xebec deburring tools give an unrivalled performance versus traditional abrasive products, resulting in increased productivity, improved quality and reduced costs.

The UK’s most comprehensive stockist of these innovative tools.

TEL: 01293 774911 EMAIL: SALES@DRILL-SERVICE.CO.UK Same day dispatch for all stock orders received before 3.45pm

Advanced Engineering Products and Services for the Manufacturing Industry Experts in Press Protection, Quality Assurance and Productivity • Load Monitoring and Automation Systems for manufacturing equipment • Process monitoring and control for assembly machines • Manufacturing Execution Systems including downtime analysis • Production recording systems • Bespoke control systems

Measuring Immunoglobulin without Sample Degradation ODIN is a new, compact, and reliable deep UV resonant Raman instrument developed

by IS-Instruments (IS-I) and TOPTICA for measurement of biopharma products.

ODIN is a new, compact, and reliable deep UV resonant Raman instrument developed by IS-Instruments (ISI) and TOPTICA for measurement of biopharma products. TOPTICA’s Industrial CW Laser TopWave 229 enables new Deep UV Raman Spectrometer ODIN.

The system combines the newly developed solid state diode laser TopWave 229 and a spatial heterodyne spectrometer integrated into a single instrument with a unique all-reflective backscatter Raman collection probe. Sample damage caused by extended laser exposure has been mitigated via the introductiwww. toptica.comon of a dynamic sample positioning stage.

www.toptica.com

• Calibration services • Repair/Maintenance

Decade Monitoring Solutions Ltd Unit 3, Octagon Business Centre, Miller St, Birmingham, B6 4NH Telephone: +44(0)121 359 3978 E-mail: sales@decade.co.uk www.decade.co.uk

Issue 57 PECM

67

PROCESS TECHNOLOGIES

New SEPURA™ app makes product selection even easier Global filtration specialist Bowman Stor, has announced the launch of a new SEPURA Technologies app for its extensive oil/water separator range.

With a growing number of customers wanting genuine SEPURA™-branded units, the UKbased company has developed a unique mobile application. The new app allows users to access a handy OEM Comparison Tool to find the most suitable product for their needs - all by simply searching for their current manufacturer.

Available on both Android and Apple platforms, the application also includes an easy-to-use oil/water calculator which helps establish the right size of filtration unit for the customer’s compressor system.

Bowman Stor’s Managing Director, Richard Potts said: “The free SEPURA™ app makes life even easier for distributors, resellers and endusers in every industry. We believe this is the first app of its kind in the filtration industry and users can now source the best separator products for their needs from any location.”

Only genuine SEPURA-branded products contain the groundbreaking SILEXA™ media - a revolutionary patented media developed through years of research in Bowman Stor’s

own laboratories. The SILEXA material has major environmental benefits, achieving outlet quality discharges as low as 5ppm.

With SEPURA’s comprehensive range of oil/ water separator units and third party service kits covering low, medium and high capacity requirements for multiple industries, the app is the perfect way to find the ideal product for each specific use and send enquiries direct to the distributor.

To download the app Go to your App Store and search “Sepura Technologies”.

To place an order or for further information on SEPURA’s unique range of filtration products contact: Multi Factor Europe Ltd., t: 01978 855995 e: sales@mfeuk.co.uk or visit our website.

Sepura App Advert 132x180L.qxp 15/03/2022 14:25 www.sepura-technologies.com Page 1

scan the code to go to the download page

Make life easier

Get the free App We have developed a mobile App that will make it easy to identify the right SEPURA™ product to fit your current oil/water filtration system.

Not only that, we have also built in a calculator so you will know straight away which product from our comprehensive range is the correct one for you.

Our unique SILEXA™ filtration media is made from recycled materials and is more effective than any other filtration media currently available. Many users are now switching to our products over their existing OEM suppliers to meet their environmental commitments.

SEPURA™ is part of the Bowman Group

www.sepura-technologies.com 68

PECM Issue 57

t: e:

+44 (0)1543 379212 sales@sepura-technologies.com

PUMPS

PUMPING LIQUID CO2 SULZER

Innovative solutions to reduce carbon emissions Every industry is being encouraged to reduce the amount of greenhouse gases to help meet global targets. One measure that the oil and gas sector is supporting is carbon capture and storage (CCS), which uses depleted oil fields to store liquid CO2.

The oil and gas industry is using innovative solutions to reduce its carbon emissions and this is exemplified by the initiative undertaken by Qatar Petroleum (QP).

Certain new facilities being built as part of the project by Qatargas Operating Company (Qatargas) will support QP’s Enhanced Oil Recovery (EOR) initiative.

Dense phase or supercritical CO2, held at sufficient temperature and pressure to keep it in the liquid phase, also has some advantages over water when it is used to purge oil and gas from a well. In a supercritical state, the CO2 can be pumped like a liquid but has the effusiveness of a gas. This means that as it sweeps through the reservoir to push the oil to the riser, it is more effective than water, making for a more efficient process.

TAKING THE NEXT STEP In Qatar, there is a major program of investment in the capture and sequestration of CO2, some of which will be used for enhanced oil recovery (EOR). As part of a project, Sulzer has been involved in the design and supply of suitable pump for pumping dense phase CO2. To this point, similar projects have mainly used either reciprocating or rotary compressors, but more recently a growing number of pumps are being considered. An initial feasibility study was conducted by Qatargas project team and based on further discussion with pump manufacturers, Sulzer’s design of the pump was selected as the best solution in this application.

Designing a pump for such a project, requires considerable experience as well as expertise and Sulzer has been involved in this specialist area for almost 40 years.

Based on its experience and excellent working relationship in Qatar, Sulzer was

Designing a pump for such a project, requires considerable experience as well as expertise and Sulzer has been involved in this specialist area for almost 40 years.

managed well. A detailed rotor-dynamic assessment and clearance review was conducted based on Sulzer’s time-served methodologies; along with a thorough investigation into the material selections, both metallic and elastomeric components along with the casing tightness calculations to ensure leak free operation under all extreme operating conditions.

awarded the contract to supply an API 610 type BB5, multi-stage, opposed impeller pump with a design pressure in excess of 200 barg, driven by high voltage electric motor and associated variable frequency drive.

Martin Uere - Head Global Technology for Sulzer Pumps explains: “High suction pressures and lightness of CO2 have a significant effect on the design of the pump and this is one of the reasons why other manufacturers have steered clear of this application in the past. Sulzer, on the other hand, has spent nearly four decades fine-tuning designs and providing increased efficiency. As a result, the operator of this project in Qatar decided that Sulzer was well-placed to support the project, from feasibility through to installation and commissioning.”

Along with the relatively high suction pressures, the lightness and effusiveness of the supercritical CO2 needed to be

You can watch a short video on how we are contributing to reducing emissions in the fossil fuel industry here!

For further information, please visit www.sulzer.com Issue 57 PECM

69

PUMPS

FLOW OPTIMIZATION SECOND TO NONE

THE NEW BLUELINE NOVA ROTARY LOBE PUMP The BLUEline Nova sets new standards in pump technology.

With or completely without casing protection – the BLUEline Nova achieves unrivaled volumetric efficiencies.

Made for one another – the newly developed DIUS rotors in combination with the flow-optimized pump chamber ensure perfectly smooth running at pressures of up to 12 bar.

EXCELLENCE – MADE TO LAST

BLUEline

NOVA www.newblueline.com

Börger UK Limited • East Wing • Watling St. Gailey • Staffordshire • +44 1902 798977 • uk@boerger.com • www.boerger.com

SEEPEX Big Pumps with Maintain-in-Place Technology: Smart Maintenance. Fast and Simple.

220318 ANZ UK NOVA 180 x132 mm_RZ.indd 1

18.03.2022 08:02:17

SEEPEX, global leader in design, manufacture and applications of progressive cavity (PC) pumps, macerators and digital technology, continues to extend its world class portfolio of maintain-in-place pump technologies.

The new patented BNM range of pumps with capacities up to 300 m3/hr and discharge pressures up to 48 bar can handle flowable to highly viscous products with a high dry solids content. The design features a suction casing that enables quick and easy access for rotor and stator removal without having to dismantle the rotor side joint. As a result, maintenance time can be reduced by up to 80% with a significant reduction in maintenance costs.

The suction casing and pressure branch remain in place, eliminating the need for pipework dismantling. The pump drive can then be quickly removed complete with mechanical seal, drive side universal joint and coupling rod.

UNIQUE PATENTED SOLUTION SEEPEX new ease of maintenance solution for big pumps complements our Smart Conveying Technology (SCT), launched in 2008 and still setting standards in the maintenance of

Above, SEEPEX Rotor Joint Access technology provides quick and easy access to the rotor-side joint. Below, With SEEPEX Drive Joint Access, the complete drive and coupling rod assembly can be easily removed from the back of the suction casing to service the mechanical seal or joints. smaller standard progressive cavity pumps, and Drive Joint Access (DJA) technology for open hopper pumps. All of these patented solutions increase uptime and plant availability.

www.seepex.com

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PECM Issue 57

SOFTWARE & SYSTEMS

DIN11864 and DIN 11853 Aseptic Unions for Orbital Welding DIN11864 and 11853 unions were developed to meet the exacting needs of the food, chemical and pharmaceutical industries.

This range of unions has been developed from the three most common systems used in the hygienic and sanitary industries; namely the “Aseptic” screwed union to DIN11864-1; the “Aseptic” flange union to DIN11864-2 and the “Aseptic” clamp union to DIN11864-3.

Available with optional lengths to suit both orbital and manual welding, these unions have been designed to match tube and pipe specifications to DIN11866 Table A (DIN11850); DIN11866 Table B (ISO 1127) & DIN11866 Table C (ASME BPE).

Size range: 10mm to 150mm and 1” to 4” Specials are available up to 304mm Materials: 316L SS 1.4404 and 1.4435 Specials available in Duplex and Alloy 22

www.alchemprocess.co.uk | 01269 843800

Issue 57 PECM

71

At its core Sapman v12 is a sophisticated Manufacturing, Warehousing and Stock Control solution. This modular product provides extensive facilities for Stock Control, Sales and Purchase Order Processing, Warehouse Management, Bill of Materials, Works Order Processing, Engineering Control, MRP and CRP. With the Microsoft SQL database engine at its core this product provides a leading edge business management solution.

Our highly skilled team has 20 years of experience resolving our customers’ Assembly, Manufacturing Control and ERP requirements, their Stock Control and Warehouse Management needs using our advanced, effective and efficient software solution.

Sapman v12 fully integrates with Sage’s Accounting solutions: Sage 50 and Sage 200. It also provides an upgrade path from Sage 100.

disposable BBQs our customers rely on Sapman v12 to run their businesses.

Sapman v12 is highly customisable to operate with virtually any business model. With successful installations in a huge range of industry types from manufacturers of medical products to

Sponsored development of specific functionality is possible where customers require some modification to allow the software to exactly map their business’s operational model.

SAPMAN V12 AND SAGE 50 IT ALL STARTS WITH A SALES ENQUIRY! SELL IT

BOM V12 produces the BoM : tree-view with collapsible/expandable nodes

Quotations: Quote ( including price breaks)& Drawings & Pricing : v12 can attach drawings to the Quote

SFDC Shop Floor Data Capture : using barcodes v12 manages the job though the shop floor

SoP : The Sales Order Processing gets underway

WiP With Shop Floor Data Capture SFDC v12 knows :

MAKE IT

What Material/Subcomponents have been used, Who has worked on the job and on what machine - Get Material, Labour & Machine Variances & produce management reports -

Stock : Stock Enquiry : Check material Needs : Make to Order or Ex Stock?

If not it may generate a Purchase Order for more Stock

Every stock issue is linked to an original GRN - ensuring full Serial Number and Batch Traceability

If the Sale item is Make To Order (MTO) then the Works Order Processing routine kicks in

Stock Finished item is booked into Stock

v12 is suitable for Batch Manufacturing, Make to Stock, make to Order, Kanban & service works

v12 knows where it is; it covers multiple sock locations and stock with Sub Contractors

Stock values from v12 update Sage50 Nominal Ledger

Stock values per client defined categories can be up dated to Sage50 Nominal at client defined times

PoP Purchase Order Raised Purchase Invoice received & Sage 50 updated for Nominal Codes, Purchase Ledger and VAT WoP The confirmed order has to be manufactured & v12 produces the works order

SEND IT Stock Stock records updated, Despatch note raised; Certificates of conformity produced

Sales Invoice raised & Sage 50 updated for

WHAT THEY SAY “We really like the Shop Floor Data Capture system which enables us to see the current status of any Works Order live and onscreen.”

Alan Saitch, Managing Director, Lada Engineering Services Ltd

“V12 offers us greater productivity, improved communications with third parties and the interconnectivity between the various menus and our Sage Accounting software makes operating our company infinitely easier.”

Colin Mallard, Finance Director, Lakeland Laboratories Limited

“V12 was a complete transformation for our business back in 2014, with the added bespoke service and repair package designed by the SMS team the customer input and traceability became seamless.”

Mike Perkins, Managing Director, Encoders UK Ltd

Nominal Codes, Sales Ledger & VAT

For more information on Sapman v12 please visit our website at Sapmanv12.co.uk.

Email us on info@sapmanv12.co.uk or please telephone us on: 0333 456 12 12.

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PECM Issue 57

SOFTWARE & SYSTEMS

COMPREHENSIVE ERP SYSTEM SAPMAN V12

If you make stuff we’ll help you make it If you have a warehouse we’ll help you manage it If you hold stock we’ll help you control it Buying an ERP system used to be a major capital expense, potentially running to tens of thousands of pounds for an up and running system. The cost of the software purchase and associated consultancy made it a hugely considered financial outlay.

For manufacturers looking for a rapid Return On Investment – this was a major obstacle for many businesses : together with the desire to spend their CapEx budgets on modern machinery and increased manufacturing capacity rather than software!

For companies that want the software “out of the tin” - and do not require any bespoke programming – a system install and set-up, including training and data conversion would be around £2,950.

Our licencing is £95-£20 per month (depending on user numbers) with no minimum contract obligation. Additional users can be added as required and, indeed, reduced.

and Sage200, and we still have some clients on Sage Line 100 yet to upgrade.

A key market for us is Sage users.

Sapphire Manufacturing Systems Ltd. The developer of Sapman v12 has been an Authorised Sage Developer for over 20 years. So most of our users run on Sage50

We can demo the software remotely via Team Viewer or organise a visit to your premises or you can visit our Bristol Demo Suite: call us on 0333 456 12 12 to have a chat.

One of the great advantages of Sapman v12 for Sage users is that users can benefit from multi depot stock and full Serial Number and Batch Traceability without the need to upgrade their accounting engine from Sage50 to Sage200. This is an additional cost saving benefit

STOP PRESS Problem Sage announce both Sage50 Manufacturing and Sage200 Manufacturing are End Of Life Solution Sapmanv12 More Features – Less Cost – Sage Developer Fully Supported – Continuous Development Sapmanv12.co.uk PLEASE CONTACT US FOR A DEMO - ON SITE OR REMOTE VIA TEAMS ETC. OR VISIT US A SOUTHERN MANUFACTURING SHOW, FARNBOROUGH: 7 - 9 FEB, 2023 Issue 57 PECM

73

SWITCHES & SENSORS

THE SENZTX PROCESS SENSING TECHNOLOGIES

Compact O2 transmitter for reliable measurement of oxygen concentration Engineers are constantly looking for new and innovative ways to improve the efficiency of their processes. In many cases, this involves finding a product that can be easily integrated and provides flexibility.

When it comes to oxygen transmitters, the SenzTx from Process Sensing Technologies (PST) is designed to meet the challenges of demanding industrial applications. Simple to install and easy to maintain, the SenzTx Oxygen Transmitter is suitable for direct insertion or remote installations and can be used in numerous applications including oxygen and nitrogen gas generation, glove box purge and leak detection, industrial gas purity applications, and measurement solutions for medical gases. The SenzTx utilizes proven sensor technology to provide accurate oxygen concentration measurement. With a choice of zirconia or electrochemical sensor technology, the SenzTx offers reliability, accuracy, and flexibility with a broad measurement capability with transmitters covering the ranges of measurement from 0...10ppm up to 100% oxygen.

Zirconia sensor technology The zirconia oxygen sensor is a non-depleting zirconia solid electrolyte sensor. It offers fast response time from ambient oxygen levels with virtually no drift, has long calibration intervals, and an expected operational life of three to five years with very little user intervention. While not able to perform measurements in a hard vacuum or a pressurized gas environment, the construction of the zirconia sensor will not be damaged if exposed to these conditions. The zirconia sensor also has low cross-sensitivity to other gases and is not position or orientation sensitive. This rugged measurement technology enables a wide range of measurement applications in many industries.

Electrochemical sensor technology The electrochemical sensor performs measurements at ambient temperatures enabling oxygen measurements in combustible gases such as Hydrogen or a process gas containing hydrocarbons.

SenzTx Electrochemical Flow Through Sensor

SenzTx Zirconia Sensor with KF40 Flange Configuration

The low power requirement of the electrochemical sensor enables low power and loop-powered instrumentation to be used making for easier integration in to control systems. In the absence of oxygen there is no output from the electrochemical sensor, meaning only one calibration is required. Ease of integration and low maintenance The choice of KF-40 flange or flow through block for the process connection enables easy mechanical integration either at the point

of measurement. The flow through block can also be specified with an orifice in the inlet port to ensure the correct pressure and flow over the sensor. The SenzTx is a self-contained calibrated transmitter.

The transmitter offers a choice of analog and digital outputs through a single electrical connector and no additional signal processing is required to achieve an accurate measurement. The compact size of the transmitter further enhances the ease of integration and installation.

For more information, visit www.ProcessSensing.com/SenzTx

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PECM Issue 57

SOFTWARE & SYSTEMS

DIGITAL TRANSFORMATION RIPLEY SOLUTIONS

The benefits of making incremental changes in IT infrastructure According to a global study from infrastructure monitoring company LogicMonitor, many IT departments had to act quickly to transition to remote working at the start of the pandemic. In the study, 70 per cent of IT professionals said they found it challenging to adapt, support a remote workforce and keep data secure.

Transitioning to remote working is just one of the reasons that some businesses should review their IT infrastructure. Here Paul Holding, solutions architect at IT integration provider Ripley Solutions explains why and how businesses can effectively upgrade their IT infrastructure.

Most businesses require some form of IT infrastructure to operate. However, because it is not always visible, IT often operates in the background unnoticed — much like the plumbing in your house. Sometimes we only decide to learn how the plumbing works when it’s too late, so we must act quickly to fix it and the same could be said for IT. When the pandemic began and we were instructed to work from home, businesses were under pressure to quickly deliver IT solutions that enabled people to access what they need remotely. Just like we often assume our plumbing will always work, some smaller enterprises rarely reviewed IT infrastructure and its performance before lockdown. However, as businesses consider their COVID exit strategy and implement long term IT solutions to continue remote working, it is clear we must pay more attention to our infrastructure.

WHY CHANGE? It’s important that IT infrastructure always meets the needs of the business — if it doesn’t suit employees, or costs too much in money or time, it might be time for an upgrade. Remote working may have exposed some of these issues and as a result employees are driving change, explaining that they cannot work effectively using existing systems.

Some might find that IT holds the business back in other ways. For example, as more businesses look at adopting cloud services, they may see costs increasing — paying

Once a business has worked out where it wants to be, it can work backwards on how to get there. a fee for every employee can be costly and is not the most effective way of using the cloud. Alternatively, costs may be high because the system is unreliable, and businesses are spending more time fighting fires than strategizing about the future.

On some occasions, businesses might not know that they need an upgrade until it’s too late. Equipment failures and cybersecurity attacks are costly ways to discover there are the problems with the system.

REVIEWING INFRASTRUCTURE Businesses are integrating advanced technologies, such as Internet of Things (IoT) devices, cloud computing, analytics and advanced sensors, into their operations to realise Industry 4.0. By digitalising processes, businesses can use analysed data to make more informed decisions, increase productivity and gain full visibility over operations.

There’s a common misconception that businesses must invest in all the latest “shiny” technologies to truly realise Industry 4.0. In reality, every company will experience a different journey to digitalisation and it doesn’t require an overhaul of operations.

To decide where to start, businesses should review current IT infrastructure, reviewing if employees are satisfied with the current set up, if it’s reliable and the potential risks. Businesses should ask what will happen if the IT systems stop working — while many small companies

say it’ll never happen to us, it’s not necessarily true. After assessing the current performance of IT infrastructure, businesses should outline business objectives, looking at what they want to achieve from an upgrade. They can also work with an IT specialist to determine what works well in a current infrastructure and where they can make improvements to determine what an upgrade could look like.

Once a business has worked out where it wants to be, it can work backwards on how to get there. That might involve one small project to address a business pain point, or a strategic plan to enable a complex change in the business. If looking to make a complex change, IT consultants can help to develop a roadmap to digitalisation, outlining the incremental steps needed to achieve the result.

Out of sight shouldn’t mean out of mind.

We often encourage homeowners to keep an eye on their plumbing to avoid costly problems, businesses should do the same with their IT infrastructure. Instead of waiting until something goes wrong to make changes, businesses should take the time to proactively review their infrastructure and explore how they can take the first steps to digitalisation.

Ripley Solutions can help to assess your current IT infrastructure, develop a roadmap to digitalisation and install new technologies to improve your operations.

To set up a consultation, contact Ripley Solutions on info@ripleysolutions.com.

For further information, please visit www.ripleysolutions.com

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PECM Issue 57

TOOLS, PLANT & EQUIPMENT

Snap-on’s Level 5 tool management system guards against FOD For engineers and technicians working in many industrial sectors FOD will always be a real and present danger.

Keeping track of every tool and piece of equipment, especially when several storage cabinets are in simultaneous use, can be challenging.

Snap-on Industrial’s Level 5™ automated total asset management system minimises the risk of FOD by constantly tracking every tool, detecting which tools have been removed or returned.

Powerful software enables users to review activity at all boxes in their location from one central computer, avoiding the need to inspect each box.

It also enables engineers and technicians to quickly find every tool they need, when they need it, saving time and easing stress.

Engineered to track individual tools by user, without bar codes, scanners, RFID tags or other add-ons, the system works at the speed its users demand.

Major benefits of the system include:

Level 5™ boxes are network ready, using either Ethernet or wireless connection.

• • • •

No individual tool scanning required; No RFID tags to install or replace; Intuitive interface, via touch screen; Audible voice confirmation of tool removal and replacement; • Automatic locking for maximum security; • Errors announced and displayed to indicate incorrect tool position or advise when a drawer is not closed;

• Keyless access control for easy access by authorised users.

Says Richard Packham, Director UK & Europe for Snap-on Industrial: “Snap-on’s automated system takes tool management to an entirely new level, giving workshop managers and other authorised users easy access to the tools they need, while protecting against foreign object damage.

“The ability to monitor several boxes from one central computer offers managers a huge time saving advantage.”

For technical details visit: snapon-industrial.co.uk; call (01536) 413904 or e-mail: ukindustrialmarketing@snapon.com

The Solano AT: Comfortable, Safe, Calibrated Digitally networked hot air blower

Take advantage of the Configuration Management service in your myLeister app right away to easily calibrate your Solano AT to meet your specific process requirements.

Developed by Leister - the leading name in plastic welding applications, the Solano AT is supplied to the UK by Welwyn Tool Group. Welwyn supply the full range of Leister plastic welding and industrial process heat equipment and offers highly competent technical support by their team of dedicated engineers.

For further information and technical advice for equipment in this field, please contact Welwyn Tool Group on 0800 856 0057, email them on info@welwyntoolgroup.com, or visit their website

www.welwyntoolgroup.com

Solano AT For professional plastic welding, heating, shrinking and drying applications.

Digitally networked hot air blower

Leister’s SOLANO AT is a safe, powerful, quiet, and lightweight heat gun for professional plastic welding, heating, shrinking and drying applications, with unique protection features such as configurable restart protection, active cool-down function and easy to install burn protection.

Thanks to the device calibration function on your Solano AT, features like the energy saving Eco-Mode or calibrating a temperature curve are easy to configure and transferable via the myLeister app. This function allows you to set the exact hot air temperature needed in the nozzle with assurance that the temperature matches the display. The read/write function of the myLeister app allows settings to be transferred easily to an unlimited number of Leister devices. The read function helps you monitor, reading out and checking defined configurations on Leister devices.

Put manual calibration and process inaccuracies firmly in the past with Leister’s Solano AT - reliability, process stability, precision, and reproducibility.

DEVICE CALIBRATION LIGHTWEIGHT ECO MODE QUIET ACTIVE COOL DOWN FUNCTION

CONFIGURABLE RESTART PROTECTION

Tel: +44 (0)1707 331111 | info@welwyntoolgroup.co.uk www.welwyntoolgroup.com

Issue 57 PECM

77

TOOLS, PLANT & EQUIPMENT

Climate Control Baselayers – For the Summer and Autumn Months

Snickers Workwear Trousers also deliver certified protection with the patented KneeGuard System for greater flexibility, comfort and durability. It’s what makes them the optimal choice for craftsmen and women who need to get every job done comfortably and sustainably on site.

Upgraded, Innovative and Sustainable - Snickers Workwear ‘Climate Control’ clothing delivers exceptional comfort and performance. There’s a range of garments that use socially and environmentally responsible fibre technology such as 100% recycled polyester, as well as others available in high-tech breathable fabrics. For consistent comfort, the seamless designs are also available in 37.5® ventilating technology for efficient body moisture transport as well as odour-reducing merino wool to suit different types of work, whatever the weather conditions. These cutting-edge AllroundWork, FLEXIWork and LITEwork designs and fabrics will keep you cool, warm and dry when you need to be. All the garments are made from quick drying, lightweight fabrics that come with special ventilation features to control and regulate the heat from your body. All in all, Snickers Workwear Baselayer clothing will give you the kind of fresh working comfort you wouldn’t have thought possible.

www.snickersworkwear.com

www.snickersworkwear.com

Snickers Workwear Trousers: More Than Fit For Purpose Snickers Workwear’s trouser families are suited to any kind of work on site. Delivering maximum functionality, comfort, protection and mobility they’re the products of choice among discerning professional tradesmen and women. For them, sustainable, street-smart, body-mapping clothing are key parts of their product choices.

Hi-tech fabrics, functionality and fit are the hallmarks of these market-leading products. The AllroundWork trousers are ready for any kind of work in any trade. FlexiWork trousers deliver superior freedom of movement.

While LiteWork trousers keep you cool, dry and ventilated.

Then there’s RuffWork trousers, reinforced and tough for the roughest work on site.

ProtecWork protective wear for hazardous environments and certified High-Vis trousers when personal visibility on site is a priority.

It’s time for your digital transformations As businesses at varying stages of their digital transformations grapple with data management, it pays to use a unifying system allowing central analysis and control. Organisations entrenched in the world of big data or those just taking their first steps into industry 4.0, will benefit from Desoutter’s data-driven solutions. It’s now very easy to manage and analyse data gathered from the widest possible array of sources.

centrally. Therefore, it’s simple and intuitive to perform analysis of historic data by searching for specific builds, events or time periods. Data can be viewed in its original state for quick reference or exported into various formats for advanced analysis and concise sharing.

BE MORE INSTANTANEOUS, IT’S EXPECTED!

Never before has there been an opportunity to gather such an abundance of data from the tools and processes used day-to-day, from machinery and test equipment in manufacturing environments, software systems in warehouses or manual entry from operators in the field.

Empowering? Yes! But, on closer inspection it’s too often left untouched, unobserved and untapped. Data for data’s sake is no good to anyone.

provides operator guidance as well as automation of equipment and tests.

Pivotware processes can be created quickly and easily, whilst also allowing the integration of our intelligent tooling and a wide variety of third-party equipment.

This allows the data from all relevant equipment or sources to flow through one system, eliminating the requirement for separate databases or traceability systems.

CAN YOU WIN THE DATA COLLECTION BATTLE?

LET YOUR HISTORY HELP SHAPE YOUR FUTURE…

With sensible planning, yes! Desoutter’s ‘Pivotware’ process control software

With the ability for data to be recorded through one system, it can be stored pivotware.com | desouttertools.com

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PECM Issue 57

Traditionally, data is used reactively as required. These days society is more connected and our business increasingly fast-paced. This means it is critical to proactively use data which drives daily decision-making within an organisation and prevents issues ahead of time.

Desoutter’s ‘Demeter’ real-time data monitoring and analysis software allows easy viewing of key data in a tailored format, accessible from any web-browser equipped device.

A proactive data strategy = reduced risk and increased productivity. Don’t risk your company’s data being left shelved with its valuable lessons unlearned.

TRAINING & RECRUITMENT

INVESTMENT IN PEOPLE ECS ENGINEERING SERVICES

New job opportunities highlight growth at ECS Engineering Services

ECS is growing its team of professionals, providing those looking to enter engineering with the opportunity to engage in landmark projects in the water, nuclear and construction sectors. New hires will support multiple framework contracts held by the business and its entrance into new markets.

Working closely with government agencies, local authorities and private companies, ECS has provided highly responsive engineering services throughout the UK for over 30 years. Based in Nottinghamshire, the business is an established framework contractor for water authorities nationwide, has achieved Fit4Nuclear status and operates a fabrications department accredited to EXC4. In-house capabilities and on-site teams combine to deliver a turnkey approach to any project.

The business is currently looking to hire a new Estimator, Mechanical Fitter, Mechanical

Project Engineer, Mechanical Supervisor and a Facilities/M&E Maintenance Manager. Anyone wanting to start their career in engineering can email their CV to bhenshaw@ecseng.co.uk, with a list of available vacancies here.

“As well as supporting the local area with new job opportunities, we have welcomed many professionals to our team. We recently hired Dileep as our new Quality Engineer, Julieanne as an Assistant Accountant, Richard as an Estimator, Stephanie our new Contracts Manager and Steve as a Project Engineer. It’s exciting to work with new people and expand our expertise,” says Steve Crapper, Precontracts Director at ECS. “We are a growing business, providing engineering solutions and turnkey services to the water, nuclear and construction industries. To meet the project requirements of our customers, we not only need to grow

our in-house and on-site capabilities but also invest in our people too. This way, we can organically improve our service levels and better support our customers.”

New employees can expect to be involved in wide range of projects. Recently, ECS has supported multiple UK nuclear sites and decommissioning projects with high-quality fabrications. ECS has also installed the first ever set of moulded fibre reinforced polymer (FRP) lock gates on behalf of the Environment Agency at Sunbury Dry Dock on the River Thames. The business was appointed as the regionwide framework contractor for mechanical services for Severn Trent Water and as a mechanical, electrical, instrumentation, control and automation (MEICA) framework contractor for Anglian Water. National Highways has also extended its agreement with ECS to maintain multiple drainage pumping stations in Derbyshire, the East Midlands and Nottinghamshire.

For further information, please visit www.ecsengineeringservices.com Issue 57 PECM

79

VALVES & FLOW CONTROL

RECOGNITION OF EXCELLENCE OLIVER VALVETEK LTD

Oliver Valvetek Ltd, second time winner of the prestigious queen’s award for enterprise Cheshire based Oliver Valvetek Ltd is to be recognised with a prestigious Queen’s Award for Enterprise for its excellence in international trade.

Established in 1994, Oliver Valvetek is a world leading manufacturer of subsea valve technology, predominantly for the oil and gas industry. Working with some of the most advanced deep-sea oil and gas extraction infrastructure manufacturers, the company produces an ever-expanding range of valves and related products that are vital components in the extraction of oil and gas.

More recently Oliver Valvetek has also found new opportunities for its technology to be used for CO2 injection into depleted oil & gas wells as part of a growing demand for carbon capture and storage applications, delivering the decarbonisation of industrial emitters.

Now a second time winner of the Queen’s award for Enterprise earning recognition by achieving consistent growth in its international sales for three consecutive years. With more than 67% of the company’s entire order book being for export sales, Oliver Valvetek boasts a truly international reputation for innovation, customer service, quality and reliability.

manufacturing hubs which service a truly international customer base spanning over 55 countries.

The rigorous Quality Control and Quality Assurance systems and advanced manufacturing techniques needed to produce valves that can operate at depths of up to 3,000m, at up to 20,000psi, for more than a quarter of a century, in some of the most aggressive environments in the world is “run of the mill” for the 77 staff, including 9 engineers and 38 valve technicians, at the Knutsford headquarters.

Utilising Oliver’s state of the art research and development facilities, which include a deep-water hyperbaric chamber, high pressure with high and low temperature environmental testing capability, Oliver Valvetek is able to continually innovate whilst ensuring extreme levels of reliability and meeting ever more stringent customer specifications. This has made Oliver Valvetek the first choice for many of the world’s leading oil and gas operators, utilising its in-house testing facilities to replicate actual “real world” operating conditions; just one of the many ways in which Oliver Valvetek partners with its customers to ensure the best possible outcome for even the most challenging applications.

Oliver Valvetek has over 140,000 valves deployed subsea, all designed in its dedicated Engineering facilities located in Knutsford and Glenrothes, Scotland. Highly trained Sales Engineers, Quality Assurance/ Control teams and Customer Care teams support a number of global customer

Founder and Chairman, Michael Oliver is rightfully extremely proud of this achievement commenting, “To win the prestigious Queen’s award is a great business achievement and of immense personal pride to me. This has only been made possible by the extraordinary talent

pool of people we employ in Cheshire and from the surrounding area. Our people are the jewel in the crown – it’s with their enthusiasm, commitment, and hard work that drive’s our global success and I’m extremely proud of the UK engineering excellence we’re delivering to the Global Oil and Gas industry of today and how we’re significantly investing in the energy demands of tomorrow with technological research and development in Hydrogen and Carbon capture… …This is an exciting and transformational time for Oliver Valvetek and the global energy sector, and it excites me to see our new generation of engineers involved and learning from industry experts working at our facilities in Knutsford, to continue providing first-class solutions to the world’s energy needs in more environmental and sustainable ways. For the business to be crowned with such a royal award for the second time demonstrates that the future of Oliver Valvetek has never looked as strong as it does today”

For further information, please visit www.valves.co.uk

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PECM Issue 57

VALVES

Flawless Design! The Next Generation of GEMÜ Rubber Lined Butterfly Valves

Myron L Company 900 Series™ Monitor/Controllers

To suit an extensive range of applications, GEMÜ offers newly redesigned butterfly valves, R480 Victoria series. The new R480 is a direct replacement for the previous 480 series offering multiple enhanced product features. Thanks to its flow-optimized and sleek disc design, the GEMÜ R480 series achieves higher flow rate factors.

This reduces the pressure loss, giving the butterfly valves greater energy efficiency. On top of that, the PTFE-coated bushes reduce torques, not only allowing further savings through lower actuator costs, but also making the valves significantly more durable and therefore increasing longevity. Using the whirl-sintering method to achieve high-quality coating, together with having layer thickness of at least 250 µm, ensures consistent corrosion protection even in the liner area. Furthermore, the technical optimization of the liner improves tightness, which guarantees bubble tight sealing and resistance to slipping – making the GEMÜ R480 remarkably reliable and greater than ever! More details here.

The innovative 900 Series Monitor/ Controllers include everything you need to simplify water quality management and chemical dosing in industrial operations in one compact userintuitive instrument.

Click here to see how we manufacture our Next Generation of GEMU rubber lined Butterfly Valves R480 Victoria series.

Tel: 01925 824044 Web: www.gemu.co.uk

Monitor 7 critical water quality parameters simultaneously from easily configured inputs: 2 Conductivity/Resistivity/TDS/Salinity; 1 pre-amplified pH/ORP; 1 BNC pH/ORP; 1 0/4-20 mA; 1 RTD Temperature; and 1 Flow/Pulse. % Rejection is available as a derived value.

Outputs include up to 3 relays; 2 remote alarms; 1 0/4-20 mA; 1 0-10 VDC; and 1 RS-485 ASCII Serial Output.

Flow Switch input can disable all relay outputs when triggered by loss of flow.

Relays output to any user-supplied control equipment requiring up to 250V each and can trigger on any input parameter.

www.myronl.com

ARI-Armaturen – your answer to all your valve ARI-Armaturen – your answer toneeds all your

valve needs

® Introducing ENCOsys ® Introducing ENCOsys Introducing ZETRIX® A COMPLETE SOLUTION FOR STEAM THE PREMIUM PROCESS VALVE

A COMPLETE SOLUTION FOR STEAM TO WATER HEAT EXCHANGE TO WATER HEAT EXCHANGE

Designed to provide hot water instantaneously whatever thetoload conditions, Designed provide hot water instantaneously whatever the load up to 2100kW without the conditions, up to 2100kW without the need for water storage. need for water storage.

Reliable, Efficient and Cost Effective Reliable, Reduced Heat Loss Efficient Improved Temperature Control and Cost Thermal Efficiency Effective Operational Savings • Reduced ARI-Armaturen UK Ltd specialises in pipeline equipment for Heat Loss steam systems, thermal oil and hot water and is a subsidiary • Improved of a large German engineering company, reputed to have the Temperature largest valve stock in Europe.

Control • Thermal Efficiency • Operational Savings ARI-Ad-UK-ENCOsys-182-129.indd 1

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PECM Issue 57

Reliably tight, durable and versatile triple offset valve with zero leakage, even in harsh industrial environments.

Changing from single to double isolation made easy with the small face-to-face dimensions of the ZETRIX® ZETRIX® Double block and bleed arrangement

Contact salesoffice officeon on 01684 01684 275752 Contact thethe UKUK sales 275752 Email: marketing@ari-armaturen.co.uk inquiries@uk.ari-armaturen.com ororEmail:

www.ari-armaturen.com 23.06.2021 14:21:36

Portable Fume Extraction, Ventilation and Cooling Solutions Where fumes, smells or dust occur, our Miniveyor Air VAF series fans can move contaminated air out of a confined space or building. They effectively exhaust fumes, ventilate confined spaces, and increase the flow of fresh air.

VAF-COOL evaporative coolers offer an alternative solution to conventional refrigeration systems or air conditioners.

The coolers are portable so provide a highly flexible solution, and their low energy consumption means they are economical to use, kinder to the planet, and unlike air conditioners, they don’t rely on a closed environment, so can be used in more open spaces, such as warehouses, factories, event spaces, agriculture building, and sports arenas.

VAF Air Ltd Tetbury, United Kingdom sales@vaf-air.com +44 (0)330 016 0002

www.vaf-air.com

Manage IO-Link sensors & actuators of all manufacturers in a single IIOT platform!

STEGO CONNECT – DATA COLLECTION & ANALYSIS: connect - monitor – control Condition Monitoring & Predictive Maintenance made easy!

STEGO-CONNECT.COM/IIOT